Caterpillar G3500 Engines Workshop Repair Service Manual PDF SENR6411 SENR6412 SENR6413 SENR6419 RENR5924 SENR1186 - MCATG3500.zip
A full workshop and repair guide for Caterpillar G3500 engines, complete with electrical wiring schematics, containing every technical detail professionals rely on to service, troubleshoot, fix, and overhaul these units.
The Caterpillar G3500-Series shop manual provides:
* 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.
SENR1186 - Schematic (G3500 Generator Set Electrical System).pdf
SENR6419 - Disassembly and Assembly (G3500 Engines).pdf
SENR6413 - Troubleshooting (G3500 Engines).pdf
SENR6412 - Testing and Adjusting (G3500 Engines).pdf
SENR6412 - Systems Operation (G3500 Engines).pdf
SENR6411 - Specifications (G3500 Engines).pdf
RENR5924 - Schematic (G3500 Engine Electrical System 114-8162-10).pdf
PRODUCT DETAILS:
Total Pages: 1,482 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
RENR5924 - Schematic (G3500 Engine Electrical System 114-8162-10)...1
SENR 1186 - Schematic (G3500 Generator Set Electrical System)...3
Main...4
Collage...6
SENR6411 - Specifications (G3500 Engines)...38
Engine Design...40
Gas Engine Ignition...42
Ignition Transformer...44
Gas Pressure Regulator...47
Camshaft...50
Valve Mechanism...53
Cylinder Head...57
Cylinder Head Valves...61
Turbocharger...63
Exhaust Manifold - Dry...66
Exhaust Flange...68
Exhaust Bypass Valve...70
Engine Oil Pump...75
Engine Oil Filter...80
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves...83
Engine Oil Pan...87
Engine Oil Temperature Regulator...90
Water Pump...92
Auxiliary Water Pump...100
Water Connection Group...108
Thermostatic Valve...110
Water Temperature Regulator...112
Cylinder Block...121
Crankshaft...125
Crankshaft Wear Sleeves and Seals...129
Connecting Rod...132
Connecting Rod and Main Bearing Journals...140
Piston and Rings...143
Cylinder Liner...147
Camshaft Bearing Position...148
Gear Group (Front)...151
Gear Group (Rear)...158
Balancer Group (Front)...162
Accessory Drive (Lower Left Hand)...164
Vibration Damper Guard...168
Vibration Damper...172
Stub Shaft (Front)...186
Flywheel...188
Flywheel Housing...191
Belt Tension Chart...194
Pressure Sensor...197
Pressure Sensor - Oil Pressure...201
Detonation Sensor...203
Manifold Air Pressure Sensor...208
Engine Speed_Timing Sensor...211
Speed Sensor...216
SENR6412 - Systems Operation (G3500 Engines)...221
Electronic Control System Operation...223
Electronic Control Module (ECM)...233
Electronic Control System Parameters...234
Engine Monitoring System...241
Ignition System...256
Air_Fuel Ratio Control...266
Governor...269
Gas Pressure Regulator...276
Carburetor...278
Air Inlet and Exhaust System Components...282
Aftercooler...287
Exhaust Manifold...290
Turbocharger...293
Exhaust Bypass Valve...295
Valve System Components...297
Lubrication System...299
Duplex Oil Filter...303
Prelube Pump - Electric...305
Prelube Pump - Air...307
Accumulator...311
Engine Oil Level Regulator...313
Crankcase Breather...315
Fumes Disposal System...317
Cooling System...319
Cylinder Block; Liners and Heads...331
Pistons; Rings and Connecting Rods...334
Crankshaft...336
Camshaft...339
Air Starting System - Starting with an Air Prelube Pump...340
Air Starting System...343
Grounding Practices...347
Charging System...348
Starting System...350
SENR6412 - Testing and Adjusting (G3500 Engines)...352
General Information (Electronic Control System)...354
Electronic Control Module (ECM)...355
Manifold Air Pressure Sensor...360
Engine Speed Sensor - Adjust...362
Detonation Sensor...363
Ignition Transformer...365
Ignition System...370
General Information (Fuel System)...372
Air_Fuel Ratio Control - Adjust...374
Carburetor - Adjust...375
Gas Pressure...376
Finding the Top Center Position for the No. 1 Piston...378
Camshaft Timing...380
Restriction of Air Inlet and Exhaust...387
Measuring Inlet Manifold Temperature...390
Measuring Exhaust Temperature...392
Exhaust Bypass Valve...393
Engine Crankcase Pressure (Blowby) - Test...395
Compression...396
Crankshaft Position for Valve Lash Setting...398
Valve Lash and Valve Bridge Adjustment...400
General Information (Lubrication System)...404
Accumulator Pressure - Test...405
Duplex Oil Filter - Adjust...409
Measuring Engine Oil Pressure...412
General Information (Cooling System)...414
Visual Inspection...416
Testing the Cooling System...418
Cylinder Block...422
Cylinder Liner Projection...424
Flywheel - Inspect...429
Flywheel Housing - Inspect...432
Vibration Damper - Check...437
Pressure Regulating Valve...439
Lubrication...441
General Information (Air_Electric Starting System)...442
Test Tools for the Electrical System...445
Charging System...450
Battery...451
Electric Starting Motor - Test...452
SENR6413 - Troubleshooting (G3500 Engines)...453
System Overview...464
Self-Diagnostics...469
Location of Components...471
Electrical Connectors and Functions...479
Electronic Service Tools...486
Engine Monitoring System...493
Programming Parameters...495
Customer Parameters Worksheet...497
Replacing the ECM...499
Replacing the EIS Control Module...502
Troubleshooting Data Sheet...505
Air Starting Motor - Malfunction...507
Alternator - Malfunction...511
Coolant in Engine Oil...513
Detonation...515
Diagnostic Code Will Not Clear...517
Electronic Service Tool Displays UNDETERMINED...518
Electronic Service Tool Will Not Communicate with ECM...519
Engine Coolant Temperature (High)...520
Engine Coolant Temperature (Low)...523
Engine Cranks but Will Not Start...524
Engine Has Early Wear...526
Engine Misfires; Runs Rough or Is Unstable...528
Engine Oil in Cooling System...531
Engine Oil Pressure (Low)...532
Engine Shutdown without a Diagnostic Code...534
Engine Starts but Stalls Immediately...536
Engine Timing Does Not Match Programmed Timing...538
Engine Will Not Crank...539
Excessive Engine Oil Consumption...541
Exhaust Port Temperature (High)...543
Fuel Metering Valve...545
Inlet Air Temperature (High)...546
Intermittent Engine Shutdown...548
Low Power_Poor or No Response to Throttle...550
Mechanical Noise (Knock) in Engine...553
Noise Coming from Cylinder...556
Poor Fuel Consumption...557
Short Spark Plug Life...558
Too Much Vibration...560
Diagnostic Codes...561
MID 014 - CID 0168 - FMI 02 System Voltage intermittent_erratic...563
MID 014 - CID 0300 - FMI 03 Primary Return short to +batt...564
MID 014 - CID 0300 - FMI 04 Primary Return short to ground...565
MID 014 - CID 0301 - FMI 05 Ignition Transformer Primary #1 open circuit...566
MID 014 - CID 0301 - FMI 06 Ignition Transformer Primary #1 short...567
MID 014 - CID 0301 - FMI 12 Ignition Transformer Primary #1 short to return...568
MID 014 - CID 0302 - FMI 05 Ignition Transformer Primary #2 open circuit...569
MID 014 - CID 0302 - FMI 06 Ignition Transformer Primary #2 short...570
MID 014 - CID 0302 - FMI 12 Ignition Transformer Primary #2 short to return...571
MID 014 - CID 0303 - FMI 05 Ignition Transformer Primary #3 open circuit...572
MID 014 - CID 0303 - FMI 06 Ignition Transformer Primary #3 short...573
MID 014 - CID 0303 - FMI 12 Ignition Transformer Primary #3 short to return...574
MID 014 - CID 0304 - FMI 05 Ignition Transformer Primary #4 open circuit...575
MID 014 - CID 0304 - FMI 06 Ignition Transformer Primary #4 short...576
MID 014 - CID 0304 - FMI 12 Ignition Transformer Primary #4 short to return...577
MID 014 - CID 0305 - FMI 05 Ignition Transformer Primary #5 open circuit...578
MID 014 - CID 0305 - FMI 06 Ignition Transformer Primary #5 short...579
MID 014 - CID 0305 - FMI 12 Ignition Transformer Primary #5 short to return...580
MID 014 - CID 0306 - FMI 05 Ignition Transformer Primary #6 open circuit...581
MID 014 - CID 0306 - FMI 06 Ignition Transformer Primary #6 short...582
MID 014 - CID 0306 - FMI 12 Ignition Transformer Primary #6 short to return...583
MID 014 - CID 0307 - FMI 05 Ignition Transformer Primary #7 open circuit...584
MID 014 - CID 0307 - FMI 06 Ignition Transformer Primary #7 short...585
MID 014 - CID 0307 - FMI 12 Ignition Transformer Primary #7 short to return...586
MID 014 - CID 0308 - FMI 05 Ignition Transformer Primary #8 open circuit...587
MID 014 - CID 0308 - FMI 06 Ignition Transformer Primary #8 short...588
MID 014 - CID 0308 - FMI 12 Ignition Transformer Primary #8 short to return...589
MID 014 - CID 0309 - FMI 05 Ignition Transformer Primary #9 open circuit...590
MID 014 - CID 0309 - FMI 06 Ignition Transformer Primary #9 short...591
MID 014 - CID 0309 - FMI 12 Ignition Transformer Primary #9 short to return...592
MID 014 - CID 0310 - FMI 05 Ignition Transformer Primary #10 open circuit...593
MID 014 - CID 0310 - FMI 06 Ignition Transformer Primary #10 short...594
MID 014 - CID 0310 - FMI 12 Ignition Transformer Primary #10 short to return...595
MID 014 - CID 0311 - FMI 05 Ignition Transformer Primary #11 open circuit...596
MID 014 - CID 0311 - FMI 06 Ignition Transformer Primary #11 short...597
MID 014 - CID 0311 - FMI 12 Ignition Transformer Primary #11 short to return...598
MID 014 - CID 0312 - FMI 05 Ignition Transformer Primary #12 open circuit...599
MID 014 - CID 0312 - FMI 06 Ignition Transformer Primary #12 short...600
MID 014 - CID 0312 - FMI 12 Ignition Transformer Primary #12 short to return...601
MID 014 - CID 0313 - FMI 05 Ignition Transformer Primary #13 open circuit...602
MID 014 - CID 0313 - FMI 06 Ignition Transformer Primary #13 short...603
MID 014 - CID 0313 - FMI 12 Ignition Transformer Primary #13 short to return...604
MID 014 - CID 0314 - FMI 05 Ignition Transformer Primary #14 open circuit...605
MID 014 - CID 0314 - FMI 06 Ignition Transformer Primary #14 short...606
MID 014 - CID 0314 - FMI 12 Ignition Transformer Primary #14 short to return...607
MID 014 - CID 0315 - FMI 05 Ignition Transformer Primary #15 open circuit...608
MID 014 - CID 0315 - FMI 06 Ignition Transformer Primary #15 short...609
MID 014 - CID 0315 - FMI 12 Ignition Transformer Primary #15 short to return...610
MID 014 - CID 0316 - FMI 05 Ignition Transformer Primary #16 open circuit...611
MID 014 - CID 0316 - FMI 06 Ignition Transformer Primary #16 short...612
MID 014 - CID 0316 - FMI 12 Ignition Transformer Primary #16 short to return...613
MID 014 - CID 0317 - FMI 08 Load Sensor (MAPS) signal abnormal...614
MID 014 - CID 0317 - FMI 11 No Inlet Manifold Pressure signal...615
MID 014 - CID 0318 - FMI 01 Loss of Right Bank Detonation Sensor Signal...616
MID 014 - CID 0318 - FMI 03 Right Bank Detonation Sensor short to +batt...617
MID 014 - CID 0318 - FMI 05 Right Bank Detonation Sensor open or short to ground...618
MID 014 - CID 0319 - FMI 01 Loss of Left Bank Detonation Sensor Signal...619
MID 014 - CID 0319 - FMI 03 Left Bank Detonation Sensor short to +batt...620
MID 014 - CID 0319 - FMI 05 Left Bank Detonation Sensor open or short to ground...621
MID 014 - CID 0320 - FMI 05 Timing Control Speed Sensor open_short to +batt...622
MID 014 - CID 0320 - FMI 07 Speed_Timing Sensor improper response...623
MID 014 - CID 0320 - FMI 08 Engine Speed_Timing signal abnormal...624
MID 014 - CID 0321 - FMI 04 Diagnostic Reset Switch short to ground...625
MID 014 - CID 0322 - FMI 03 Shutdown Relay short to +batt...626
MID 014 - CID 0322 - FMI 05 Shutdown Relay open_short to ground...627
MID 014 - CID 0323 - FMI 03 Shutdown Lamp short to +batt...628
MID 014 - CID 0323 - FMI 05 Shutdown Lamp open_short to ground...629
MID 014 - CID 0324 - FMI 03 Warning Lamp short to +batt...630
MID 014 - CID 0324 - FMI 05 Warning Lamp open_short to ground...631
MID 014 - CID 0325 - FMI 00 Excessive Detonation...632
MID 014 - CID 0326 - FMI 01 Detonation Retarded Timing...633
MID 014 - CID 0327 - FMI 02 Number of Detonation Sensors mismatch...634
MID 014 - CID 0328 - FMI 02 Number of Cylinders mismatch...635
MID 014 - CID 0329 - FMI 11 Communication Fault with CAT A_F Ratio Control...636
MID 014 - CID 0330 - FMI 11 Propane Timing Mode requested...637
MID 014 - CID 0331 - FMI 11 Ignition Shutdown requested...638
MID 014 - CID 0401 - FMI 00 Ignition Transformer Secondary #1 maintenance needed...639
MID 014 - CID 0401 - FMI 05 Ignition Transformer Secondary #1 open circuit...640
MID 014 - CID 0401 - FMI 06 Ignition Transformer Secondary #1 short to ground...641
MID 014 - CID 0401 - FMI 12 Ignition Transformer Secondary #1 noisy component...642
MID 014 - CID 0402 - FMI 00 Ignition Transformer Secondary #2 maintenance needed...643
MID 014 - CID 0402 - FMI 05 Ignition Transformer Secondary #2 open circuit...644
MID 014 - CID 0402 - FMI 06 Ignition Transformer Secondary #2 short to ground...645
MID 014 - CID 0402 - FMI 12 Ignition Transformer Secondary #2 noisy component...646
MID 014 - CID 0403 - FMI 00 Ignition Transformer Secondary #3 maintenance needed...647
MID 014 - CID 0403 - FMI 05 Ignition Transformer Secondary #3 open circuit...648
MID 014 - CID 0403 - FMI 06 Ignition Transformer Secondary #3 short to ground...649
MID 014 - CID 0403 - FMI 12 Ignition Transformer Secondary #3 noisy component...650
MID 014 - CID 0404 - FMI 00 Ignition Transformer Secondary #4 maintenance needed...651
MID 014 - CID 0404 - FMI 05 Ignition Transformer Secondary #4 open circuit...652
MID 014 - CID 0404 - FMI 06 Ignition Transformer Secondary #4 short to ground...653
MID 014 - CID 0404 - FMI 12 Ignition Transformer Secondary #4 noisy component...654
MID 014 - CID 0405 - FMI 00 Ignition Transformer Secondary #5 maintenance needed...655
MID 014 - CID 0405 - FMI 05 Ignition Transformer Secondary #5 open circuit...656
MID 014 - CID 0405 - FMI 06 Ignition Transformer Secondary #5 short to ground...657
MID 014 - CID 0405 - FMI 12 Ignition Transformer Secondary #5 noisy component...658
MID 014 - CID 0406 - FMI 00 Ignition Transformer Secondary #6 maintenance needed...659
MID 014 - CID 0406 - FMI 05 Ignition Transformer Secondary #6 open circuit...660
MID 014 - CID 0406 - FMI 06 Ignition Transformer Secondary #6 short to ground...661
MID 014 - CID 0406 - FMI 12 Ignition Transformer Secondary #6 noisy component...662
MID 014 - CID 0407 - FMI 00 Ignition Transformer Secondary #7 maintenance needed...663
MID 014 - CID 0407 - FMI 05 Ignition Transformer Secondary #7 open circuit...664
MID 014 - CID 0407 - FMI 06 Ignition Transformer Secondary #7 short to ground...665
MID 014 - CID 0407 - FMI 12 Ignition Transformer Secondary #7 noisy component...666
MID 014 - CID 0408 - FMI 00 Ignition Transformer Secondary #8 maintenance needed...667
MID 014 - CID 0408 - FMI 05 Ignition Transformer Secondary #8 open circuit...668
MID 014 - CID 0408 - FMI 06 Ignition Transformer Secondary #8 short to ground...669
MID 014 - CID 0408 - FMI 12 Ignition Transformer Secondary #8 noisy component...670
MID 014 - CID 0409 - FMI 00 Ignition Transformer Secondary #9 maintenance needed...671
MID 014 - CID 0409 - FMI 05 Ignition Transformer Secondary #9 open circuit...672