Caterpillar CG137-8 CG137-12 Gas Engine Workshop Repair Manual PDF - MCATCG137.zip
This is a full factory-style service and repair guide, complete with Electrical Wiring Diagrams, covering the Caterpillar CG137-08 and CG137-12 Engines. It contains every piece of technical data needed to service, troubleshoot, fix, and overhaul these engines the way trained professionals do.
The Caterpillar CG137-8 and CG137-12 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.
KENR9787 - Specifications (CG137-08 and CG137-12 Generator Sets).pdf
KENR9788 - Systems Operation (CG137-08 and CG137-12 Industrial Engines).pdf
KENR9788 - Testing and Adjusting (CG137-08 and CG137-12 Industrial Engines).pdf
KENR9788 - Troubleshooting (CG137-08 and CG137-12 Industrial Engines).pdf
M0090979 - Systems Operation (CG137-8 Gas Engine).pdf
M0090979 - Testing and Adjusting (CG137-8 Gas Engine).pdf
M0090983 - Troubleshooting (CG137-8 Gas Engine).pdf
M0092679 - Disassembly and Assembly (CG137-08 Engines).pdf
M0109962 - Schematic (CG137-8 Engine HMI Display Electrical System).pdf
M0115971 - Schematic (CG137-8 Engine Control Panel Electrical System).pdf
UENR0103 - Disassembly and Assembly (CG137-08 and CG137-12 Engines).pdf
UENR3682 - Schematic (CG137-8 Engine Electrical System).pdf
UENR8336 - Schematic (CG137-8 Engine HMI Display Electrical System).pdf
UENR8340 - Schematic (CG137-8 Engine Electrical System).pdf
PRODUCT DETAILS:
Total Pages: 1,708 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KENR9787 - Specifications (CG137-08 and CG137-12 Generator Sets)....1
Gas Engine Ignition....3
Ignition Transformer....8
Gas Pressure Regulator....10
Governor Drive....12
Engine Oil Lines....17
Camshaft....23
Valve Cover....29
Valve Mechanism....35
Cylinder Head....42
Cylinder Head Valves....49
Turbocharger....53
Accumulator....57
Exhaust Manifold - Water Cooled....58
Exhaust Manifold....64
Exhaust Bypass Valve....70
Air Cleaner....77
Air Cleaner Adapter....79
Engine Oil Pump....81
Engine Oil Filter Base....87
Crankcase Breather....92
Water Pump....94
Auxiliary Water Pump....100
Water Temperature Regulator....102
Cylinder Block....105
Crankshaft....114
Connecting Rod....119
Connecting Rod and Main Bearing Journals....122
Piston and Rings....123
Cylinder Liner....127
Camshaft Bearings....128
Camshaft Bearing Position....131
Crankshaft Pulley....135
Gear Group (Front)....136
Cover Group (Front Housing)....143
Gear Group (Rear)....144
Vibration Damper and Pulley....146
Stub Shaft (Rear)....148
Flywheel Housing Cover....150
Flywheel....153
Flywheel Housing....155
Alternator and Regulator....157
Electric Starting Motor....161
Air Starting Motor....163
Gas Solenoid Valve....167
Engine Speed Sensor....168
Coolant Temperature Sensor....169
Pressure Sensor....170
Fuel Pressure Sensor....171
Inlet Air Temperature Sensor....172
Engine Oil Temperature Sensor....173
Engine Oil Pressure Sensor....174
Exhaust Temperature Sensor....175
Engine Speed_Timing Sensor....177
Magnetic Switch....178
KENR9788 - Systems Operation (CG137-08 and CG137-12 Industrial Engines)....180
Engine Control Panel....181
Electronic Control System Components....191
Electronic Control Module (ECM)....200
Electrical Connectors....203
System Configuration Parameters....220
Engine Monitoring Parameters....228
Engine Monitoring System....233
Ignition Transformer....234
Spark Plug....237
Carburetor....239
Gas Pressure Regulator....242
Aftercooler....244
Catalytic Converter....246
Exhaust Manifold....248
Exhaust Bypass Valve....249
Turbocharger....251
Lubrication System....253
Accumulator....257
Cooling System....260
Cylinder Block; Liners and Heads....265
Pistons; Rings and Connecting Rods....270
Crankshaft....271
Camshaft....273
Vibration Damper....274
Air Starting System....276
Charging System....279
Starting System....281
KENR9788 - Testing and Adjusting (CG137-08 and CG137-12 Industrial Engines)....284
Spark Plug - Test....286
Carburetor (Low Pressure Gas) - Adjust....287
Engine Governing - Adjust....288
Finding Top Center Position for No. 1 Piston....289
Gas Pressure - Check and Adjust....292
Air Inlet Restriction and Exhaust Restriction - Test....297
Inlet Manifold Pressure - Test....301
Aftercooler - Test....304
Catalytic Converter Substrate - Inspect....310
Catalytic Converter Performance - Test....313
Catalytic Converter Pressure - Test....316
Engine Crankcase Pressure (Blowby) - Test....317
Compression - Test....319
Engine Valve Lash - Inspect_Adjust....321
Accumulator Pressure - Test....327
Engine Oil Pressure - Test....335
Excessive Bearing Wear - Inspect....342
Excessive Engine Oil Consumption - Inspect....343
Increased Engine Oil Temperature - Inspect....344
Cooling System - Check....345
Cooling System - Inspect....352
Cooling System - Test....354
Water Temperature Regulator - Test....362
Water Pump - Test....364
Connecting Rod - Inspect....368
Connecting Rod Bearings - Inspect....369
Main Bearings - Inspect....370
Cylinder Block - Inspect....372
Cylinder Liner Projection - Inspect....373
Flywheel - Inspect....385
Flywheel Housing - Inspect....388
Vibration Damper - Check....393
Starting Air Pressure - Adjust....395
Air Starting Motor - Lubricate....397
Battery - Test....398
Charging System - Test....401
Electric Starting System - Test....404
Factory Password - Obtain....407
ECM Will Not Accept Factory Passwords....409
Electronic Service Tool Does Not Communicate....410
ECM Software - Install....414
ECM - Replace....416
Electrical Connector - Inspect....419
Unburned Gas - Purge....425
KENR9788 - Troubleshooting (CG137-08 and CG137-12 Industrial Engines)....427
General Information....429
Welding Precaution....430
Electronic Service Tools....432
Diagnostic Capabilities....442
Troubleshooting Data Sheet....443
Diagnostic Trouble Codes....446
Symptom Troubleshooting....473
Air_Fuel Ratio Problem....474
Alternator Problem - Charging Problem and_or Noisy Operation....475
Catalytic Converter Has High Differential Temperature....477
Catalytic Converter Has High Inlet Temperature....479
Catalytic Converter Has High Outlet Temperature....482
Catalytic Converter Has Low Inlet Temperature....484
Coolant Temperature Is High....486
Coolant Temperature Is Low....490
Engine Cranks but Does Not Start....492
Engine Does Not Crank....495
Engine Misfires; Runs Rough or Is Unstable....498
Engine Overspeeds....502
Engine Shutdown Is Intermittent....504
Engine Shutdown Occurrence....506
Engine Shutdown or Start Inhibit Initiated by Driven Equipment....510
Engine Stalls Immediately After Starting....512
Engine Timing Does Not Match Programmed Timing....515
Exhaust Temperature Is High....516
Exhaust Temperature Is Low....522
Fuel Energy Content Problem....526
Fuel Flow Rate Is Low....527
Fuel Pressure Problem....529
Inlet Air Is Restricted....530
Inlet Air Temperature Is High....532
Intake Manifold Air Pressure Is High....535
Intake Manifold Air Temperature Is High....537
Oil Filter Differential Pressure Problem....539
Oil Pressure Is Low....541
Oil Temperature Is High....544
Power Is Low....546
Turbocharger Turbine Temperature Is High....548
Valve Lash Is Excessive....550
CAN Data Link - Test....552
Electrical Power Supply - Test....568
Engine Control Switch - Test....587
Exhaust Temperature Module - Test....592
Fuel Actuator - Test....602
Fuel Shutoff - Test....612
Ignition Primary - Test....625
Ignition Secondary - Test....648
Oxygen Level - Test....657
Sensor Signal (Analog; Active) - Test....687
Sensor Signal (Analog; Passive) - Test....706
Sensor Supply - Test....716
Shutdown - Test....732
Speed_Timing (Primary) - Test....741
Speed_Timing (Secondary) - Test....752
Starting - Test....761
Throttle Actuator - Test....774
M0090979 - Systems Operation (CG137-8 Gas Engine)....784
Electronic Control System Operation....785
Engine Control Panel....789
Electronic Control System Parameters - Configuration Parameters....790
Electronic Service Tools....798
Engine Monitoring System....799
Ignition System....801
Fuel System Operation....804
Air Inlet and Exhaust System Components....806
Aftercooler....808
Turbocharger....810
Exhaust Bypass Valve....812
Lubrication System....814
Accumulator....818
Cylinder Block; Liners and Heads....821
Pistons; Rings and Connecting Rods....825
Crankshaft....826
Camshaft....828
Air Starting System....829
Charging System....832
Starting System....834
M0090979 - Testing and Adjusting (CG137-8 Gas Engine)....837
Engine Governing - Adjust....839
Spark Plug - Test....840
Air_Fuel Ratio Control - Adjust....841
Finding the Top Center Position for the No. 1 Piston....842
Air Inlet Restriction and Exhaust Restriction - Test....845
Inlet Manifold Pressure - Test....849
Aftercooler - Test....852
Engine Crankcase Pressure (Blowby) - Test....858
Compression - Test....860
Engine Valve Lash - Inspect_Adjust....862
Catalytic Converter Pressure - Test....868
Accumulator Pressure - Test....869
Engine Oil Pressure - Test....877
Excessive Bearing Wear - Inspect....884
Excessive Engine Oil Consumption - Inspect....885
Increased Engine Oil Temperature - Inspect....886
Cooling System - Check....887
Cooling System - Inspect....894
Cooling System - Test....896
Water Temperature Regulator - Test....904
Water Pump - Test....906
Connecting Rod - Inspect....910
Connecting Rod Bearings - Inspect....911
Main Bearings - Inspect....912
Cylinder Block - Inspect....914
Cylinder Liner Projection - Inspect....915
Flywheel - Inspect....927
Flywheel Housing - Inspect....930
Vibration Damper - Check....935
Starting Air Pressure - Adjust....937
Air Starting Motor - Lubricate....939
Charging System - Test....940
Battery - Test....943
Electric Starting System - Test....946
M0090983 - Troubleshooting (CG137-8 Gas Engine)....948
General Information....951
Welding Precaution....952
Electronic Service Tools....954
Component Location....963
Engine Monitoring System....964
Diagnostic Capabilities....974
Programmable Parameters....976
Electrical Connectors....977
Configuration Parameters....978
Diagnostic Trouble Codes....979
Event Codes....992
Symptom Troubleshooting....1008
Alternator Problem - Charging Problem and_or Noisy Operation....1010
Catalytic Converter Has High Differential Temperature....1013
Catalytic Converter Has High Inlet Temperature....1015
Catalytic Converter Has High Outlet Temperature....1018
Catalytic Converter Has Low Inlet Temperature....1020
Clean Emissions Module Has High Oxygen Level....1022
Coolant Temperature Is High....1024
Coolant Temperature Is Low....1030
Engine Cranks but Does Not Start....1034
Engine Does Not Crank....1037
Engine Misfires; Runs Rough or Is Unstable....1040
Engine Overspeeds....1045
Engine Shutdown Occurrence....1048
Engine Shutdown Occurs Intermittently....1052
Engine Shutdown or Start Inhibit Initiated by Driven Equipment....1055
Engine Stalls Immediately After Starting....1057
Exhaust Temperature Is High....1060