Caterpillar G3520C G3520E G3500C G3500E Generator Set Engine Workshop Repair Service Manual PDF - MCATG3520CE.zip

A full service and repair guide, complete with electrical wiring schematics, covering the Caterpillar G3520C and G3520E generator set engines. Inside you'll find everything needed to service, troubleshoot, fix, and overhaul these units the way trained technicians do.

The workshop service repair manual for Caterpillar G3520C and G3520E generator set engines contains:

* 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