Caterpillar G3520C, G3520E Generator Set Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar G3520C, G3520E Generator Set Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar G3520C, G3520E 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.
PRODUCT DETAILS:
Total Pages: 1,301 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
G3520C and G3520E Generator Set Engines/RENR8103 - Schematic (G3500C & G3500E Generator Electrical System) (B9P201-; CWW207-; CWY207-; All other Serial Numbers 1-UP)
G3520C and G3520E Generator Set Engines/RENR5955 - Schematic (G3520C and G3520E Engine Electrical System).pdf
G3520C and G3520E Generator Set Engines/RENR5977 - Specifications (G3520C and G3520E Engines).pdf
G3520C and G3520E Generator Set Engines/RENR5978 - Systems Operation (G3520C and G3520E Generator Set Engines).pdf
G3520C and G3520E Generator Set Engines/RENR5978 - Testing and Adjusting (G3520C and G3520E Generator Set Engines).pdf
G3520C and G3520E Generator Set Engines/RENR5979 - Troubleshooting (G3520C and G3520E Generator Set Engines).pdf
G3520C and G3520E Generator Set Engines/RENR5980 - Disassembly and Assembly (G3520C and G3520E Generator Set Engines).pdf
G3520C and G3520E Generator Set Engines/RENR8103 - Schematic (G3500C & G3500E Generator Electrical System) (B9P201-; CWW207-; CWY207-; All other Serial Numbers 1-UP).pdf
TABLE OF CONTENTS
RENR5980 - Disassembly and Assembly (G3520C and G3520E Generator Set Engines)...2
Electronic Control Module - Remove and Install...5
Fuel Control Valve - Remove and Install...9
Throttle Control Valve - Remove...14
Throttle Control Valve - Install...18
Spark Plug - Remove and Install...22
Exhaust Elbow - Remove and Install...30
Exhaust Manifold - Remove...35
Exhaust Manifold - Install...38
Aftercooler - Remove...42
Aftercooler - Install...48
Air Inlet Manifold - Remove and Install...53
Turbocharger - Remove...67
Turbocharger - Disassemble - Dual Turbochargers...71
Turbocharger - Assemble - Dual Turbochargers...73
Turbocharger - Install...76
Actuator Bypass Valve (Variable) - Remove...79
Actuator Bypass Valve (Variable) - Install...82
Water Temperature Regulators - Remove...90
Water Temperature Regulators - Install...96
Thermostatic Valve - Remove...104
Thermostatic Valve - Disassemble...106
Thermostatic Valve - Assemble...108
Thermostatic Valve - Install...110
Water Pump - Remove...112
Water Pump - Disassemble...115
Water Pump - Assemble...128
Water Pump - Install...142
Auxiliary Water Pump - Remove...144
Auxiliary Water Pump - Disassemble...146
Auxiliary Water Pump - Assemble...152
Auxiliary Water Pump - Install...160
Engine Oil Pump - Remove...162
Engine Oil Pump - Disassemble...168
Engine Oil Pump - Assemble...175
Engine Oil Pump - Install...182
Engine Oil Cooler - Remove...187
Engine Oil Cooler - Install...198
Engine Oil Filter Base - Remove...207
Engine Oil Filter Base - Disassemble...213
Engine Oil Filter Base - Assemble...215
Engine Oil Filter Base - Install...217
Engine Oil and Water Pump Drive - Remove...223
Engine Oil and Water Pump Drive - Disassemble...225
Engine Oil and Water Pump Drive - Assemble...230
Engine Oil and Water Pump Drive - Install...234
Engine Oil Pan - Remove...236
Engine Oil Pan - Disassemble...240
Engine Oil Pan - Assemble...242
Engine Oil Pan - Install...245
Engine Oil Sequence Valves - Remove and Install...250
Drive Housing (Front) - Remove and Install...255
Vibration Damper - Remove and Install...266
Flywheel - Remove and Install...271
Flywheel Housing - Remove...285
Flywheel Housing - Install...295
Crankshaft Front Seal and Wear Sleeve - Remove...310
Crankshaft Front Seal and Wear Sleeve - Install...312
Crankshaft Rear Seal and Wear Sleeve - Remove...319
Crankshaft Rear Seal and Wear Sleeve - Install...321
Accessory Drive (Front) - Remove...327
Accessory Drive (Front) - Disassemble...335
Accessory Drive (Front) - Assemble...342
Accessory Drive (Front) - Install...348
Gear Group (Rear) - Remove...355
Gear Group (Rear) - Install...358
Crankcase Breather - Remove and Install...364
Valve Cover - Remove and Install...366
Rocker Shaft and Push Rod - Remove...370
Rocker Shaft - Disassemble...372
Rocker Shaft - Assemble...374
Rocker Shaft and Push Rod - Install...376
Cylinder Head - Remove...378
Cylinder Head - Disassemble...389
Cylinder Head - Assemble...401
Cylinder Head - Install...413
Piston Cooling Jets - Remove and Install...425
Bearing Clearance - Check...428
Connecting Rod Bearings - Remove and Install...430
Piston and Connecting Rods - Remove...435
Piston and Connecting Rods - Install...439
Cylinder Liner - Remove...444
Cylinder Liner - Install...446
Camshaft - Remove...450
Camshaft - Install...457
Camshaft Bearings - Remove...466
Camshaft Bearings - Install...468
Crankshaft Main Bearings - Remove...470
Crankshaft Main Bearings - Install...474
Crankshaft - Remove...479
Crankshaft - Install...482
RENR5955 - Schematic (G3520C and G3520E Engine Electrical System)...487
RENR5977 - Specifications (G3520C and G3520E Engines)...489
Engine Design...491
Spark Plug...493
Air Lines - Compressor Bypass...495
Air Inlet Elbow...497
Gas Engine Ignition...499
Actuator Linkage...501
Fuel Lines...503
Camshaft...505
Valve Mechanism...507
Cylinder Head...509
Cylinder Head Valves...514
Turbocharger...517
Exhaust Manifold...519
Air Cleaner...522
Engine Oil Pump...524
Engine Oil Filter...531
Engine Oil Cooler Bypass Valve...535
Engine Oil Pan...538
Engine Oil Temperature Regulator...540
Crankcase Breather...542
Water Pump...544
Thermostatic Valve...547
Water Temperature Regulator...555
Cylinder Block...561
Crankshaft...564
Crankshaft Wear Sleeves and Seals...568
Connecting Rod...570
Connecting Rod and Main Bearing Journals...573
Piston and Rings...574
Cylinder Liner...578
Camshaft Bearing Position...579
Gear Group (Front)...581
Gear Group (Rear)...584
Accessory Drive (Upper Left Hand)...588
Auxiliary Drive (Lower Left Hand)...590
Engine Mount...594
Vibration Damper Guard...595
Flywheel Housing Cover...597
Flywheel...598
Flywheel Housing...600
Belt Tension Chart...602
Accessory Drive...605
Alternator and Regulator...608
Alternator Mounting...610
Electric Starting Motor...612
Engine Speed Sensor...614
Temperature Sensor - Thermocouple...615
Temperature Sensor...616
Pressure Sensor...620
Detonation Sensor...625
Jacket Water Inlet Pressure Switch...626
Disconnect Switch...627
Engine Speed_Timing Sensor...628
Magnetic Switch...631
Junction Box...633
RENR5978 - Systems Operation (G3520C and G3520E Generator Set Engines)...635
Electronic Control System Operation...637
Electronic Control Module (ECM)...640
Start_Stop Control...643
Engine Governing...645
Integrated Temperature Sensing Module...647
Electronic Control System Parameters - Configuration Parameters...652
Engine Sensors...671
Electronic Service Tools...677
Engine Monitoring System...679
Ignition System...686
Fuel System Operation...689
Air_Fuel Ratio Control...699
Aftercooler...705
Compressor Bypass...707
Exhaust Manifold...709
Turbocharger...711
Valve System Components...713
Lubrication System...715
Cooling System...719
Cylinder Block; Liners and Heads...723
Pistons; Rings and Connecting Rods...726
Crankshaft...728
Camshaft...731
Air Starting System...732
Electric Starting System...735
Power Supply...737
Grounding Practices...738
Alternator...739
Starting Solenoid...741
Starting Motor...743
Circuit Breaker...745
RENR5978 - Testing and Adjusting (G3520C and G3520E Generator Set Engines)...747
General Information (Electronic Control System)...749
Engine Governing - Adjust...753
Manifold Air Pressure Sensor...756
Detonation Sensor...758
Engine Speed_Timing Sensor...759
Ignition Transformer...762
Ignition Timing - Adjust...768
General Information (Fuel System) - Gas...769
Air_Fuel Ratio Control - Adjust...770
Finding the Top Center Position for the No. 1 Piston...772
Camshaft Timing...774
Restriction of Air Inlet and Exhaust...780
Measuring Inlet Manifold Temperature...783
Measuring Exhaust Temperature...785
Compression...786
Crankshaft Position for Valve Lash Setting...788
Valve Lash and Valve Bridge Adjustment...789
General Information (Lubrication System)...795
Excessive Bearing Wear - Inspect...796
Excessive Engine Oil Consumption - Inspect...797
Increased Engine Oil Temperature - Inspect...798
Measuring Engine Oil Pressure...799
General Information (Cooling System)...801
Visual Inspection...803
Test Tools for the Cooling System...805
Testing the Cooling System...809
Cylinder Block...817
Cylinder Liner Projection...819
Flywheel - Inspect...824
Flywheel Housing - Inspect...828
Vibration Damper - Check...833
General Information (Air_Electric Starting System)...835
Test Tools for the Electrical System...838
Battery...843
RENR5979 - Troubleshooting (G3520C and G3520E Generator Set Engines)...844
General Information...847
Welding Precaution...848
Electronic Service Tools...850
Troubleshooting Data Sheet...860
System Overview...862
Component Location...865
Engine Monitoring System...875
Diagnostic Capabilities...877
Programmable Parameters...878
Electrical Connectors...879
Configuration Parameters...885
Diagnostic Trouble Codes...888
Event Codes...905
Symptom Troubleshooting...923
Coolant Pressure Is High...924
Coolant Pressure Is Low...926
Coolant Temperature Is High...928
Coolant Temperature Is Low...932
Detonation Occurrence...934
Engine Cranks but Does Not Start...942
Engine Does Not Crank...945
Engine Misfires; Runs Rough or Is Unstable...948
Engine Overcrank Occurrence...952
Engine Overloads...955
Engine Overspeeds...957
Engine Shutdown Is Intermittent...959
Engine Shutdown Occurrence...962
Engine Shutdown or Start Inhibit Initiated by Driven Equipment...966
Engine Stalls Immediately After Starting...968
Engine Timing Does Not Match Programmed Timing...971
Exhaust Temperature Is High...972
Exhaust Temperature Is Low...981
Fuel Differential Pressure Is High...987
Fuel Differential Pressure Is Low...989
Fuel Energy Content Problem...991
Fuel Flow Rate Is Low...993
Fuel Metering Valve Problem...995
Fuel Pressure Problem...997
Fuel Temperature Is High...999
Generator Output Power Readings Do Not Match...1000
Inlet Air Temperature Is High...1003
Oil Filter Differential Pressure Problem...1006
Oil Pressure Is High...1009
Oil Pressure Is Low...1010
Oil Temperature Is High...1013
System Voltage Problem...1015
Temperature Ratio of Coolant to Oil Is Low...1016
Turbocharger Turbine Temperature Is High...1018
Turbocharger Turbine Temperature Is Low...1021
Cat Data Link - Test...1023
Detonation - Test...1031
Electrical Power Supply - Test...1044
Engine Speed - Test...1053
Fuel Control - Test...1058
Fuel Metering Valve - Test...1073
Generator Output Power - Test...1086
Ignition Primary - Test...1097
Ignition Secondary - Test...1117
Indicator Lamp - Test...1126
Integrated Temperature Sensing Module - Test...1135
Sensor Signal (Analog; Active) - Test...1150
Sensor Signal (Analog; Passive) - Test...1162
Sensor Signal (PWM) - Test...1168
Sensor Supply - Test...1176
Speed Control (Switch) - Test...1182
Speed_Timing - Test...1188
Starting - Test...1199
Throttle Actuator - Test...1216
Turbocharger Compressor Bypass - Test...1227
Customer Passwords...1238
Factory Passwords...1240
ECM Will Not Accept Factory Passwords...1242
Electronic Service Tool Does Not Communicate...1244
ECM Software - Install...1248
ECM - Replace...1250
Control Module - Replace...1253
Electrical Connectors - Inspect...1258
Unburned Gas - Purge...1265
Generator Output Power Sensor - Set...1266
Timing - Calibrate...1270
RENR8103 - Schematic (G3500C & G3500E Generator Electrical System) (B9P201-; CWW207-; CWY207-; All other Serial Numbers 1-UP)...1273
Main...1274
Collage...1278
Caterpillar G3520C, G3520E Generator Set Engines Repair Service Manual
