CAT Caterpillar CG137-12 Service Repair Manual PDF Download by Heavy Equipment Manual

CG137-12 GENERATOR SET SC200001-UP

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

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

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

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

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

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

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

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 

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

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

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

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 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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











































































































This is the sample of the manual click on the download link for complete manual

DOWNLOAD LINK For some reason if link does not work download this pdf and then click

  Product: GENERATOR SET Model: CG137-12 GENERATOR SET SC2 Configuration: CG137–12 Generator Set SC200001-UP

Disassembly and Assembly CG137-08 and CG137-12 Engines Media Number -UENR0103-04

Publication Date -01/05/2016

Date Updated -03/05/2016

i05183090

Aftercooler - Remove and Install - G3408B SMCS - 1063-010 S/N - FPL1-UP S/N - SC21-UP S/N - WWF1-UP

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

207-1600(1)

Rubber Lubricant

207-1601

Rubber Lubricant

A (1)

For Use in EAME

Start By: a. Remove the carburetor. 1. Refer to Operation and Maintenance Manual, "Coolant - Change" for the proper draining and filling procedures.

Illustration 1

g03323356

2. Remove bracket (1). If necessary place tube assembly (3) to the side. 3. Remove clips (5). 4. Remove bolts (4). Remove adapters (6) and O-ring seals. 5. Remove bolts (7) and cover (2). Inspect and replace gasket if necessary.

Illustration 2

g03323380

6. Remove bolts (9) and attach a suitable lifting device to Locations (X) on aftercooler (8). The weight of aftercooler (8) is approximately 30 kg (65 lb). 7. Remove aftercooler (8). If necessary, remove housing (10).

Illustration 3

g03323550

8. Remove O-ring seals (11) from aftercooler (8).

Installation Procedure 1. Install aftercooler (8) in the reverse order of removal. a. Apply Tooling (A) to O-ring seals (11) and the bores. Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Thu Feb 8 23:04:06 UTC+0530 2024

  Product: GENERATOR SET Model: CG137-12 GENERATOR SET SC2 Configuration: CG137–12 Generator Set SC200001-UP

Disassembly and Assembly CG137-08 and CG137-12 Engines Media Number -UENR0103-04

Publication Date -01/05/2016

Date Updated -03/05/2016

i05202404

Aftercooler - Remove and Install - G3412B SMCS - 1063-010 S/N - FYR1-UP S/N - SC21-UP S/N - WRX1-UP

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

207-1600(1)

Rubber Lubricant

207-1601

Rubber Lubricant

A (1)

For Use in EAME

1. Refer to Operation and Maintenance Manual, "Coolant - Change" for the proper draining and filling procedures.

Illustration 1

g02735879

2. Remove bolts (1) and remove tube assembly (3). Remove throttle (2).

Illustration 2

g02735882

3. Remove bolts (6). Remove adapters (7) and remove the O-ring seals. 4. Remove bolts (5). Note: Position any clips, brackets, and harness assemblies out of the way. 5. Use two people to remove cover (4). The weight of cover (4) is approximately 25 kg (55 lb). Discard the gasket and replace upon installation.

Illustration 3

g02735899

6. If necessary, remove bracket (8). 7. Remove bolts (9) and attach a suitable lifting device to Locations (X) on aftercooler (10). The weight of aftercooler (10) is approximately 59 kg (130 lb). 8. Remove aftercooler (10). If necessary, remove housing (11). The weight of housing (11) is approximately 40 kg (88 lb).

Illustration 4

g02735920

9. Remove O-ring seals (12) from aftercooler (10).

Installation Procedure 1. Install aftercooler (10) in the reverse order of removal. a. Apply Tooling (A) to O-ring seals (12) and the bores. Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Thu Feb 8 23:04:25 UTC+0530 2024

  Product: GENERATOR SET Model: CG137-12 GENERATOR SET SC2 Configuration: CG137–12 Generator Set SC200001-UP

Disassembly and Assembly CG137-08 and CG137-12 Engines Media Number -UENR0103-04

Publication Date -01/05/2016

Date Updated -03/05/2016

i04471436

Air Cleaner Housing - Remove and Install SMCS - 1051-010

Removal Procedure

Illustration 1

g02653124

1. Remove cover (1) and the air filter element. 2. Disconnect tube assembly (2).

Illustration 2

g02653133

3. Disconnect hose assembly (5). Remove bolts (4). 4. Use two people to support air cleaner housing (3). The weight of air cleaner housing (3) is approximately 36 kg (79 lb). 5. Remove bolts (6) and remove air cleaner housing (3).

Thu Feb 8 23:04:45 UTC+0530 2024

  Product: GENERATOR SET Model: CG137-12 GENERATOR SET SC2 Configuration: CG137–12 Generator Set SC200001-UP

Disassembly and Assembly CG137-08 and CG137-12 Engines Media Number -UENR0103-04

Publication Date -01/05/2016

Date Updated -03/05/2016

i04533719

Air Starting Motor - Remove and Install - Alternate Air Starting Motor - TDI SMCS - 1451-010 S/N - FYR1-UP S/N - SC21-UP S/N - WRX1-UP S/N - WWF1-UP

Removal Procedure

Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

1. 367-6268 Pressure Regulator is not shown. If equipped, remove the pressure regulator first, and procedure with the procedure below.

Illustration 1

g02712075

2. Disconnect harness assembly (1). 3. Remove hose assembly (2). 4. Remove solenoid valve assembly (3) and remove relay valve (4).

Illustration 2

g02712081

5. Remove bolts (5). Remove air starting motor (6) and discard the gasket. Install a new gasket upon installation.

Thu Feb 8 22:58:38 UTC+0530 2024

  Product: GENERATOR SET Model: CG137-12 GENERATOR SET SC2 Configuration: CG137–12 Generator Set SC200001-UP

Disassembly and Assembly CG137-08 and CG137-12 Engines Media Number -UENR0103-04

Publication Date -01/05/2016

Date Updated -03/05/2016

i04533715

Air Starting Motor - Remove and Install SMCS - 1451-010

Removal Procedure

Illustration 1

g02712053

1. Drain the fuel from air motor lubricator assembly (1). 2. Disconnect harness assembly (2). Remove solenoid valve (3). 3. Remove hose assemblies (4) and the elbow adapters

Illustration 2

g02712064

4. Disconnect reducing valve (5) and remove hose assembly (7). 5. Remove air motor lubricator assembly (1).

Illustration 3

g02712069

6. Remove bolts (8). Remove air starting motor (9), the bracket, and the gasket. Discard the gasket, and replace with a new gasket for installation.

Installation Procedure 1. Install air starting motor (9) in the reverse order of removal. a. After installation, fill air motor lubricator assembly (1) with diesel fuel. Thu Feb 8 22:58:25 UTC+0530 2024

  Product: GENERATOR SET Model: CG137-12 GENERATOR SET SC2 Configuration: CG137–12 Generator Set SC200001-UP

Disassembly and Assembly CG137-08 and CG137-12 Engines Media Number -UENR0103-04

Publication Date -01/05/2016

Date Updated -03/05/2016

i04982052

Auxiliary Water Pump - Assemble SMCS - 1361-016

Assembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

1P-1857

Snap Ring Pliers

1P-1855

Snap Ring Pliers

9S-9152

Bearing Puller

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g01425756

1. Install lip seal (29) in the pump housing. 2. Install lip seal (29) with the lip away from the impeller.

Illustration 2

g01425757

3. Install slinger (28) in the pump housing.

Illustration 3

g01425758

4. Install ceramic ring (27) in the pump housing.

Illustration 4

g01425759

5. Put the intermediate shaft in Tooling (D) . 6. Raise the temperature of bearing (26) to a temperature of 135 °C (275 °F) and install bearing (26) on the shaft.

Illustration 5

g01425764

7. Install spacer (24) . Raise the temperature of bearing (25) to a temperature of 135 °C (275 ° F) and install bearing (25) on the shaft. 8. Raise the temperature of gear (23) to a temperature of 135 °C (275 °F) and install gear (23) on the shaft.

Illustration 6

g01425765

9. Install shaft assembly (21) into the pump housing. Position lock (20) and install bolts (22) . Tighten bolts (22) to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

Illustration 7

g01425766

10. Install retainer ring (14) on the shaft with Tool (C) . 11. Install bearing (17) . Raise the temperature of bearing (15) to a temperature of 135 °C (275 ° F). Install bearing (15) . Install spacer (18) , shims (16) , and keys (13) and (19) on the shaft.

Illustration 8

g01425875

12. Install the shaft assembly in the pump housing. 13. Install retainer ring (12) with Tool (A) .

Illustration 9

g01425770

14. Install gear (10) , the washer, and nut (11) . Tighten nut (11) to a torque of 60 ± 7 N·m (44 ± 5 lb ft).

Illustration 10

g01425772

NOTICE Clean water only is permitted for use as a lubricant for assistance at installation. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.

15. Position the lower portion of seal assembly (9) in hot water. Install seal assembly (9) on the shaft. Install shims (7) and key (8) .

Illustration 11

g01425775

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

16. Install spring (6) and retainer (5) .

Illustration 12

g01425776

17. Restrain gears with a soft jawed vise. Install impeller (4) and locknut (3) . Tighten locknut (3) to a torque of 29.5 ± 2.5 N·m (21.80 ± 1.80 lb ft). Note: Do not hold impeller (4) while tightening locknut (3) .

Illustration 13

g00792363

18. Check the clearance of the impeller. Shims should be added just until the impeller is clear of the housing.

Illustration 14

19. Install gasket (2) on the impeller housing.

g00792161

Illustration 15

g01425777

20. Install impeller housing (2) on pump housing (1) . Ensure that the identification marks are in alignment.

Illustration 16

g00792366

21. Check the impeller clearance again. End By: Install the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water Pump - Install". Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Thu Feb 8 23:11:58 UTC+0530 2024

  Product: GENERATOR SET Model: CG137-12 GENERATOR SET SC2 Configuration: CG137–12 Generator Set SC200001-UP

Disassembly and Assembly CG137-08 and CG137-12 Engines Media Number -UENR0103-04

Publication Date -01/05/2016

Date Updated -03/05/2016

i02852691

Auxiliary Water Pump - Disassemble SMCS - 1361-015

Disassembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

1P-1857

Snap Ring Pliers

1P-0510

Driver Group

1P-1855

Snap Ring Pliers

9S-9152

Bearing Puller

Start By: a. Remove the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water Pump - Remove".

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g00792160

Illustration 2

g00792161

1. Put identification marks on the pump housings (1) and separate the housings. Remove gasket (2) between the housings.

Illustration 3

g00792163

Illustration 4

g00792169

2. Remove locknut (4), the washer, and gear (3). 3. Remove retainer ring (5) with Tooling (A).

Illustration 5

g00792172

This is the sample of the manual click on the download link for complete manual

DOWNLOAD LINK For some reason if link does not work download this pdf and then click