Caterpillar G3408C and G3412C Engines Repair Service Manual

Complete service repair manual with Electrical Wiring Diagrams for Caterpillar G3408C and G3412C Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Caterpillar G3408C and G3412C 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.

RENR5900 - Schematic (G3408C and G3412C Engine Electrical System).pdf
RENR5902 - Schematic (Caterpillar G3408C and G3412C Industrial and Gen Set EIS Electrical System).pdf
SENR6535 - Troubleshooting (G3400 Engines (EIS)).pdf
SENR6537 - Specifications (G3408C and G3412C Engines).pdf
SENR6538 - Systems Operation (G3408C and G3412C Engines).pdf
SENR6538 - Testing and Adjusting (G3408C and G3412C Engines).pdf
SENR6568 - Disassembly and Assembly (G3408C and G3412C Engines).pdf

PRODUCT DETAILS:
Total Pages: 1,022 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
RENR5900 - Schematic (G3408C and G3412C Engine Electrical System)....1
  Feature....1
  Cover Page....3
  Information....0
    Related Electrical Service manuals....4
    Additional Information....0
      Abbreviations....5
      2301A Gov Control (Optional)....6
      Pro-Act Gov (optional)....7
      Splice Detail....8
      Circuit Identification Tables....9
      Reference For G3400 Modular Harnesses....10
  Schematics....0
    Vol 1 - Non CSA Engine....11
    Vol 2 - CSA Engine....12
  Machine Views....0
    Vol 1 - Non CSA Engine....0
      Front View of Engine - G3408....13
      Left Side View of Engine - G3408....14
      Right Side View of Engine - G3408....15
      Left Side View of Engine - G3412....16
      Rear View of Engine - G3412....17
      Right Side of Engine - G3412....18
    Vol 2 - CSA Engine....0
      Front View of Engine - G3408....19
      Left Side View of Engine - G3408....20
      Right Side View of Engine - G3408....21
      Left Side View of Engine - G3412....22
      Rear View of Engine - G3412....23
      Right Side View of Engine - G3412....24
RENR5902 - Schematic (Caterpillar G3408C and G3412C Industrial and Gen Set EIS Electrical System)....25
  Collage....25
  Main....47
SENR6535 - Troubleshooting (G3400 Engines (EIS))....49
  System Overview....57
  Self-Diagnostics....60
  Location of Components....62
  Electrical Connectors and Functions....71
  Electronic Service Tools....75
  Engine Monitoring System....81
  Programming Parameters....83
  Customer Parameters Worksheet....86
  Replacing the EIS Control Module....87
  Troubleshooting Data Sheet....90
  Air Starting Motor - Malfunction....92
  Alternator - Malfunction....96
  Coolant in Engine Oil....98
  Detonation....100
  Diagnostic Code Will Not Clear....102
  Electronic Service Tool Displays UNDETERMINED....103
  Electronic Service Tool Will Not Communicate with ECM....104
  Engine Coolant Temperature (High)....105
  Engine Coolant Temperature (Low)....108
  Engine Cranks but Will Not Start....109
  Engine Has Early Wear....111
  Engine Misfires; Runs Rough or Is Unstable....113
  Engine Oil in Cooling System....116
  Engine Oil Pressure (Low)....117
  Engine Shutdown without a Diagnostic Code....119
  Engine Starts but Stalls Immediately....121
  Engine Timing Does Not Match Programmed Timing....123
  Engine Will Not Crank....124
  Excessive Engine Oil Consumption....126
  Exhaust Port Temperature (High)....128
  Fuel Metering Valve....130
  Inlet Air Temperature (High)....131
  Intermittent Engine Shutdown....133
  Low Power_Poor or No Response to Throttle....135
  Mechanical Noise (Knock) in Engine....138
  Noise Coming from Cylinder....140
  Poor Fuel Consumption....141
  Short Spark Plug Life....143
  Too Much Vibration....145
  Diagnostic Codes....146
  MID 014 - CID 0168 - FMI 02 System Voltage intermittent_erratic....148
  MID 014 - CID 0300 - FMI 03 Primary Return short to +batt....149
  MID 014 - CID 0300 - FMI 04 Primary Return short to ground....150
  MID 014 - CID 0301 - FMI 05 Ignition Transformer Primary #1 open circuit....151
  MID 014 - CID 0301 - FMI 06 Ignition Transformer Primary #1 short....152
  MID 014 - CID 0301 - FMI 12 Ignition Transformer Primary #1 short to return....153
  MID 014 - CID 0302 - FMI 05 Ignition Transformer Primary #2 open circuit....154
  MID 014 - CID 0302 - FMI 06 Ignition Transformer Primary #2 short....155
  MID 014 - CID 0302 - FMI 12 Ignition Transformer Primary #2 short to return....156
  MID 014 - CID 0303 - FMI 05 Ignition Transformer Primary #3 open circuit....157
  MID 014 - CID 0303 - FMI 06 Ignition Transformer Primary #3 short....158
  MID 014 - CID 0303 - FMI 12 Ignition Transformer Primary #3 short to return....159
  MID 014 - CID 0304 - FMI 05 Ignition Transformer Primary #4 open circuit....160
  MID 014 - CID 0304 - FMI 06 Ignition Transformer Primary #4 short....161
  MID 014 - CID 0304 - FMI 12 Ignition Transformer Primary #4 short to return....162
  MID 014 - CID 0305 - FMI 05 Ignition Transformer Primary #5 open circuit....163
  MID 014 - CID 0305 - FMI 06 Ignition Transformer Primary #5 short....164
  MID 014 - CID 0305 - FMI 12 Ignition Transformer Primary #5 short to return....165
  MID 014 - CID 0306 - FMI 05 Ignition Transformer Primary #6 open circuit....166
  MID 014 - CID 0306 - FMI 06 Ignition Transformer Primary #6 short....167
  MID 014 - CID 0306 - FMI 12 Ignition Transformer Primary #6 short to return....168
  MID 014 - CID 0307 - FMI 05 Ignition Transformer Primary #7 open circuit....169
  MID 014 - CID 0307 - FMI 06 Ignition Transformer Primary #7 short....170
  MID 014 - CID 0307 - FMI 12 Ignition Transformer Primary #7 short to return....171
  MID 014 - CID 0308 - FMI 05 Ignition Transformer Primary #8 open circuit....172
  MID 014 - CID 0308 - FMI 06 Ignition Transformer Primary #8 short....173
  MID 014 - CID 0308 - FMI 12 Ignition Transformer Primary #8 short to return....174
  MID 014 - CID 0309 - FMI 05 Ignition Transformer Primary #9 open circuit....175
  MID 014 - CID 0309 - FMI 06 Ignition Transformer Primary #9 short....176
  MID 014 - CID 0309 - FMI 12 Ignition Transformer Primary #9 short to return....177
  MID 014 - CID 0310 - FMI 05 Ignition Transformer Primary #10 open circuit....178
  MID 014 - CID 0310 - FMI 06 Ignition Transformer Primary #10 short....179
  MID 014 - CID 0310 - FMI 12 Ignition Transformer Primary #10 short to return....180
  MID 014 - CID 0311 - FMI 05 Ignition Transformer Primary #11 open circuit....181
  MID 014 - CID 0311 - FMI 06 Ignition Transformer Primary #11 short....182
  MID 014 - CID 0311 - FMI 12 Ignition Transformer Primary #11 short to return....183
  MID 014 - CID 0312 - FMI 05 Ignition Transformer Primary #12 open circuit....184
  MID 014 - CID 0312 - FMI 06 Ignition Transformer Primary #12 short....185
  MID 014 - CID 0312 - FMI 12 Ignition Transformer Primary #12 short to return....186
  MID 014 - CID 0317 - FMI 08 Load Sensor (MAPS) signal abnormal....187
  MID 014 - CID 0317 - FMI 11 No Inlet Manifold Pressure signal....188
  MID 014 - CID 0318 - FMI 01 Loss of Right Bank Detonation Sensor Signal....189
  MID 014 - CID 0318 - FMI 03 Right Bank Detonation Sensor short to +batt....190
  MID 014 - CID 0318 - FMI 05 Right Bank Detonation Sensor open or short to ground....191
  MID 014 - CID 0319 - FMI 01 Loss of Left Bank Detonation Sensor Signal....192
  MID 014 - CID 0319 - FMI 03 Left Bank Detonation Sensor short to +batt....193
  MID 014 - CID 0319 - FMI 05 Left Bank Detonation Sensor open or short to ground....194
  MID 014 - CID 0320 - FMI 05 Timing Control Speed Sensor open_short to +batt....195
  MID 014 - CID 0320 - FMI 07 Speed_Timing Sensor improper response....196
  MID 014 - CID 0320 - FMI 08 Engine Speed_Timing signal abnormal....197
  MID 014 - CID 0321 - FMI 04 Diagnostic Reset Switch short to ground....198
  MID 014 - CID 0322 - FMI 03 Shutdown Relay short to +batt....199
  MID 014 - CID 0322 - FMI 05 Shutdown Relay open_short to ground....200
  MID 014 - CID 0323 - FMI 03 Shutdown Lamp short to +batt....201
  MID 014 - CID 0323 - FMI 05 Shutdown Lamp open_short to ground....202
  MID 014 - CID 0324 - FMI 03 Warning Lamp short to +batt....203
  MID 014 - CID 0324 - FMI 05 Warning Lamp open_short to ground....204
  MID 014 - CID 0325 - FMI 00 Excessive Detonation....205
  MID 014 - CID 0326 - FMI 01 Detonation Retarded Timing....206
  MID 014 - CID 0327 - FMI 02 Number of Detonation Sensors mismatch....207
  MID 014 - CID 0328 - FMI 02 Number of Cylinders mismatch....208
  MID 014 - CID 0329 - FMI 11 Communication Fault with CAT A_F Ratio Control....209
  MID 014 - CID 0330 - FMI 11 Propane Timing Mode requested....210
  MID 014 - CID 0331 - FMI 11 Ignition Shutdown requested....211
  MID 014 - CID 0401 - FMI 00 Ignition Transformer Secondary #1 maintenance needed....212
  MID 014 - CID 0401 - FMI 05 Ignition Transformer Secondary #1 open circuit....213
  MID 014 - CID 0401 - FMI 06 Ignition Transformer Secondary #1 short to ground....214
  MID 014 - CID 0401 - FMI 12 Ignition Transformer Secondary #1 noisy component....215
  MID 014 - CID 0402 - FMI 00 Ignition Transformer Secondary #2 maintenance needed....216
  MID 014 - CID 0402 - FMI 05 Ignition Transformer Secondary #2 open circuit....217
  MID 014 - CID 0402 - FMI 06 Ignition Transformer Secondary #2 short to ground....218
  MID 014 - CID 0402 - FMI 12 Ignition Transformer Secondary #2 noisy component....219
  MID 014 - CID 0403 - FMI 00 Ignition Transformer Secondary #3 maintenance needed....220
  MID 014 - CID 0403 - FMI 05 Ignition Transformer Secondary #3 open circuit....221
  MID 014 - CID 0403 - FMI 06 Ignition Transformer Secondary #3 short to ground....222
  MID 014 - CID 0403 - FMI 12 Ignition Transformer Secondary #3 noisy component....223
  MID 014 - CID 0404 - FMI 00 Ignition Transformer Secondary #4 maintenance needed....224
  MID 014 - CID 0404 - FMI 05 Ignition Transformer Secondary #4 open circuit....225
  MID 014 - CID 0404 - FMI 06 Ignition Transformer Secondary #4 short to ground....226
  MID 014 - CID 0404 - FMI 12 Ignition Transformer Secondary #4 noisy component....227
  MID 014 - CID 0405 - FMI 00 Ignition Transformer Secondary #5 maintenance needed....228
  MID 014 - CID 0405 - FMI 05 Ignition Transformer Secondary #5 open circuit....229
  MID 014 - CID 0405 - FMI 06 Ignition Transformer Secondary #5 short to ground....230
  MID 014 - CID 0405 - FMI 12 Ignition Transformer Secondary #5 noisy component....231
  MID 014 - CID 0406 - FMI 00 Ignition Transformer Secondary #6 maintenance needed....232
  MID 014 - CID 0406 - FMI 05 Ignition Transformer Secondary #6 open circuit....233
  MID 014 - CID 0406 - FMI 06 Ignition Transformer Secondary #6 short to ground....234
  MID 014 - CID 0406 - FMI 12 Ignition Transformer Secondary #6 noisy component....235
  MID 014 - CID 0407 - FMI 00 Ignition Transformer Secondary #7 maintenance needed....236
  MID 014 - CID 0407 - FMI 05 Ignition Transformer Secondary #7 open circuit....237
  MID 014 - CID 0407 - FMI 06 Ignition Transformer Secondary #7 short to ground....238
  MID 014 - CID 0407 - FMI 12 Ignition Transformer Secondary #7 noisy component....239
  MID 014 - CID 0408 - FMI 00 Ignition Transformer Secondary #8 maintenance needed....240
  MID 014 - CID 0408 - FMI 05 Ignition Transformer Secondary #8 open circuit....241
  MID 014 - CID 0408 - FMI 06 Ignition Transformer Secondary #8 short to ground....242
  MID 014 - CID 0408 - FMI 12 Ignition Transformer Secondary #8 noisy component....243
  MID 014 - CID 0409 - FMI 00 Ignition Transformer Secondary #9 maintenance needed....244
  MID 014 - CID 0409 - FMI 05 Ignition Transformer Secondary #9 open circuit....245
  MID 014 - CID 0409 - FMI 06 Ignition Transformer Secondary #9 short to ground....246
  MID 014 - CID 0409 - FMI 12 Ignition Transformer Secondary #9 noisy component....247
  MID 014 - CID 0410 - FMI 00 Ignition Transformer Secondary #10 maintenance needed....248
  MID 014 - CID 0410 - FMI 05 Ignition Transformer Secondary #10 open circuit....249
  MID 014 - CID 0410 - FMI 06 Ignition Transformer Secondary #10 short to ground....250
  MID 014 - CID 0410 - FMI 12 Ignition Transformer Secondary #10 noisy component....251
  MID 014 - CID 0411 - FMI 00 Ignition Transformer Secondary #11 maintenance needed....252
  MID 014 - CID 0411 - FMI 05 Ignition Transformer Secondary #11 open circuit....253
  MID 014 - CID 0411 - FMI 06 Ignition Transformer Secondary #11 short to ground....254
  MID 014 - CID 0411 - FMI 12 Ignition Transformer Secondary #11 noisy component....255
  MID 014 - CID 0412 - FMI 00 Ignition Transformer Secondary #12 maintenance needed....256
  MID 014 - CID 0412 - FMI 05 Ignition Transformer Secondary #12 open circuit....257
  MID 014 - CID 0412 - FMI 06 Ignition Transformer Secondary #12 short to ground....258
  MID 014 - CID 0412 - FMI 12 Ignition Transformer Secondary #12 noisy component....259
  MID 014 - CID 0591 - FMI 12 EEPROM checksum fault or ECM not programmed....260
  Control Module Self Test....261
  Detonation Retard and Detonation Shutdown....268
  Detonation Sensors....280
  Diagnostic Reset Switch....292
  Electrical Power Supply....299
  Engine Speed_Timing Sensor....307
  Ignition Shutdown Circuit....316
  Ignition Transformers Primary Circuit....323
  Ignition Transformers Secondary Circuit and Spark Plugs....345
  Inlet Manifold Pressure Sensor....355
  Inspecting Electrical Connectors....361
  Programmable Parameters....372
  Propane Switch....391
  Shutdown Lamp....396
  Shutdown Relay....402
  Warning Lamp Circuit - Test....407
  Engine Speed_Timing Sensor - Calibrate....413
SENR6537 - Specifications (G3408C and G3412C Engines)....419
  Engine Design....421
  Gas Engine Ignition....423
  Ignition Transformer....433
  Gas Pressure Regulator....436
  Governor Drive....439
  Actuator Linkage....444
  Valve Cover....446
  Valve Mechanism....449
  Cylinder Head....452
  Cylinder Head Valves....458
  Turbocharger....461
  Exhaust Manifold....463
  Exhaust Bypass Valve....467
  Air Cleaner....471
  Engine Oil Pump....473
  Engine Oil Filter Base....475
  Engine Oil Pan....477
  Crankcase Breather....478
  Water Pump....479
  Water Temperature Regulator....481
  Cylinder Block....483
  Crankshaft....489
  Connecting Rod....491
  Connecting Rod and Main Bearing Journals....494
  Piston and Rings - Gallery Cooled Piston....496
  Cylinder Liner....499
  Camshaft Bearings....501
  Camshaft Bearing Position....503
  Gear Group (Front)....505
  Gear Group (Rear)....508
  Vibration Damper and Pulley....509
  Flywheel....513
  Flywheel Housing....515
  Electric Starting Motor....520
  Engine Speed Sensor....522
  Engine Detonation Sensor....523
  Engine Speed_Timing Sensor....524
  Tachometer....525
  Service Meter....527
SENR6538 - Systems Operation (G3408C and G3412C Engines)....529
  Electronic Control System Operation....530
  Electronic Control System Parameters....533
  Engine Monitoring System....536
  Ignition System....544
  Air_Fuel Ratio Control - Oxygen Feedback....553
  Air_Fuel Ratio Control - NOX Feedback....558
  Governor....563
  Gas Pressure Regulator....565
  Carburetor....568
  Air Inlet and Exhaust System Components....573
  Aftercooler....575
  Exhaust Manifold....576
  Turbocharger....577
  Exhaust Bypass Valve....579
  Valve System Components....582
  Lubrication System....584
  Accumulator....588
  Cooling System....591
  Cylinder Block; Liners and Heads....596
  Pistons; Rings and Connecting Rods....598
  Crankshaft....600
  Camshaft....602
  Air Starting System Operation....603
  Grounding Practices....605
  Charging System....606
  Starting System....608
  Related Components....610
SENR6538 - Testing and Adjusting (G3408C and G3412C Engines)....613
  General Information (Electronic Control System)....615
  Manifold Air Pressure Sensor....616
  Detonation Sensor....618
  Engine Speed_Timing Sensor....620
  Ignition Transformer....622
  Ignition System....628
  General Information (Fuel System)....636
  Carburetor - Adjust....638
  Gas Pressure....641
  Finding the Top Center Position for the No. 1 Piston....645
  Restriction of Air Inlet and Exhaust....647
  Measuring Inlet Manifold Temperature....649
  Measuring Exhaust Temperature....651
  Turbocharger - Inspect....652
  Exhaust Bypass Valve....654
  Engine Crankcase Pressure (Blowby) - Test....656
  Compression....658
  Crankshaft Position for Valve Lash Setting....660
  Valve Lash and Valve Bridge Adjustment....664
  General Information (Lubrication System)....669
  Accumulator Pressure - Test....670
  Measuring Engine Oil Pressure....674
  General Information (Cooling System)....677
  Visual Inspection....679
  Testing the Cooling System....681
  Cylinder Block....685
  Cylinder Liner Projection....686
  Flywheel - Inspect....693
  Flywheel Housing - Inspect....696
  Vibration Damper - Check....701
  Pressure Regulating Valve....702
  Lubrication....704
  General Information (Air_Electric Starting System)....705
  Test Tools for the Electrical System....708
  Charging System....713
  Battery....714
SENR6568 - Disassembly and Assembly (G3408C and G3412C Engines)....715
  Engine Support - Remove and Install....719
  Generator - Remove....721
  Generator - Install....726
  Service Meter - Remove and Install....731
  Electronic Control Module (Engine) - Remove and Install....733
  Air Starting Motor - Remove and Install....736
  Gas Pressure Regulator - Remove....739
  Gas Pressure Regulator - Disassemble....741
  Gas Pressure Regulator - Assemble....749
  Gas Pressure Regulator - Install....756
  Governor - Remove and Install....758
  Governor Drive - Remove....761
  Governor Drive - Disassemble....765
  Governor Drive - Assemble....769
  Governor Drive - Install....773
  Carburetor - Remove....777
  Carburetor - Disassemble....780
  Carburetor - Assemble....785
  Carburetor - Install....789
  Transformer - Remove and Install....792
  Spark Plugs - Remove and Install....795
  Spark Plug Adapter - Remove and Install....798
  Exhaust Bypass - Remove....803
  Exhaust Bypass - Disassemble....806
  Exhaust Bypass - Assemble....810
  Exhaust Bypass - Install....814
  Exhaust Manifold - Remove....816
  Exhaust Manifold - Install....819
  Aftercooler - Remove....822
  Aftercooler - Install....828
  Air Cleaner Housing - Remove and Install....832
  Turbocharger - Remove....835
  Turbocharger - Disassemble....838
  Turbocharger - Assemble....844
  Turbocharger - Install....850
  Water Temperature Regulator - Remove....853
  Water Temperature Regulator - Install....856
  Water Pump - Remove....859
  Water Pump - Disassemble....862
  Water Pump - Assemble....864
  Water Pump - Install....866
  Auxiliary Water Pump - Remove....868
  Auxiliary Water Pump - Disassemble....870
  Auxiliary Water Pump - Assemble....877
  Auxiliary Water Pump - Install....885
  Engine Oil Pump - Remove....886
  Engine Oil Pump - Disassemble....888
  Engine Oil Pump - Assemble....892
  Engine Oil Pump - Install....896
  Engine Oil Cooler - Remove....898
  Engine Oil Cooler - Install....902
  Engine Oil Filter Base - Remove and Install....904
  Engine Oil Pan - Remove....907
  Engine Oil Pan - Install....909
  Vibration Damper and Pulley - Remove....911
  Vibration Damper and Pulley - Install....913
  Flywheel - Remove and Install....915
  Flywheel Housing - Remove....921
  Flywheel Housing - Install....925
  Crankshaft Front Seal and Wear Sleeve - Remove....929
  Crankshaft Front Seal and Wear Sleeve - Install....931
  Crankshaft Rear Seal and Wear Sleeve - Remove....934
  Crankshaft Rear Seal and Wear Sleeve - Install....936
  Timing Gear Cover - Remove and Install....939
  Timing Gears - Remove....945
  Timing Gears - Install....948
  Engine Balancer - Remove and Install....952
  Valve Cover - Remove and Install....957
  Valve Cover Base - Remove....960
  Valve Cover Base - Install....962
  Rocker Shaft and Push Rod - Remove....964
  Rocker Shaft - Disassemble....966
  Rocker Shaft - Assemble....969
  Rocker Shaft and Push Rod - Install....973
  Valve Lifter - Remove....976
  Valve Lifter - Install....979
  Inlet and Exhaust Valves - Remove and Install....982
  Inlet and Exhaust Valve Guides - Remove and Install....986
  Bridge Dowels - Remove and Install....989
  Inlet and Exhaust Valve Seat Inserts - Remove and Install....992
  Cylinder Head - Remove....995
  Cylinder Head - Install....999
  Piston Cooling Jets - Remove and Install....1005
  Connecting Rod Bearings - Remove and Install....1008
  Pistons and Connecting Rods - Remove....1012
  Pistons and Connecting Rods - Disassemble - One-Piece Piston....1014
  Pistons and Connecting Rods - Assemble - One-Piece Piston....1016
  Pistons and Connecting Rods - Install....1020
  Cylinder Liner - Remove....1024
  Cylinder Liner - Install....1026
  Camshaft - Remove....1030
  Camshaft - Install....1034
  Camshaft Bearings - Remove....1039
  Camshaft Bearings - Install....1041
  Crankshaft Main Bearings - Remove....1045
  Crankshaft Main Bearings - Install....1048
  Crankshaft - Remove....1052
  Crankshaft - Install....1055
 
Caterpillar G3408C and G3412C Engines Repair Service Manual