Caterpillar G3406 and G3412 Generator Set Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar G3406 and G3412 Generator Set Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar G3406 and G3412 Generator Set 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.
RENR5952 - Specifications (G3406 and G3412 Generator Set Engines).pdf
RENR5953 - Systems Operation (G3406 and G3412 Generator Set Engines).pdf
RENR5953 - Testing and Adjusting (G3406 and G3412 Generator Set Engines).pdf
RENR5956 - Schematic (G3406 & G3412 Generator Set Electrical System).pdf
RENR8112 - Schematic (G3406 and G3412 Generator Set Electrical System R7A102-UP; R7E103-UP; KAP232-UP; KAR280-UP).pdf
SENR3091 - Disassembly and Assembly (3408 & 3412 NATURAL GAS ENGINE).pdf
SENR6535 - Troubleshooting (G3400 Engines (EIS)).pdf
PRODUCT DETAILS:
Total Pages: 990 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
RENR5952 - Specifications (G3406 and G3412 Generator Set Engines)....1
Engine Design....3
Spark Plug Adapter....5
Spark Plug Adapter ....7
Spark Plug and Transformer....9
Spark Plug and Transformer - 011.41 Compression Ratio....11
Spark Plug and Transformer - 008.51 and 9.71 Compression Ratio....12
Gas Engine Ignition....13
Ignition Transformer....16
Gas Pressure Regulator....22
Governor Drive....24
Carburetor Control Linkage....28
Camshaft....32
Valve Cover....34
Valve Mechanism....37
Cylinder Head....40
Cylinder Head Valves....43
Turbocharger....46
Exhaust Manifold....48
Exhaust Bypass Valve....52
Air Cleaner....53
Engine Oil Pump....57
Engine Oil Filter Base....59
Crankcase Breather....61
Water Pump....63
Auxiliary Water Pump....67
Fan Drive....69
Water Temperature Regulator....71
Cylinder Block....73
Crankshaft....79
Connecting Rod....81
Connecting Rod and Main Bearing Journals....84
Piston and Rings - Gallery Cooled Piston....86
Cylinder Liner....89
Camshaft Bearings....91
Camshaft Bearing Position....93
Gear Group (Front)....95
Housing (Front)....98
Cover Group (Front Housing)....100
Idler Gear Assembly....102
Gear Group (Rear) ....104
Cover Group (Rear Housing)....105
Vibration Damper and Pulley....107
Flywheel....109
Flywheel Housing....111
Belt Tension Chart....116
Alternator and Regulator....118
Electric Starting Motor....120
Air Starting Motor....122
Gas Solenoid Valve....124
Engine Speed Sensor....126
Coolant Level Sensor....128
Coolant Temperature Sensor....131
Detonation Sensor....133
Manifold Air Pressure Sensor....134
Engine Oil Pressure Sensor....136
Engine Speed_Timing Sensor....138
RENR5953 - Systems Operation (G3406 and G3412 Generator Set Engines)....141
Electronic Control System Operation....142
Electronic Control System Parameters - Electronic Ignition System (EIS)....143
Engine Monitoring System....146
Engine Monitoring System - Electronic Ignition System (EIS)....150
Ignition System....153
Ignition System - Electronic Ignition System (EIS)....159
Governor....168
Gas Pressure Regulator....170
Carburetor....173
Air Inlet and Exhaust System Components....177
Aftercooler....179
Exhaust Manifold....180
Turbocharger....181
Exhaust Bypass Valve....183
Valve System Components....186
Lubrication System....188
Cooling System....196
Cylinder Block; Liners and Heads....205
Pistons; Rings and Connecting Rods....209
Crankshaft....211
Camshaft....213
Air Starting System Operation....214
Grounding Practices....216
Charging System....217
Starting System....219
Related Components....221
RENR5953 - Testing and Adjusting (G3406 and G3412 Generator Set Engines)....224
Troubleshooting....226
General Information (Electronic Control System)....257
Manifold Air Pressure Sensor....258
Detonation Sensor....260
Engine Speed_Timing Sensor....262
Ignition Transformer....268
Ignition System....277
General Information (Fuel System)....289
Carburetor - Adjust....291
Gas Pressure....294
Finding the Top Center Position for the No. 1 Piston....298
Governor - Adjust....300
Restriction of Air Inlet and Exhaust....305
Measuring Inlet Manifold Temperature....307
Turbocharger - Inspect....310
Measuring Inlet Manifold Pressure....312
Measuring Exhaust Temperature....313
Exhaust Bypass Valve....314
Compression....316
Crankshaft Position for Valve Lash Setting....318
Valve Lash and Valve Bridge Adjustment....322
General Information (Lubrication System)....330
Measuring Engine Oil Pressure....331
General Information (Cooling System)....334
Testing the Cooling System....336
Cylinder Block....340
Cylinder Liner Projection....341
Flywheel - Inspect....348
Flywheel Housing - Inspect....351
Vibration Damper - Check....356
Pressure Regulating Valve....357
Lubrication....359
General Information (Air_Electric Starting System)....360
Test Tools for the Electrical System....363
Charging System....368
Battery....369
RENR5956 - Schematic (G3406 & G3412 Generator Set Electrical System)....370
Collage....370
Main....385
RENR8112 - Schematic (G3406 and G3412 Generator Set Electrical System R7A102-UP; R7E103-UP; KAP232-UP; KAR280-UP)....387
Collage....387
Main....411
SENR3091 - Disassembly and Assembly (3408 & 3412 NATURAL GAS ENGINE)....413
Aftercooler....415
Turbocharger....419
Exhaust Manifolds (3408 Watercooled)....431
Exhaust Manifolds (3412 Watercooled)....441
Valve Covers....447
Rocker Shaft Assembly And Push Rods....450
Valve Lifters....457
Cylinder Head....460
Valves....469
Valve Guides....472
Valve Guides (New Taller Head)....474
Bridge Dowels....477
Valve Seat Inserts....479
Vibration Damper And Pulley....481
Crankshaft Front Seal And Wear Sleeve....483
Engine Front Support....486
Timing Gear Cover....487
Camshaft....490
Camshaft Bearings....495
Timing Gears....498
Crankshaft Rear Seal And Wear Sleeve....502
Flywheel....506
Flywheel Housing....509
Camshaft Rear Gear And Balancer....514
Pistons....518
Cylinder Liners....524
Connecting Rod Bearings....528
Crankshaft....531
Crankshaft Main Bearings....541
Auxiliary Sea Water Pump....545
Water Pump....555
Water Temperature Regulator....561
Oil Pan....563
Oil Pump....564
Piston Cooling Tubes....569
Engine Oil Cooler....571
Oil Filters And Oil Filter Base....574
Gas Pressure Regulator....576
Magneto (3408 & 3412)....581
Magneto And Governor Drive Housing....586
Exhaust Bypass Valve....595
Carburetor....600
Spark Plugs....607
Spark Plug Adapters....608
Generator....611
Inlet and Exhaust Valve Guides (New Taller Head)....618
SENR6535 - Troubleshooting (G3400 Engines (EIS))....621
System Overview....629
Self-Diagnostics....632
Location of Components....634
Electrical Connectors and Functions....643
Electronic Service Tools....647
Engine Monitoring System....653
Programming Parameters....655
Customer Parameters Worksheet....658
Replacing the EIS Control Module....659
Troubleshooting Data Sheet....662
Air Starting Motor - Malfunction....664
Alternator - Malfunction....668
Coolant in Engine Oil....670
Detonation....672
Diagnostic Code Will Not Clear....674
Electronic Service Tool Displays UNDETERMINED....675
Electronic Service Tool Will Not Communicate with ECM....676
Engine Coolant Temperature (High)....677
Engine Coolant Temperature (Low)....680
Engine Cranks but Will Not Start....681
Engine Has Early Wear....683
Engine Misfires; Runs Rough or Is Unstable....685
Engine Oil in Cooling System....688
Engine Oil Pressure (Low)....689
Engine Shutdown without a Diagnostic Code....691
Engine Starts but Stalls Immediately....693
Engine Timing Does Not Match Programmed Timing....695
Engine Will Not Crank....696
Excessive Engine Oil Consumption....698
Exhaust Port Temperature (High)....700
Fuel Metering Valve....702
Inlet Air Temperature (High)....703
Intermittent Engine Shutdown....705
Low Power_Poor or No Response to Throttle....707
Mechanical Noise (Knock) in Engine....710
Noise Coming from Cylinder....712
Poor Fuel Consumption....713
Short Spark Plug Life....715
Too Much Vibration....717
Diagnostic Codes....718
MID 014 - CID 0168 - FMI 02 System Voltage intermittent_erratic....720
MID 014 - CID 0300 - FMI 03 Primary Return short to +batt....721
MID 014 - CID 0300 - FMI 04 Primary Return short to ground....722
MID 014 - CID 0301 - FMI 05 Ignition Transformer Primary #1 open circuit....723
MID 014 - CID 0301 - FMI 06 Ignition Transformer Primary #1 short....724
MID 014 - CID 0301 - FMI 12 Ignition Transformer Primary #1 short to return....725
MID 014 - CID 0302 - FMI 05 Ignition Transformer Primary #2 open circuit....726
MID 014 - CID 0302 - FMI 06 Ignition Transformer Primary #2 short....727
MID 014 - CID 0302 - FMI 12 Ignition Transformer Primary #2 short to return....728
MID 014 - CID 0303 - FMI 05 Ignition Transformer Primary #3 open circuit....729
MID 014 - CID 0303 - FMI 06 Ignition Transformer Primary #3 short....730
MID 014 - CID 0303 - FMI 12 Ignition Transformer Primary #3 short to return....731
MID 014 - CID 0304 - FMI 05 Ignition Transformer Primary #4 open circuit....732
MID 014 - CID 0304 - FMI 06 Ignition Transformer Primary #4 short....733
MID 014 - CID 0304 - FMI 12 Ignition Transformer Primary #4 short to return....734
MID 014 - CID 0305 - FMI 05 Ignition Transformer Primary #5 open circuit....735
MID 014 - CID 0305 - FMI 06 Ignition Transformer Primary #5 short....736
MID 014 - CID 0305 - FMI 12 Ignition Transformer Primary #5 short to return....737
MID 014 - CID 0306 - FMI 05 Ignition Transformer Primary #6 open circuit....738
MID 014 - CID 0306 - FMI 06 Ignition Transformer Primary #6 short....739
MID 014 - CID 0306 - FMI 12 Ignition Transformer Primary #6 short to return....740
MID 014 - CID 0307 - FMI 05 Ignition Transformer Primary #7 open circuit....741
MID 014 - CID 0307 - FMI 06 Ignition Transformer Primary #7 short....742
MID 014 - CID 0307 - FMI 12 Ignition Transformer Primary #7 short to return....743
MID 014 - CID 0308 - FMI 05 Ignition Transformer Primary #8 open circuit....744
MID 014 - CID 0308 - FMI 06 Ignition Transformer Primary #8 short....745
MID 014 - CID 0308 - FMI 12 Ignition Transformer Primary #8 short to return....746
MID 014 - CID 0309 - FMI 05 Ignition Transformer Primary #9 open circuit....747
MID 014 - CID 0309 - FMI 06 Ignition Transformer Primary #9 short....748
MID 014 - CID 0309 - FMI 12 Ignition Transformer Primary #9 short to return....749
MID 014 - CID 0310 - FMI 05 Ignition Transformer Primary #10 open circuit....750
MID 014 - CID 0310 - FMI 06 Ignition Transformer Primary #10 short....751
MID 014 - CID 0310 - FMI 12 Ignition Transformer Primary #10 short to return....752
MID 014 - CID 0311 - FMI 05 Ignition Transformer Primary #11 open circuit....753
MID 014 - CID 0311 - FMI 06 Ignition Transformer Primary #11 short....754
MID 014 - CID 0311 - FMI 12 Ignition Transformer Primary #11 short to return....755
MID 014 - CID 0312 - FMI 05 Ignition Transformer Primary #12 open circuit....756
MID 014 - CID 0312 - FMI 06 Ignition Transformer Primary #12 short....757
MID 014 - CID 0312 - FMI 12 Ignition Transformer Primary #12 short to return....758
MID 014 - CID 0317 - FMI 08 Load Sensor (MAPS) signal abnormal....759
MID 014 - CID 0317 - FMI 11 No Inlet Manifold Pressure signal....760
MID 014 - CID 0318 - FMI 01 Loss of Right Bank Detonation Sensor Signal....761
MID 014 - CID 0318 - FMI 03 Right Bank Detonation Sensor short to +batt....762
MID 014 - CID 0318 - FMI 05 Right Bank Detonation Sensor open or short to ground....763
MID 014 - CID 0319 - FMI 01 Loss of Left Bank Detonation Sensor Signal....764
MID 014 - CID 0319 - FMI 03 Left Bank Detonation Sensor short to +batt....765
MID 014 - CID 0319 - FMI 05 Left Bank Detonation Sensor open or short to ground....766
MID 014 - CID 0320 - FMI 05 Timing Control Speed Sensor open_short to +batt....767
MID 014 - CID 0320 - FMI 07 Speed_Timing Sensor improper response....768
MID 014 - CID 0320 - FMI 08 Engine Speed_Timing signal abnormal....769
MID 014 - CID 0321 - FMI 04 Diagnostic Reset Switch short to ground....770
MID 014 - CID 0322 - FMI 03 Shutdown Relay short to +batt....771
MID 014 - CID 0322 - FMI 05 Shutdown Relay open_short to ground....772
MID 014 - CID 0323 - FMI 03 Shutdown Lamp short to +batt....773
MID 014 - CID 0323 - FMI 05 Shutdown Lamp open_short to ground....774
MID 014 - CID 0324 - FMI 03 Warning Lamp short to +batt....775
MID 014 - CID 0324 - FMI 05 Warning Lamp open_short to ground....776
MID 014 - CID 0325 - FMI 00 Excessive Detonation....777
MID 014 - CID 0326 - FMI 01 Detonation Retarded Timing....778
MID 014 - CID 0327 - FMI 02 Number of Detonation Sensors mismatch....779
MID 014 - CID 0328 - FMI 02 Number of Cylinders mismatch....780
MID 014 - CID 0329 - FMI 11 Communication Fault with CAT A_F Ratio Control....781
MID 014 - CID 0330 - FMI 11 Propane Timing Mode requested....782
MID 014 - CID 0331 - FMI 11 Ignition Shutdown requested....783
MID 014 - CID 0401 - FMI 00 Ignition Transformer Secondary #1 maintenance needed....784
MID 014 - CID 0401 - FMI 05 Ignition Transformer Secondary #1 open circuit....785
MID 014 - CID 0401 - FMI 06 Ignition Transformer Secondary #1 short to ground....786
MID 014 - CID 0401 - FMI 12 Ignition Transformer Secondary #1 noisy component....787
MID 014 - CID 0402 - FMI 00 Ignition Transformer Secondary #2 maintenance needed....788
MID 014 - CID 0402 - FMI 05 Ignition Transformer Secondary #2 open circuit....789
MID 014 - CID 0402 - FMI 06 Ignition Transformer Secondary #2 short to ground....790
MID 014 - CID 0402 - FMI 12 Ignition Transformer Secondary #2 noisy component....791
MID 014 - CID 0403 - FMI 00 Ignition Transformer Secondary #3 maintenance needed....792
MID 014 - CID 0403 - FMI 05 Ignition Transformer Secondary #3 open circuit....793
MID 014 - CID 0403 - FMI 06 Ignition Transformer Secondary #3 short to ground....794
MID 014 - CID 0403 - FMI 12 Ignition Transformer Secondary #3 noisy component....795
MID 014 - CID 0404 - FMI 00 Ignition Transformer Secondary #4 maintenance needed....796
MID 014 - CID 0404 - FMI 05 Ignition Transformer Secondary #4 open circuit....797
MID 014 - CID 0404 - FMI 06 Ignition Transformer Secondary #4 short to ground....798
MID 014 - CID 0404 - FMI 12 Ignition Transformer Secondary #4 noisy component....799
MID 014 - CID 0405 - FMI 00 Ignition Transformer Secondary #5 maintenance needed....800
MID 014 - CID 0405 - FMI 05 Ignition Transformer Secondary #5 open circuit....801
MID 014 - CID 0405 - FMI 06 Ignition Transformer Secondary #5 short to ground....802
MID 014 - CID 0405 - FMI 12 Ignition Transformer Secondary #5 noisy component....803
MID 014 - CID 0406 - FMI 00 Ignition Transformer Secondary #6 maintenance needed....804
MID 014 - CID 0406 - FMI 05 Ignition Transformer Secondary #6 open circuit....805
MID 014 - CID 0406 - FMI 06 Ignition Transformer Secondary #6 short to ground....806
MID 014 - CID 0406 - FMI 12 Ignition Transformer Secondary #6 noisy component....807
MID 014 - CID 0407 - FMI 00 Ignition Transformer Secondary #7 maintenance needed....808
MID 014 - CID 0407 - FMI 05 Ignition Transformer Secondary #7 open circuit....809
MID 014 - CID 0407 - FMI 06 Ignition Transformer Secondary #7 short to ground....810
MID 014 - CID 0407 - FMI 12 Ignition Transformer Secondary #7 noisy component....811
MID 014 - CID 0408 - FMI 00 Ignition Transformer Secondary #8 maintenance needed....812
MID 014 - CID 0408 - FMI 05 Ignition Transformer Secondary #8 open circuit....813
MID 014 - CID 0408 - FMI 06 Ignition Transformer Secondary #8 short to ground....814
MID 014 - CID 0408 - FMI 12 Ignition Transformer Secondary #8 noisy component....815
MID 014 - CID 0409 - FMI 00 Ignition Transformer Secondary #9 maintenance needed....816
MID 014 - CID 0409 - FMI 05 Ignition Transformer Secondary #9 open circuit....817
MID 014 - CID 0409 - FMI 06 Ignition Transformer Secondary #9 short to ground....818
MID 014 - CID 0409 - FMI 12 Ignition Transformer Secondary #9 noisy component....819
MID 014 - CID 0410 - FMI 00 Ignition Transformer Secondary #10 maintenance needed....820
MID 014 - CID 0410 - FMI 05 Ignition Transformer Secondary #10 open circuit....821
MID 014 - CID 0410 - FMI 06 Ignition Transformer Secondary #10 short to ground....822
MID 014 - CID 0410 - FMI 12 Ignition Transformer Secondary #10 noisy component....823
MID 014 - CID 0411 - FMI 00 Ignition Transformer Secondary #11 maintenance needed....824
MID 014 - CID 0411 - FMI 05 Ignition Transformer Secondary #11 open circuit....825
MID 014 - CID 0411 - FMI 06 Ignition Transformer Secondary #11 short to ground....826
MID 014 - CID 0411 - FMI 12 Ignition Transformer Secondary #11 noisy component....827
MID 014 - CID 0412 - FMI 00 Ignition Transformer Secondary #12 maintenance needed....828
MID 014 - CID 0412 - FMI 05 Ignition Transformer Secondary #12 open circuit....829
MID 014 - CID 0412 - FMI 06 Ignition Transformer Secondary #12 short to ground....830
MID 014 - CID 0412 - FMI 12 Ignition Transformer Secondary #12 noisy component....831
MID 014 - CID 0591 - FMI 12 EEPROM checksum fault or ECM not programmed....832
Control Module Self Test....833
Detonation Retard and Detonation Shutdown....840
Detonation Sensors....852
Diagnostic Reset Switch....864
Electrical Power Supply....871
Engine Speed_Timing Sensor....879
Ignition Shutdown Circuit....888
Ignition Transformers Primary Circuit....895
Ignition Transformers Secondary Circuit and Spark Plugs....917
Inlet Manifold Pressure Sensor....927
Inspecting Electrical Connectors....933
Programmable Parameters....944
Propane Switch....963
Shutdown Lamp....968
Shutdown Relay....974
Warning Lamp Circuit - Test....979
Engine Speed_Timing Sensor - Calibrate....985
Caterpillar G3406 and G3412 Generator Set Engines Repair Service Manual
