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SEBU6496-06

January 2005

Operation and
Maintenance
Manual
G3612 and G3616 Engines
1YG1-Up (Engine)
4CG1-Up (Engine)

i01658146

Important Safety Information


Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:


Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this


product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.

SEBU6496-06

Table of Contents
Foreword ................................................................. 4

Safety Section
Safety Messages .................................................... 6
General Hazard Information ................................. 13
Burn Prevention .................................................... 15
Fire Prevention and Explosion Prevention ............ 16
Crushing Prevention and Cutting Prevention ........ 17
Mounting and Dismounting ................................... 17
Ignition Systems ................................................... 18
Before Starting Engine .......................................... 18
Engine Starting ..................................................... 19
Engine Stopping ................................................... 19
Electrical System .................................................. 19

Product Information Section


General Information .............................................. 21
Model Views and Specifications ........................... 22
Product Identification Information ........................ 30

Operation Section
Lifting and Storage ................................................ 32
Features and Controls .......................................... 34
Engine Starting ..................................................... 46
Engine Operation .................................................. 52
Engine Stopping ................................................... 53

Maintenance Section
Refill Capacities .................................................... 55
Maintenance Interval Schedule (G3612 and G3616
Engines That Use Bio-Gas) ................................ 59
Maintenance Interval Schedule (G3612 and G3616
Engines That Have a 10.5:1 or an 11:1 Compression
Ratio and Use Natural Gas) ................................ 61

3
Table of Contents

Maintenance Interval Schedule (G3612 and G3616


Engines That Have a 9.2:1 Compression Ratio and
Use Wellhead or Natural Gas) ............................ 63

Reference Information Section


Customer Service ............................................... 123
Reference Materials ............................................ 125

Index Section
Index ................................................................... 132

4
Foreword

Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.
English is the primary language for all Caterpillar
publications. The English used facilitates translation
and consistency in electronic media delivery.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Caterpillar dealer for the latest
available information.

Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product.

Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.

Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.

SEBU6496-06

Use service hours to determine intervals. Calendar


intervals shown (daily, annually, etc) may be used
instead of service meter intervals if they provide more
convenient schedules and approximate the indicated
service meter reading.
Recommended service should always be
performed at the service hour interval. The actual
operating environment of the engine also governs
the maintenance schedule. Therefore, under
extremely severe, dusty, wet or freezing cold
operating conditions, more frequent lubrication and
maintenance than is specified in the maintenance
schedule may be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.

Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation and application. We recommend that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engines permanent record.
See the section in the Operation and Maintenance
Manual, Maintenance Records for information
regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized
Caterpillar dealer can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.

California Proposition 65 Warning


Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after
handling.

SEBU6496-06

Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
programs. If you experience a major engine failure,
there are also numerous after failure overhaul options
available from your Caterpillar dealer. Consult with
your dealer for information regarding these options.

5
Foreword

6
Safety Section
Safety Messages

SEBU6496-06

Safety Section

Pinch Point (Linkage)


i02213799

Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on
your engine. The exact location and a description of
the safety messages are reviewed in this section.
Please become familiar with all safety messages.
Ensure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water,
and soap to clean the safety messages. Do not
use solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off
of the engine.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part
of the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.

Do not operate or work on this engine unless you


have read and understand the instructions and
warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.
The safety messages that may be attached on the
engine are illustrated and described below.

Illustration 1

g00299779

(1) Air choke actuator


(2) Fuel control actuator
(3) Exhaust bypass actuator

The safety messages for the pinch point (linkage) are


located on the covers of the following components:
air choke actuator (1), fuel control actuator (2), and
exhaust bypass actuator (3). Illustration 1 shows
electronic actuators. Some engines have hydraulic
actuators. The hydraulic actuators are mounted in
the same locations as the electronic actuators.

g00123168

The movement of the linkage can form a pinch point.


This can cause personal injury. Keep hands away
from the linkage.

SEBU6496-06

7
Safety Section
Safety Messages

Oil Filter (Engines That Have a


Control Valve For the Oil Filters)

Illustration 2

Oil Filter (Engines That Do Not


Have a Control Valve For the Oil
Filters)

g00294550

(1) Safety message


(2) Control valve

Illustration 3

The safety message for the oil filters is located on


the oil filter covers.

g00123170

Filter contains hot pressurized fluid when engine


is running. Follow instructions on control valve to
avoid injury if rapid air movement exists to blow
fluid. Stop engine to avoid fire.

g00294548

The safety message for the oil filters is located on


the oil filter covers.

g00296929

Filter contains hot pressurized fluid when engine


is running.
To avoid personal injury, stop engine before removing filter cover.

8
Safety Section
Safety Messages

SEBU6496-06

Engine Lifting (Message On the


Number One Camshaft Cover and
On the Number Two Camshaft
Cover)

Illustration 4

g00299781

Engine Lifting (Message On the


Number Three Camshaft Cover
and On the Number Four Camshaft
Cover)

Illustration 5

g00299840

(1) Safety message on the camshaft cover of the number two


cylinder

(1) Safety message on the camshaft cover of the number four


cylinder

The safety messages for engine lifting are located on


the camshaft cover of the number one cylinder and
on the camshaft cover of the number two cylinder.

The safety messages for engine lifting are located on


the camshaft cover of the number three cylinder and
on the camshaft cover of the number four cylinder.

g00299818

g00299841

Improper lift rigging can allow unit to tumble causing injury and damage.

Improper lift rigging can allow unit to tumble causing injury and damage.

If improper equipment is used to lift the engine, injury


and damage can occur. Use cables that are properly
rated for the weight. Use a spreader bar and attach
the cables according to the information on the safety
message.

If improper equipment is used to lift the engine, injury


and damage can occur. Use cables that are properly
rated for the weight. Use a spreader bar and attach
the cables according to the information on the safety
message.

SEBU6496-06

9
Safety Section
Safety Messages

Barring Device

Base Lifting

Illustration 6

g00296938

The safety message for lifting the base is located on


the base.

Illustration 7

g00295926

The safety message for the barring device is located


on the guard of the barring device.

g00296943

g00296978

Improper lift rigging can allow unit to tumble causing injury and damage.

Guards must be in place prior to operating barring


device motor.

If improper equipment is used to lift the engine, injury


and damage can occur. Use cables that are properly
rated for the weight. Use a spreader bar and attach
the cables according to the information on the safety
message.

Remove all hand tools prior to operating barring


device motor.
The guard covers gears that rotate. Hands can be
trapped in rotating gears. This can cause personal
injury. Tools can be trapped in rotating gears. This
can cause property damage. Ensure that no tools are
in the barring device and ensure that the guard is
secure before the barring device is operated.

10
Safety Section
Safety Messages

SEBU6496-06

Drain Coolant

Illustration 8

Crankcase Covers

g00123178

The safety message for coolant is located on the


expansion tank or on the heat exchanger. The safety
message for coolant is also located on the covers of
the outlets for the cooling system.

Illustration 9

g00123184

The safety message for the crankcase covers is


located on the crankcase covers.

g00123185
g00123182

Drain coolant before removing covers.


When the engine is at operating temperature,
the engine coolant is hot. The engine coolant is
also under pressure. The radiator and/or the heat
exchanger contain hot coolant. All lines to the heaters
or to the engine contain hot coolant. Contact can
cause severe burns.

Flash fire may result in personal injury, if


crankcase covers are removed within fifteen
minutes after emergency shut down. Do not
restart engine until cause for shutdown has been
corrected.

SEBU6496-06

11
Safety Section
Safety Messages

Electrical Distribution (Generator)


The safety message for electrical distribution
(generator) is located on the covers of the generator.

g00297180

g00296980

Do not connect generator to a utility electrical distribution system unless it is isolated from the system. Electrical feedback into the distribution system can occur and could cause personal injury or
death.
Open and secure main distribution system switch,
or if the connection is permanent, install a double
throw transfer switch to prevent electrical feedback. Some generators are specifically approved
by a utility to run in parallel with the distribution
system and isolation may not be required. Always
check with your utility as to the applicable circumstances.

CSA Hazardous Atmosphere


(Junction Box)

Do not disconnect equipment unless power has


been disconnected or the area is known to be nonhazardous
Approval by the CSA is a requirement for engines that
operate in hazardous locations. Volatile flammable
gases are present in these locations. The gases
are normally confined within closed systems. The
gases can only escape if the system accidentally
breaks down. The CSA safety message is intended
to prevent a hazardous atmosphere from igniting.
Volatile flammable gas that is contacted by a spark
will cause an explosion. This could result in personal
injury or death. Also, property could be damaged.
Do not disconnect electrical equipment unless the
power has been disconnected. Otherwise, ensure
that the atmosphere is not hazardous. Electrical
equipment includes the following components:
ignition system, engine control system, wiring
harnesses, and sensors.

CSA Hazardous Atmosphere


(Control Panel)

Illustration 10

g00299842

A safety message for the Canadian Standards


Association (CSA) hazardous atmosphere is located
on the junction box.

Illustration 11

g00297181

12
Safety Section
Safety Messages

SEBU6496-06

A safety message for the Canadian Standards


Association (CSA) hazardous atmosphere is located
on the control panel.

CSA Installation of Transformers

Illustration 12
g00297183

Do not disconnect equipment unless power has


been disconnected or the area is known to be nonhazardous

g00297177

(1) Safety message on transformer


(2) Flange
(3) Tube

The safety messages for the Canadian Standards


Association (CSA) installation of transformers are
located on the transformers.

Approval by the CSA is a requirement for engines that


operate in hazardous locations. Volatile flammable
gases are present in these locations. The gases
are normally confined within closed systems. The
gases can only escape if the system accidentally
breaks down. The CSA safety message is intended
to prevent a hazardous atmosphere from igniting.
Volatile flammable gas that is contacted by a spark
will cause an explosion. This could result in personal
injury or death. Also, property could be damaged.
Do not disconnect electrical equipment unless the
power has been disconnected. Otherwise, ensure
that the atmosphere is not hazardous. Electrical
equipment includes the following components:
ignition system, engine control system, wiring
harnesses, and sensors.

g00297178

Coil must be mounted without flange gasket.


Approval by the CSA is a requirement for engines that
operate in hazardous locations. Volatile flammable
gases are present in these locations. The gases
are normally confined within closed systems. The
gases can only escape if the system accidentally
breaks down. The CSA safety message is intended
to prevent a hazardous atmosphere from igniting.
Volatile flammable gas that is ignited will cause an
explosion. This could result in personal injury or
death. Also, property could be damaged.
If a fire should occur within tube (3), the flame could
possibly burn through a gasket. This would create
a gap under flange (2). The gap would enable the
flame to ignite a hazardous atmosphere.

SEBU6496-06

13
Safety Section
General Hazard Information

To meet the approval of the CSA, the transformer


(coil) must be installed without a gasket under
flange (2). This provides a connection that limits the
potential for an explosion.
i01359759

Use caution when cover plates are removed.


Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.

General Hazard Information


SMCS Code: 1000; 4450; 7405

Illustration 14

g00702020

Wear a hard hat, protective glasses, and other


protective equipment, as required.

Illustration 13

g00104545

Attach a Do Not Operate warning tag or a similar


warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine and to
each operator control station. When it is appropriate,
disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.

Filler caps
Grease fittings
Pressure taps
Breathers
Drain plugs

When work is performed around an engine that is

operating, wear protective devices for ears in order


to help prevent damage to hearing.

Do not wear loose clothing or jewelry that can snag


on controls or on other parts of the engine.

Ensure that all protective guards and all covers are


secured in place on the engine.

Never put maintenance fluids into glass containers.


Glass containers can break.

Use all cleaning solutions with care.


Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:

The engine is stopped. Ensure that the engine


cannot be started.

Disconnect the batteries when maintenance

is performed or when the electrical system is


serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.

Do not attempt any repairs that are not understood.


Use the proper tools. Replace any equipment that
is damaged or repair the equipment.

California Proposition 65 Warning

14
Safety Section
General Hazard Information

SEBU6496-06

Some engine exhaust constituents are known to the


State of California to cause cancer, birth defects, and
other reproductive harm.

Pressure Air and Water


Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.

Tools that are suitable for containing fluids and


equipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Asbestos Information

When pressure air and/or pressure water is used for


cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).

Fluid Penetration

Illustration 16

g00702022

Caterpillar equipment and replacement parts that are


shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.

Illustration 15

g00687600

Always use a board or cardboard when you check


for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.

Containing Fluid Spillage


Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Tools and
Shop Products Guide for the following items:

Tools that are suitable for collecting fluids and


equipment that is suitable for collecting fluids

Use caution. Avoid inhaling dust that might be


generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:

Never use compressed air for cleaning.


Avoid brushing materials that contain asbestos.
Avoid grinding materials that contain asbestos.
Use a wet method in order to clean up asbestos
materials.

A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be


used.

Use exhaust ventilation on permanent machining


jobs.

SEBU6496-06

15
Safety Section
Burn Prevention

Wear an approved respirator if there is no other


way to control the dust.

Comply with applicable rules and regulations

for the work place. In the United States, use


Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in 29 CFR 1910.1001.

Obey environmental regulations for the disposal


of asbestos.

Stay away from areas that might have asbestos


particles in the air.

Dispose of Waste Properly

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the
cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool. Ensure
that the filler cap is cool before removing the filler
cap. The filler cap must be cool enough to touch with
a bare hand. Remove the filler cap slowly in order
to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.

Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot components
to contact the skin.
If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.
Illustration 17

g00706404

Improperly disposing of waste can threaten the


environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i02088921

Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure in
the appropriate system before any lines, fittings or
related items are disconnected.

Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.

16
Safety Section
Fire Prevention and Explosion Prevention

SEBU6496-06

i01372262

Fire Prevention and Explosion


Prevention
SMCS Code: 1000; 4450; 7405

Do not weld on lines or tanks that contain flammable


fluids. Do not flame cut lines that contain flammable
fluid. Clean any such lines thoroughly with a
nonflammable solvent prior to welding or flame
cutting.
Wiring must be kept in good condition. All electrical
wires must be properly routed and securely attached.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or unnecessary.
Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.

Illustration 18

g00704000

All fuels, most lubricants, and some coolant mixtures


are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
an emergency shutdown.

Arcing or sparking could cause a fire. Secure


connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
deterioration. The hoses must be properly routed.
The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
Oil filters and fuel filters must be properly installed.
The filter housings must be tightened to the proper
torque.

Determine whether the engine will be operated in an


environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of combustible
gases, consult your Caterpillar dealer for additional
information about suitable protection devices.
Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
a hose, or a seal failure. Exhaust shields must be
installed correctly.

Illustration 19

g00704135

Gases from a battery can explode. Keep any open


flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.

SEBU6496-06

Never check the battery charge by placing a metal


object across the terminal posts. Use a voltmeter or
a hydrometer.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This may cause an
explosion.
The batteries must be kept clean. The covers
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.

Fire Extinguisher

17
Safety Section
Crushing Prevention and Cutting Prevention

i01359666

Crushing Prevention and


Cutting Prevention
SMCS Code: 1000; 4450; 7405
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.

Make sure that a fire extinguisher is available. Be


familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

Keep objects away from moving fan blades. The fan


blades will throw objects or cut objects.

Lines, Tubes and Hoses

Chips or other debris may fly off objects when objects


are struck. Before objects are struck, ensure that no
one will be injured by flying debris.

Do not bend high pressure lines. Do not strike high


pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:

End fittings are damaged or leaking.


Outer coverings are chafed or cut.
Wires are exposed.
Outer coverings are ballooning.
Flexible part of the hoses are kinked.
Outer covers have embedded armoring.
End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.

When objects are struck, wear protective glasses in


order to avoid injury to the eyes.

i01372247

Mounting and Dismounting


SMCS Code: 1000; 4450; 7405
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
controls as handholds.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.

18
Safety Section
Ignition Systems

SEBU6496-06

i00661252

Ignition Systems
SMCS Code: 1550
Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and
wiring.

Electronic Ignition
Do not inspect the valve mechanism or the
transformers while the engine is operating. Personal
injury or death may result.
The ignition system will be damaged if the ignition
harness is removed during engine operation.
If the mode control switch is in the AUTOMATIC or
START position and the wiring harness is connected,
the ignition system may discharge and a spark plug
will ignite. The spark plug will ignite any gas that has
accumulated in that cylinder. The crankshaft and the
driven equipment can move. Personal injury may
result. The driven equipment could be damaged. Gas
that has accumulated in the exhaust system can also
be ignited.
Turn the mode control switch to the STOP or
OFF/RESET position before connecting the wiring
harness. When the mode control switch is in the
STOP or OFF/RESET position, the ignition system
is disabled.

Magneto
The storage capacitor in a breakerless magneto can
be charged by turning the magneto by hand. The
storage capacitor can be charged even when the
wiring harness is disconnected from the magneto.
If the mode control switch is in the AUTOMATIC
or START position and the wiring harness is being
connected, the storage capacitor may discharge and
a spark plug will ignite. The spark plug will ignite
any gas that has accumulated in that cylinder. The
crankshaft and the driven equipment can move.
Personal injury may result. The driven equipment
could be damaged. Gas that has accumulated in the
exhaust system can also be ignited.
Before connecting the wiring harness to a breakerless
magneto, discharge the storage capacitor to the
ground. Use the following procedure to discharge the
storage capacitor:
1. Attach one end of a wire to the magneto housing.
2. Contact the other end of the wire to the connector
pins for the wiring harness that is on the magneto.

You will hear a snap when the storage capacitor


discharges.
3. Ground all of the connector pins.
This will ensure that no charge is in the magneto.
Some breakerless magnetos have more than one
storage capacitor.
Turn the mode control switch to the STOP or
OFF/RESET position before connecting the wiring
harness. When the mode control switch is in the
STOP or OFF/RESET position, the ignition system
is disabled.
i00659904

Before Starting Engine


SMCS Code: 1000
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
Ensure that the engine is equipped with a lighting
system that is suitable for the conditions. Ensure that
all lights work properly.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
On the initial start-up of a new engine or an engine
that has been serviced, be prepared to stop the
engine if an overspeed condition occurs. This may
be accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
See the Service Manual for repairs and for
adjustments.

SEBU6496-06

19
Safety Section
Engine Starting

i02136012

Engine Starting
SMCS Code: 1000
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
If there is a possibility that unburned gas remains in
the exhaust system, refer to the purge procedure in
this Operation and Maintenance Manual, Engine
Starting topic in the Operation Section.
Start the engine from the operators compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, Engine Starting topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature and the oil
temperature during heater operation.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
i00659907

Engine Stopping
SMCS Code: 1000
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to the instructions in this Operation and
Maintenance Manual, Engine Stopping topic
(Operation Section).

Use the Emergency Stop Button (if equipped) ONLY


in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corrected.
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop
the engine if an overspeed occurs. This may be
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
i01032810

Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is operated. Repair all frayed
electrical wires before the engine is started.

Grounding Practices
Proper grounding is necessary for optimum engine
performance and reliability. Improper grounding will
result in uncontrolled electrical circuit paths and in
unreliable electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
Uncontrolled electrical circuit paths can also cause
electrical activity that may degrade the engine
electronics and communications.
Ensure that all grounds are secure and free of
corrosion.
The engine alternator must be grounded to the
negative - battery terminal with a wire that is
adequate to carry the full charging current of the
alternator.
For the starting motor, do not attach the battery
negative terminal to the engine block.
Ground the engine block with a ground strap that is
furnished by the customer. Connect this ground strap
to the ground plane.
Use a separate ground strap to ground the battery
negative terminal for the control system to the ground
plane.

20
Safety Section
Electrical System

If rubber couplings connect the steel piping of the


cooling system and the radiator, the piping and the
radiator can be electrically isolated. Ensure that the
piping and the radiator are continuously grounded
to the engine. Use ground straps that bypass the
rubber couplings.

SEBU6496-06

SEBU6496-06

21
Product Information Section
General Information

Product Information
Section
General Information
i01472899

Welding on Engines with


Electronic Controls
SMCS Code: 1000
NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equipment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
To help avoid damage to the electronic controls,
proper welding procedures are necessary. Before
you weld on equipment with electronic controls,
observe the following precautions:
1. Turn off the engine. Place the engine control
switch in the OFF position.
2. If the engine has a battery disconnect switch, open
the switch. Otherwise, disconnect the negative -
battery cable from the battery of the equipment.
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other components.
Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the possibility of damage.
3. Clamp the ground cable from the welder to the
component that will be welded. Place the clamp
as close as possible to the weld.
4. Protect wiring harnesses from welding debris and
from spatter. Use proper welding procedures.

22
Product Information Section
Model Views and Specifications

SEBU6496-06

Model Views and


Specifications
i00682395

Model View Illustrations


SMCS Code: 1000; 4450
The illustrations show various typical features of
G3600 Engines. The illustrations do not show all of
the options that are available.

g00295813

Illustration 20
(1)
(2)
(3)
(4)

Gas shutoff valve


Fuel control actuator
Exhaust bypass actuator
Lifting eye

(5)
(6)
(7)
(8)

Crankcase breather
Transformer
Oil filter
Junction box

(9) Barring device


(10) Oil level gauge
(11) Oil filler
(12) Oil drain

SEBU6496-06

23
Product Information Section
Model Views and Specifications

g00295814

Illustration 21
(13) Air choke actuator
(14) Crankcase explosion relief valve

(15) Starting motor


(16) Air starting motor lubricator

24
Product Information Section
Model Views and Specifications

SEBU6496-06

g00297151

Illustration 22
(17) Air inlet
(18) Exhaust
(19) Jacket water pump

(20) Aftercooler and oil cooler pump


(21) Flywheel housing
(22) Crankshaft vibration damper

i02245854

Product Description
SMCS Code: 1000; 4450
The G3600 Family of Engines are designed to
provide power for the following applications:

Direct drive chiller


Electrical power generation
Gas compression
Industrial air compression
Petroleum
The engines incorporate advanced technology that is
essential for obtaining these qualities:

High output
Low emissions
High thermal efficiency

(23) Prelube pump

Precise control of the engine parameters enable


optimum engine performance. The engines are
capable of using a variety of fuels in various ambient
conditions.
The fuel system of these engines does not use a
carburetor. A control valve allows the fuel to enter
the gas manifold. The control valve is actuated by
an actuator. The fuel pressure in the manifold is
regulated by the actuator and the control valve.
Fuel flows from the manifold through an orifice. Some
of the gas is routed through an adjustable needle
valve and into a precombustion chamber. The fuel in
the precombustion chamber is ignited by the spark
plug. This provides the ignition for the air/fuel mixture
in the cylinder. The rest of the gas is routed through
a valve (gas admission valve). The gas admission
valve is actuated by the camshaft. This allows fuel to
enter the inlet port in the cylinder head. The gas is
mixed with air in the cylinder head.

SEBU6496-06

Air for combustion flows from the turbocharger to a


choke (air inlet). The air inlet choke is actuated by an
actuator. The air travels through the aftercooler to the
air plenum and into the cylinder head inlet port. The
inlet manifold pressure is controlled by the air inlet
choke and the exhaust bypass valve. An electronic
control system determines the air pressure that is
required to maintain the correct air/fuel ratio. The
electronic control system controls the air inlet choke
and the exhaust bypass valve.
The electronic control system controls the ignition
timing. The control system monitors changes in
the load. The control system modifies the timing
in response to the change in the load. The timing
can also be modified in order to compensate for
detonation that is detected.
The engine has two cooling circuits. Water
temperature regulators are used in both circuits in
order to maintain the correct operating temperatures.
Water temperature regulators can be installed in
order to regulate the inlet or outlet temperature of
the water.
A centrifugal pump (gear type) pulls the jacket water
from an external source. The coolant is circulated
through the water jacket to the cylinder heads.
The coolant flows through water manifolds to the
outlet. The coolant flows through a remote water
temperature regulator and to a heat exchanger. The
coolant is returned to the engine.
For engines with a standard cooling system, the
lube oil and the air for combustion are cooled in a
separate circuit. A pump pulls the coolant from the
heat exchanger. Some of the coolant goes to the oil
cooler. Most of the coolant goes to the aftercooler.
The coolant returns to the heat exchanger.
The lube oil is supplied by a gear type pump. The
temperature of the lube oil is regulated. The oil is
filtered before the oil is circulated in the cylinder
block.

Engine Service Life


Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. This
includes use of the recommended lubricants, fuels,
and coolant/antifreezes.
For the engine maintenance that is required, see this
Operation and Maintenance Manual, Maintenance
Interval Schedule (Maintenance Section).

25
Product Information Section
Model Views and Specifications

26
Product Information Section
Model Views and Specifications

SEBU6496-06

i02243745

Specifications
SMCS Code: 1000

Engine Specifications
Table 1

Engine Specifications
G3612

G3616

Operating RPM

750 to 1000

Low Idle RPM


Cylinders and Arrangement

550
50 degree vee 12

50 degree vee 16

Bore

300 mm (11.8 inch)

Stroke

300 mm (11.8 inch)

Aspiration

TA
9.2:1
10.5:1
11:1

Compression Ratio
Displacement Per Cylinder
Total Displacement

21.2 L (1294 in3)


254.4 L (15528 in3)

339.2 L (20704 in3)

Mean Velocity of the Pistons at 900


RPM

9 m/s (1772 ft/min)

Mean Velocity of the Pistons at 1000


RPM

10 m/s (1969 ft/min)

Flywheel Rotation (Standard)


Fuel
Method of Starting

Counterclockwise
See this Operation and Maintenance Manual, Refill Capacities
and Recommendations (Maintenance Section). Also, see the
Application and Installation Guide.
Air starting motors

Performance of the Cooling System

See the Application and Installation Guide.

Maximum Allowable Exhaust Back


Pressure

3 kPa (12 inches of H2O)

Maximum Allowable Inlet Air Restriction


Air Cleaners

3.7 kPa (15 inches of H2O)


Remote

Valve Lash (Gas Admission Valve)(1)

0.64 mm (.025 inch)

Inlet Valve Lash

0.50 mm (.020 inch)

Exhaust Valve Lash

1.25 mm (.050 inch)

(1)

This measurement is for newer engines. For earlier engines, the valve lash is set by turning an adjustment screw and counting the clicks.

SEBU6496-06

27
Product Information Section
Model Views and Specifications

Drives and Gear Trains


Front Drives

Illustration 23

g00291490

G3612 Engine cylinder numbers


(A) Gas admission valves
(B) Inlet valves
(C) Exhaust valves
(D) Front

g00291362

Illustration 25
SAE standard engine crankshaft rotation
(1) Jacket water pump
(2) Aftercooler and oil cooler pump
(3) Oil pump

Illustration 24

g00291492

G3616 Engine cylinder numbers


(A) Gas admission valves
(B) Inlet valves
(C) Exhaust valves
(D) Front

g00291363

Illustration 26
SAE standard engine crankshaft rotation
(4)
(5)
(6)
(7)

Water outlet
Water inlet
Oil outlet
Oil inlet

Table 2

Front Drives
Component

Speed(1)

Jacket Water Pump

2522

Aftercooler and Oil Cooler Pump

2522

Oil Pump

1524

(1)

The speed of the component is listed for an engine that is


operating at 1000 rpm. For an engine that is operating at
900 rpm, multiply the speed of the component by .9. For an
engine that is operating at 800 rpm, multiply the speed of the
component by .8.

28
Product Information Section
Model Views and Specifications

SEBU6496-06

Engine Front Gear Train

Engine Rear Gear Train

g00268306

Illustration 27

g00268312

Illustration 28

SAE standard engine crankshaft rotation

SAE standard engine crankshaft rotation

(1)
(2)
(3)
(4)
(5)
(6)
(7)

(1)
(2)
(3)
(4)
(5)

Crankshaft
Idler
Idler
Jacket water pump
Aftercooler and oil cooler pump
Auxiliary pump
Oil pump

Crankshaft
Large cluster idler
Small cluster idler
Camshaft
Idler

Table 4

Rear Gear Train

Table 3

Gear

Front Gear Train


Gear

Number Of
Teeth

(1) Crankshaft

96

(2) Idler

68

(3) Idler

67

(4) Jacket Water Pump

38

(5) Aftercooler and Oil Cooler Pump

38

(6) Auxiliary Pump

43

(7) Oil Pump

63

Number Of Teeth

(1) Crankshaft

81

(2) Large Cluster Idler

90

(3) Small Cluster Idler

45

(4) Camshaft

81

(5) Idler

81

Reference Weights
Table 5

Approximate Engine Weights


Dry Weight of
the Engine with
Attachments

G3612

G3616

25084 kg
(55300 lb)

29892 kg
(65900 lb)

SEBU6496-06

29
Product Information Section
Model Views and Specifications

Table 6

Approximate Weights Of Serviceable Parts


Component
Cylinder Block

G3612
Engine

G3616
Engine

6805 kg
(14971 lb)

9625 kg
(21219 lb)

Bearing Cap

65 kg (144 lb)
2091 kg
(4600 lb)

Crankshaft

3800 kg
(8378 lb)

Flywheel Assembly

491 kg (1082 lb)

Crankshaft Vibration
Damper

183 kg (403 lb)

Cylinder Head
Assembly

196 kg (432 lb)

Cylinder Liner

110 kg (243 lb)

Piston Assembly

48 kg (106 lb)

Piston Pin

19 kg (42 lb)

Piston Rod Assembly

57 kg (126 lb)

Turbocharger (one)

401 kg (884 lb)

Aftercooler Core(1)

94 kg (207 lb)

125 kg
(275 lb)

Front Housing

258 kg (569 lb)

Rear Housing

350 kg (772 lb)

Used Air Cleaner


Element
(1)

29 kg (64 lb)

The weight that is listed is for a first stage aftercooler. A second


stage aftercooler and an aftercooler with a deeper core are
also available.

Table 7

Approximate Weights Of Package Generator Sets


Item
Engine(1)
Generator
Module
Mounting Base
Coupling
Total
(1)

G3612 Engine

G3616 Engine

25084 kg
(55300 lb)

29892 kg
(65900 lb)

15855 kg (34954 lb)


1650 kg (3638 lb)
12700 kg (28000 lb)
977 kg (2154 lb)
56266 kg
(124045 lb)

61074 kg
(134645 lb)

The weights of the engines that are listed includes attachments


that are mounted on the engines. The engine weights are
dry weights.

30
Product Information Section
Product Identification Information

SEBU6496-06

Product Identification
Information

Serial Number Plate

i02172306

Plate Locations and Film


Locations
SMCS Code: 1000; 4450

Engine Identification
Caterpillar engines are identified with serial numbers,
with performance specification numbers, and with
arrangement numbers. In some of the cases,
modification numbers are used. These numbers
are shown on the Serial Number Plate and the
Information Plate that are mounted on the engine.
Caterpillar dealers need these numbers in order to
determine the components that were included with
the engine. This permits accurate identification of
replacement part numbers.

Engine Information Plate

Illustration 30

g01023277

(1) Serial number plate

The serial number plate is located on the side of the


cylinder block above one of the crankshaft inspection
covers.
i01519312

Reference Information
SMCS Code: 1000; 4450
Identification of the items in Table 8 may be needed
in order to obtain parts and service. Some of the
numbers are on the engine Serial Number Plate
and/or Information Plate. Locate the information
for your engine. Record the information on the
appropriate space in Table 8. Make a copy of this
list for a record. Retain the information for future
reference.
The top level part numbers in the Parts Manual for
the engine are listed with the engine arrangement
number.

Illustration 29

g01053234

(1) Engine information plate

The engine information plate is located on the side


of the cylinder block above one of the crankshaft
inspection covers.

The performance specification can be used by


your Caterpillar dealer with the Technical Marketing
Information system. Before the engine leaves the
factory, the engine performance is tested. Detailed
performance data is recorded. The performance
specification number can be used for obtaining the
data.

SEBU6496-06

31
Product Information Section
Product Identification Information

Table 8

Record Of Reference Numbers


Item
Engine Model
Serial Number
Arrangement Number
Modification Number
Performance Specification
Power Rating
Personality Module (Revision)
Low Idle rpm
High Idle rpm
Full Load rpm
Overspeed Setpoint
Air Choke Actuator
Exhaust Bypass Actuator
Fuel Actuator
Lubrication Oil Filter Element
Lube Oil Capacity (total)
Air Cleaner Element
Alternator Belt
Supplemental Coolant Additive
Cooling System Capacity (total)
Turbocharger

Identification

32
Operation Section
Lifting and Storage

SEBU6496-06

Operation Section

Engine Lifting with a Generator

Lifting and Storage

NOTICE
Do not use the engine lifting eyes to remove the engine and generator together.
i01536259

Product Lifting
SMCS Code: 7000; 7002

A lifting plate is provided with the package generator


set. Instructions for lifting the package generator set
are stamped on the lifting plate.
Consult your Caterpillar dealer for information
regarding proper fixtures and lifting devices.
Lifting packaged generator sets will not be level if you
lift the unit with a single point lift. A counterweight can
be added between the package frame rails whenever
the application requires frequent relocation of the
unit. For complete information about adding the
counterweight, consult your Caterpillar dealer.

Illustration 31

g00103219

NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle
between the supporting members and the object becomes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting fixtures in order to
obtain proper balance and safety.
To remove the engine ONLY, use the lifting eyes that
are on the engine.
Lifting eyes are designed and installed for the specific
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.

The single point lifting eye is secured from the


factory before the enclosure is shipped. The correct
orientation of the single point lifting eye will allow you
to look through the eye when you stand at the side of
the enclosure. The lifting eye may stretch when the
package is lifted. This may cause the locking nuts
to loosen. This could cause the lifting eye to swivel.
Ensure that the lifting eye is correctly oriented on the
packaged generator set. Ensure that the lifting eye
is tightened to the correct torque before you lift the
packaged generator set.

SEBU6496-06

33
Operation Section
Lifting and Storage

i02046791

Product Storage
SMCS Code: 7002
If the engine will not be started for several weeks, the
lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface, which will increase engine wear which
can reduce engine service life.
To help prevent excessive engine wear, use the
following guidelines:

Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance


Manual, Maintenance Interval Schedule
(Maintenance Section).

If freezing temperatures are expected, check the

cooling system for adequate protection against


freezing. See this Operation and Maintenance
Manual, Refill Capacities and Recommendations
(Maintenance Section).

If an engine is out of operation and if use of the engine


is not planned, special precautions should be made.
If the engine will be stored for more than one month,
a complete protection procedure is recommended.
Your Caterpillar dealer will have instructions for
preparing the engine for extended storage periods.
For more detailed information on engine storage, see
Special Instruction, SEHS9031, Storage Procedure
for Caterpillar Products.

Generator Storage
For information on generator storage, see the
literature that is provided by the OEM of the
generator. Consult your Caterpillar dealer for
assistance.

34
Operation Section
Features and Controls

SEBU6496-06

Features and Controls

Monitoring
Controlling
i00664828

Control Panel
SMCS Code: 7451

Engine Supervisory System


The engine supervisory system is specifically
designed for Caterpillar G3600 Engines. The engine
supervisory system integrates several engine control
systems. The engine supervisory system optimizes
each controlled parameter in order to ensure
maximum engine performance.

Stopping
The components of the control panel are briefly
described in this section. For more detailed
information on the engine supervisory system, see
the Service Manual, Systems Operation/Testing and
Adjusting module.

Control Panel

The engine supervisory system consists of the


following components:

Control panel
Junction box
Actuators
Potentiometers
Relays, solenoids, sensors, and switches
Wiring
The engine supervisory system includes three
systems that are integrated:
Start/Stop/Prelube System This system controls
the starting of the engine, the stopping of the engine,
and the prelube pump.
Engine Monitoring And Protection System This
system provides a display of parameters of engine
operation. The system generates warnings when
one or more parameters are outside acceptable
limits. The system can stop the engine if the engine
operation reaches a setpoint that is programmed
for shutdown. The system can prevent the engine
from starting if certain parameters are outside of
acceptable limits.
Engine Control System This system governs the
engine. This system controls the air/fuel ratio, the
ignition timing, and the limiting of power.
Some of the components within the engine
supervisory system perform more than one function.
For example, the engine control module is involved
with these activities:

Starting

Illustration 32
(1) Caterpillar monitoring system
(2) Timing control module
(3) FUEL ENERGY CONTENT potentiometer
(4) Engine control module
(5) SPEED CONTROL potentiometer
(6) Status control module
(7) Mode control switch
(8) Pyrometers
(9) EMERGENCY STOP button
(10) MANUAL PRELUBE switch

g00291852

SEBU6496-06

35
Operation Section
Features and Controls

Start/Stop/Prelube

The mode control switch is turned to the STOP


position.

The mode control switch is turned to the


OFF/RESET position.

The EMERGENCY STOP button is pressed.


An undesirable operating condition is sensed and
an engine shutdown is initiated by the engine
supervisory system.

STOP When the mode control switch is turned


to the STOP position, the engine will shut off. If
the cool down cycle is programmed, the engine
will operate for the cool down period before the
engine stops. After the engine stops, a postlube
cycle will operate. The power to the control panel is
maintained when the mode control switch is in the
STOP position. The STOP mode can be used
to troubleshoot some problems without starting the
engine.
Illustration 33

g00291853

(1) Mode control switch


(2) EMERGENCY STOP button
(3) MANUAL PRELUBE switch

Mode Control Switch


Mode control switch (1) has four positions:

AUTO
START
STOP
OFF/RESET
AUTO When the mode control switch is in the
AUTO position, the system is configured for remote
operation. When the remote start/stop initiate contact
closes, the prelube system will operate and the
engine will start. When the remote start/stop initiate
contact opens, the engine will shut off. If the cool
down cycle is programmed, the engine will operate
for the cool down period before the engine stops. The
cool down cycle can be programmed for a 0 to 30
minute period.
START When the mode control switch is turned
to the START position, the prelube system will
operate. When the prelube pressure is sufficient,
the engine will start. The engine will operate until
the engine supervisory system receives a shutdown
signal.
The following methods cause a shutdown signal:

The remote start/stop initiate contact opens when

the mode control switch is in the AUTO position.

OFF/RESET When the mode control switch is


turned to the OFF/RESET position, the engine is
immediately shut off and the diagnostic lights of the
status control module are reset. Power is removed
from the control panel and the actuators after the
engine completes the postlube cycle. This method for
stopping bypasses the normal stopping procedure.
This method for stopping is not recommended.
EMERGENCY STOP Button
NOTICE
Only use the Emergency Stop button in order to stop
the engine in an emergency situation. Do not use the
Emergency Stop button for normal engine stopping.
To prevent damage to the engine, use the mode control switch or use the remote start/stop initiate contact
for normal engine stopping.
The fuel and the ignition are immediately shut off
when EMERGENCY STOP button (2) is pressed.
No postlube cycle occurs.
The EMERGENCY STOP button and the mode
control switch must be reset before the engine will
start. To reset the EMERGENCY STOP button,
turn the button clockwise. To reset the mode control
switch, turn the switch to the OFF/RESET position.
Note: More than one EMERGENCY STOP button
may be available for use.

36
Operation Section
Features and Controls

SEBU6496-06

MANUAL PRELUBE Switch


MANUAL PRELUBE switch (3) enables the operator
to prelube the engine. Lubrication is required prior to
rotation of the crankshaft. This includes crankshaft
rotation in order to service the engine. Rotating the
crankshaft before prelube may cause damage to the
crankshaft bearings if the surfaces of the bearings
are dry.
All G3600 Engines require lubrication prior to start-up.
The engine supervisory system will not permit the
engine to start until sufficient prelube pressure has
been achieved. The actuators will be powered up
after the engine has been prelubed.
Note: The engine control module is programmed to
provide engine lubrication after the engine is shut off.
The typical duration of the postlube is 60 seconds.

Engine Monitoring and Protection


System
Status Control Module
The status control module includes the following
features:

Control of starting the engine and stopping the


engine
Basic engine protection
A display of the status of certain parameters
Shutdown indicators
Diagnostic information
When the status control module receives a signal
to start the engine, the module activates the fuel
system and the starting motor. When the engine rpm
reaches the crank termination speed, the starting
motor is disengaged.
The module will sequentially display the following
parameters in two second increments: service hours,
engine rpm, battery voltage, engine oil pressure, and
engine oil temperature. The module also monitors
the engine for faults.
The engine will operate until the module receives a
shutdown signal.

Illustration 34

g00291943

Status control module


(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Liquid Crystal Display (LCD)


Switch
LOW OIL PRESSURE LED
OVERCRANK LED
OVERSPEED LED
HIGH OIL TEMPERATURE LED
EMERGENCY STOP LED
AUXILIARY LED

Liquid Crystal Display (LCD) International


Standards Organization (ISO) symbols for the
following parameters are located under LCD (1).
The LCD provides a digital display of the status of
these parameters. When the status of a parameter is
displayed, an arrow at the bottom of the LCD points
the corresponding ISO symbol. The display can be in
metric units or English units.
Hour meter When the arrow points to
this symbol, the hours of engine operation
are displayed.
Engine speed When the arrow points to
this symbol, the engine rpm is displayed.
System battery voltage When the arrow
points to this symbol, the voltage of the
electrical systems battery is displayed.

SEBU6496-06

37
Operation Section
Features and Controls

Engine oil pressure When the arrow


points to this symbol, the engine oil
pressure is displayed.
Engine oil temperature When the
arrow points to this symbol, the engine oil
temperature is displayed.
The parameters are displayed sequentially. To lock
the display onto one of the parameters, press switch
(2). To resume the sequential display, press the
switch again.
The LCD is also used to display diagnostic codes.
A diagnostic indication signifies that the system
has detected the failure of components that are
associated with the status control module. When a
diagnostic code is displayed, the arrow that indicates
the display of the parameters will be missing. A
flashing dIAG will be displayed. If more than one
diagnostic code is present, the diagnostic codes will
be displayed in sequence.
Table 9 is a list of the diagnostic codes that can
be generated by the status control module and a
brief explanation of the codes. For more detailed
information on diagnostic codes and troubleshooting,
see the Service Manual, Troubleshooting module.
Table 9

Display Of Diagnostic Codes For The Status


Control Module
Code

Indication

01

There is no signal from the engine speed


sensor.(1)

02

There is no signal from the oil


pressure/temperature transducer.(1)

03

There is a problem with the signal from the


mode control switch.(1)

04

There is a loss of the setpoints in the memory


of the status control module.(1)

05

The engine has shut down without a signal


from the status control module.(1)

06

There is an internal failure of the status control


module or the voltage supply is unstable.(1)(2)

07

There is an error in the programming of the


status control module.(3)

08

There is a problem with the oil temperature


sensor.(1)

09

There is a problem with the oil pressure


sensor.(1)

(1)
(2)
(3)

If the engine is operating, the engine will shut down. The


engine will not start.
If the engine is not operating, the engine may be unable to start.
If the engine is not operating, the engine will not start.

The status control module has six light emitting


diodes (Illustration 34) that indicate an engine
shutdown. The shutdowns that are associated with
the indicators are described below.
Overcrank If the engine fails to start
within a programmed amount of time, the
status control module will deactivate the
starting sequence. LED (4) will flash. The mode
control switch must be turned to the OFF/RESET
position before another attempt to start the engine
can be made.
LOW OIL PRESSURE If the engine
oil pressure decreases below the setpoint,
the fuel to the engine will be shut off. LED
(3) will flash. There are two setpoints for low oil
pressure. The setpoints depend on the engine rpm.
One setpoint is for engine rpm that is below the oil
step speed setting. The other setpoint is for engine
rpm that is above the oil step speed setting.
OVERSPEED If the engine rpm
exceeds the setpoint for overspeed, the
fuel and the ignition will be shut off. LED
(5) will flash.

will flash.

HIGH OIL TEMPERATURE If the


engine oil temperature exceeds the
setpoint, the fuel will be shut off. LED (6)

EMERGENCY STOP LED (7) will flash


if the EMERGENCY STOP button is used
to stop the engine.
AUXILIARY LED (8) is available as a custom
shutdown indicator.
Note: If a fault occurs and the control for the fuel
does not shut down the engine, the ignition is shut off
five seconds after the fault has occurred.
Caterpillar Monitoring System
The Caterpillar monitoring system monitors
parameters of engine operation. The parameters are
displayed on digital gauges and a digital display.
The panel also has indicators that illuminate when
faults are detected. The monitoring system receives
information from sensors. The monitoring system
communicates the information to the engine control
module.

38
Operation Section
Features and Controls

SEBU6496-06

g00291963

Illustration 35
Caterpillar monitoring system
(1) Small gauges
(2) GAGE GROUP SELECT switch
(3) Identification of the small gauges (film)

(4) Large gauge


(5) Digital display
(6) GAGE DATA SELECT switch

DIMMER switch (7) enables the operator to control


the brightness of the lighting for the control panel.
The brightness is reduced when the switch is toggled.
After the dimmest light has been reached, toggle the
switch in order to return the display to the maximum
brightness.
Large gauge (4) is a tachometer. This gauge always
indicates the engine rpm.
Two sets of parameters can be displayed on the six
small gauges (1). The display will be in either metric
units or English units. Identification for the two sets
of parameters are listed on film (3). The film includes
the ISO symbols of the parameters and the units that
are displayed on the gauges.
The information that is displayed on the six small
gauges is controlled by GAGE GROUP SELECT
switch (2). To display the parameters that are listed
on the left side of the film, move the switch to the left.
To display the parameters that are listed on the right
side of the film, move the switch to the right.

(7) DIMMER switch


(8) Fault indicators
(9) Identification of the fault indicators (film)

The information that is displayed on digital display


(5) is controlled by GAGE DATA SELECT switch
(6). This switch enables the operator to view a digital
display of the parameters that are listed on film (3).
The upper number in the digital display indicates the
parameter that is displayed. Toggling the GAGE
DATA SELECT switch causes the next gauge to be
displayed.
If the GAGE GROUP SELECT switch is toggled,
the digital display will change to the gauge that
corresponds with the position. For example, if gauge
1 AIR TEMPERATURE was selected and the
GAGE GROUP SELECT switch is toggled, the
digital display will show the data for gauge 7 OIL
FILTER DIFFERENTIAL.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a period of time.

SEBU6496-06

Noticeable changes in gauge readings can indicate


potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if the readings are within specifications.
Determine and correct the cause of any significant
change in the readings. Consult your Caterpillar
dealer for assistance.
The following engine parameters can be displayed
on the six small gauges and on the digital display.
1 AIR TEMPERATURE This gauge
indicates the inlet manifold air temperature
after the aftercooler. As the inlet air
increases in temperature the air expands and the
exhaust bypass closes. If the temperature of the inlet
air is too high during full speed and load operation,
the engine may misfire. Also, detonation may occur.
2 COOLANT TEMPERATURE This
gauge indicates the temperature of the
engine coolant at the outlet for the jacket
water. The jacket water temperature may vary
according to the load. The jacket water temperature
should never be allowed to exceed the boiling
temperature of the pressurized cooling system.
3 FUEL CORRECTION This gauge
indicates the fuel correction factor that is
applied by the air/fuel ratio control system.
An indication to the left side of the gauge signifies the
following condition. The same condition is signified
by a digital display of less than 100.

The fuel exhibits a lower fuel energy content than


indicated by the setting of the FUEL ENERGY
CONTENT potentiometer.

An indication to the right side of the gauge signifies


the following condition. The same condition is
signified by a digital display that is greater than 100.

The fuel exhibits a higher fuel energy content than


indicated by the setting of the FUEL ENERGY
CONTENT potentiometer.

When the load is greater than 50 percent for more


than three minutes, the air/fuel ratio is automatically
controlled. The control is based on the following
factors:

The setting of the FUEL ENERGY CONTENT


potentiometer

Duration of combustion that is measured in the


cylinders

39
Operation Section
Features and Controls

This automatic control is called feedback mode.


When the engine is in this mode, a red circle around
the gauge is ON.
When the engine is in prechamber calibration mode
or magneto calibration mode, the automatic control is
not used. The red circle around the gauge is OFF and
the fuel correction factor is secured at 100 percent
when the engine is in this mode.
These modes can only be accessed through the
digital diagnostic tool. The magneto calibration mode
is used only for setting the initial calibration of the
magneto. The magneto calibration mode is used only
with a load of less than 50 percent of rated torque.
The prechamber calibration mode is used only for
setting the needle valves for the prechamber and for
some troubleshooting procedures.
4 AIR INLET PRESSURE This gauge
indicates the air pressure in the air plenum
(air inlet manifold) after the aftercooler. The
pressure depends on the engine rating, the load,
and the operating conditions. To establish the normal
pressure, compare the data from the gauge to the
data from the engine commissioning and look for
trends.
5 ENGINE OIL PRESSURE This
gauge indicates the pressure of the engine
oil. The pressure will be highest after a
cold engine is started. The pressure will decrease
as the engine warms up. The pressure will increase
when the engine rpm is increased. The pressure will
stabilize when the engine rpm is stable.
Note: If the mode control switch is in the AUTO
or START position, the prelube oil pressure is
indicated by a green ring around the oil pressure
gauge. A ring that is continuously displayed indicates
sufficient prelube pressure. A ring that is flashing
indicates that the prelube pressure is NOT sufficient.
6 ENGINE LOAD This gauge indicates
a percentage of the engines full rated
torque. The calculation of the percentage is
based on these factors: flow of fuel, engine rpm, fuel
energy content, and fuel correction factor. This gauge
flashes if the torque exceeds the maximum limit that
is programmed into the control strategy.
7 OIL FILTER DIFFERENTIAL This
gauge indicates the difference in pressure
between the inlet side and the outlet side of
the engine oil filters. As the oil filter elements become
plugged, the pressure will increase.

40
Operation Section
Features and Controls

SEBU6496-06

8 AIR RESTRICTION LEFT This


gauge indicates the air restriction for the left
air inlet. This gauge indicates the difference
in air pressure between the inlet side (ambient air
pressure) and the engine side (turbocharger inlet) of
the air filter element. The air restriction is measured
from the turbocharger air inlet. As the air filter element
becomes plugged, the difference in pressure between
the two sides of the air cleaner element will increase.
Normal air restriction is 1.25 kPa (5 inches of H2O).
9 CRANKCASE PRESSURE This
gauge indicates the pressure that is inside
the crankcase. The typical crankcase
pressure is 0.125 kPa (.5023 inches of H2O).
Changes in the crankcase pressure may indicate
problems with the following components: crankcase
ventilation system, pistons, piston rings, and cylinder
liners.
10 COOLANT OUTLET PRESSURE
This gauge is usually blank. Some
applications use the gauge in order to
display the outlet pressure of the engine coolant.
11 AIR RESTRICTION RIGHT This
gauge indicates the air restriction for the
right air inlet.
12 STARTING PRESSURE This
gauge indicates the air pressure that is
available for starting the engine.
Fault Indicators
The monitoring system has 12 fault indicators
(Illustration 35). The indicators are identified by the
film that is located beneath the fault indicators on the
panel. This enables the operator to investigate the
faults. Table 10 is a list of the fault indicators and a
brief explanation of each fault.
Table 10

Fault Indicators For The Caterpillar Monitoring System


Fault

Indication

F1 CHECK GAGES

One or more gauges indicate that a parameter is outside of the normal range.

F2 CHECK FLUID LEVELS(1)

One or more fluid levels are below an acceptable level.

F3 AUXILIARY EQUIPMENT(1)

One or more problems exist in the interface for the driven equipment.

F4 FUEL SUPPLY SYSTEM(1)

One or more problems exist in the system that controls the fuel.

F5 AIR INLET SYSTEM(1)

One or more problems exist in the system that controls the inlet air.

F6 EXHAUST
F7

SYSTEM(1)

MODULES/WIRING(1)

One or more problems exist in the exhaust system.


One or more problems exist with specific control modules and/or the wiring.
(continued)

SEBU6496-06

41
Operation Section
Features and Controls

(Table 10, contd)

Fault Indicators For The Caterpillar Monitoring System


F8 COMBUSTION FEEDBACK SYSTEM(1)

One or more problems exist in the controls for the feedback from the
combustion system.

F9 IGNITION SYSTEM(1)

One or more problems exist in the ignition system.

F10 SENSORS/DEVICES(1)

One or more problems exist on specific control devices. This includes


sensors, actuators, etc.

F11 STARTING SYSTEM(1)

One or more problems exist in the engine starting system.

F12 DETONATION SYSTEM(1)

One or more problems exist in the system that detects detonation.

(1)

Note the diagnostic codes that are displayed on the engine control module. Refer to the Service Manual, Troubleshooting module.

Pyrometer
The digital pyrometer is an electronic instrument
that is designed to monitor exhaust temperatures.
The pyrometer uses K type thermocouple probes.
The pyrometer can display the temperatures of nine
points in the exhaust system. The nine points include
the exhaust stack and eight exhaust ports.
G3612 and G3616 Engines use two pyrometers. One
pyrometer is for the left side and one pyrometer is for
the right side of the exhaust system.

The setpoint is established during the engine


commissioning. To adjust the setpoint, use the
following procedure:
Note: Do not increase the setpoint above 600 C
(1112 F) without approval from the factory.
1. Press PUSH TO ADVANCE button (2) until
channel 0 is displayed.
2. Press PUSH TO READ button (3) in order to
display the setpoint.
Note: A switch on the back of the pyrometer
enables the operator to select a display of Celsius or
Farenheit degrees.
3. Turn adjustment screw (setpoint) (4) until the
temperature that is desired for the setpoint is
reached.
To increase the temperature of the setpoint, turn
the adjustment screw clockwise. To decrease the
temperature of the setpoint, turn the adjustment
screw counterclockwise.

Illustration 36

g00292106

Pyrometer
(1)
(2)
(3)
(4)

Display
PUSH TO ADVANCE button
PUSH TO READ button
Adjustment screw (setpoint)

The exhaust port and the exhaust temperatures


are shown on display (1). Channel 0 is displayed
when the control panel is powered up. Channel 0
displays the exhaust stack temperature. PUSH TO
ADVANCE button (2) enables the operator to select
the temperatures from the different exhaust ports.
The temperature of channel 0 is continuously
compared against the setpoint for high exhaust
stack temperature. If the setpoint is exceeded, the
pyrometer will close an output switch to the ground.
This instructs the engine control module to shut down
the engine.

Engine Control System


Operator Inputs
The engine control module monitors the fuel energy
content for the air/fuel ratio control and for limiting
the power. The engine control module relies on
information from sensors, buffers, and the setting
of the FUEL ENERGY CONTENT potentiometer.
The information is necessary in order to maintain the
air/fuel ratio and the following conditions:

Combustion that is consistent


Control of emissions
Optimum performance

42
Operation Section
Features and Controls

SEBU6496-06

The duration of combustion is measured in each


cylinder. Each cylinder has a sensor for combustion
and a buffer. The pulse of the ignition starts the timer
for the buffer. The flame travels in the cylinder from
the spark plug to the sensor for combustion. A signal
from the sensor stops the timer.
The duration of combustion is an excellent method
of measuring the air/fuel ratio. A rich mixture of fuel
provides a fast duration of combustion. A lean mixture
of fuel provides slower duration of combustion.
During normal operation, the engine control module
will calculate the air/fuel ratio. The air/fuel ratio can
be rich or lean in order to suit the fuel. The engine
control module calculates a new inlet manifold air
pressure that will provide the ideal air/fuel ratio for the
engine speed and load. The exhaust bypass valve is
repositioned in order to maintain the calculated inlet
manifold air pressure.

After the engine has operated for three minutes at


a load that is greater than 50 percent, the engine
control module will maintain the proper air/fuel
ratio by using the actual duration of combustion in
the cylinders. This occurs unless the engine is in
prechamber calibration mode or magneto calibration
mode.
Note: The low heat value is based on data from a
fuel analysis. To determine the low heat value of the
fuel, the data from the fuel analysis must be input into
the Caterpillar PC Software, LEKQ6378, Methane
Number Program.
SPEED CONTROL potentiometer (1) allows the
operator to select the engine rpm that is needed.
Low idle speed is 550 rpm. Rated speed can be as
high as 1000 rpm.
Engine Control Module
The engine control module performs the following
functions:

Under the following circumstances, the air/fuel ratio


is maintained only by measuring the fuel flow and
the setting of the FUEL ENERGY CONTENT
potentiometer:

Controlling the air/fuel ratio

Operation at less than 50 percent of the rated

Governing the engine rpm

torque

The engine is in prechamber calibration mode or


magneto calibration mode.

Monitoring operation
Protecting the engine
Starting the engine
Stopping the engine
Most of the functions of the engine supervisory
system are routed through the engine control module.
The module controls most of the operations of the
engine supervisory system. The control strategy of
the module contains many of the setpoints for the
protective system.

Illustration 37

g00292108

(1) SPEED CONTROL potentiometer


(2) FUEL ENERGY CONTENT potentiometer

Note: Remote control of the FUEL ENERGY


CONTENT and the SPEED CONTROL is
available. Use of the remote control disables the
potentiometers on the control panel.
FUEL ENERGY CONTENT potentiometer (2)
enables the operator to adjust the setting for the low
heat value of the fuel that is being used. The engine
control module will display the setting. The setting
provides a starting point for air/fuel ratio control. The
setting is used until information about the duration of
combustion is available.

Illustration 38
Engine control module
(1) Display
(2) LED indicators
(3) DISPLAY SELECT switch

g00292112

SEBU6496-06

43
Operation Section
Features and Controls

The engine control module uses display (1) and


LED indicators (2) to provide status and diagnostic
information. Diagnostic codes are shown on display
(1). Identification of the indicators is adjacent to the
indicators. If an indicator is ON continuously, the
corresponding diagnostic code is displayed. If an
indicator is flashing, the corresponding diagnostic
code is available, but not presently displayed.
For example, if the engine control module is indicating
a continuously green STATUS mode, but the red
SENSOR FAULT LED is flashing, a fault is present
but not currently displayed. DISPLAY SELECT
switch (3) must be toggled in order to display the
diagnostic code.
The DISPLAY SELECT switch enables the operator
to view the information on the display. When the
switch is toggled, the next parameter is displayed.
The parameters are displayed in the following order:

Desired engine rpm


Fuel energy content
Diagnostic codes in order of occurrence
Write down all diagnostic codes that are
displayed. The display of the diagnostic code
is cleared when the DISPLAY SELECT switch
is toggled or when power is removed from the
electronic control module. Log the diagnostic
codes before clearing the codes. Logging the
diagnostic codes will help to solve engine
problems. For detailed information regarding
diagnostic codes, see the Service Manual,
Troubleshooting module.
The eight engine control module indicators and a brief
explanation of the indicators are listed in Table 11.
Table 11

LED Display On The Engine Control Module


LED

Color

Indication

STATUS

Green

Status information is displayed.

COMMUNICATION LINK 1
ACTIVE

Green

The engine control module is communicating properly with the Timing


Control Module.

COMMUNICATION LINK 2
ACTIVE

Yellow

The engine control module is communicating properly with the gauges


of the monitoring system, the ports for the digital diagnostic tool, the
customer communication module, and the detonation mixing control.

CAUTION MODE

Red

One or more problems exist. The code that indicates the exact nature
of the condition will be displayed.

SENSOR FAULT

Red

A problem with one of the sensors has been detected. One or more
problems exist. The code that indicates the exact nature of the condition
will be displayed.

ACTUATOR FAULT

Red

A problem with one of the actuators has been detected. The code that
indicates the exact nature of the problem will be displayed.
(continued)

44
Operation Section
Features and Controls

SEBU6496-06

(Table 11, contd)

SYSTEM FAULT

Red

A problem with one of the control systems has been detected. The code
that indicates the exact nature of the problem will be displayed.

CONTROL MODULE FAULT

Red

A problem with one of the control modules has been detected. The code
that indicates the exact nature of the problem will be displayed.

The display will normally indicate either the desired


engine rpm or the fuel energy content for the engine
operation. If diagnostic codes are present, the
appropriate engine control module indicator and the
corresponding Caterpillar monitoring system fault
indicator (F1 through F12) are illuminated. See
Illustrations 38 and 35.
Using the DISPLAY SELECT will reveal the
diagnostic code. Toggling the DISPLAY SELECT
switch will cause the display to indicate any other
diagnostic codes in the order of occurrence.
If the engine control module shuts down the
engine because of a fault, the condition which
caused the shutdown will be indicated by a
FLASHING diagnostic code. Diagnostic codes
which do not cause an engine shutdown are
warning codes. A display of a warning code does
not flash. Correct the cause of the warning code
in order to avoid problems with operation.
If the engine control module initiates an engine
shutdown, a RST REQD message will also be
present on the engine control module. To view the
message, toggle the DISPLAY SELECT switch.
This message indicates that the system must be reset
before the engine can be started. To reset the system,
turn the mode control switch to the OFF/RESET
position. This will also clear the message.
Use of the mode control switch or the remote
start/stop initiate contact causes the status control
module to shut down the engine. The status control
module sends a signal to the engine control module.
The engine control module will display SHUT DN
when the signal from the status control module is
received.
A SHUT DN display indicates one of the following
occurrences:

The engine has completed a normal shutdown that


was initiated by an external signal.

The mode control switch is in the STOP position.


This code will be cleared when the engine is started.
Resetting the engine control module is not required.

If a diagnostic code has been acknowledged but the


status control module continues to send a shutdown
signal, the yellow CAUTION MODE indicator will
flash. The diagnostic code will appear during a scroll
of the display until the shutdown signal is removed.
A display of PC CAL indicates that the engine is in
prechamber calibration mode or magneto calibration
mode.
Timing Control Module
The timing control module maintains the ignition
timing that is determined by the engine control
module. The timing control module also protects the
engine from unacceptable levels of detonation.
The timing control module provides the engine control
module with information about timing and detonation.
The engine control module sends a signal to the
timing control module for the engine timing that is
desired. The signal can be retarded if detonation is
sensed. The engine will be shut down if high levels of
detonation persist.

SEBU6496-06

45
Operation Section
Features and Controls

(Table 12, contd)

LED Display On The Timing Control Module


CONTROL ON

Green

DETONATION ENGINE SHUTDOWN

Red

MAGNETO OUT OF CALIBRATION

Red

NO RH DETONATION SENSOR SIGNAL

Red

NO LH DETONATION SENSOR SIGNAL

Red

NO SPEED SENSOR SIGNAL(1)

Red

NO CRANK ANGLE SENSOR


NO MAGNETO INTERFACE

SIGNAL(1)

SIGNAL(1)

NO COMMUNICATION SIGNAL(1)
(1)

Red
Red
Red

This fault will not cause an engine shutdown. If the engine is


shut off, the condition must be cleared before the engine is
allowed to start.

For more detailed explanations of the faults that are


generated by the timing control module, see the
Service Manual, Troubleshooting module.

g00292329

Illustration 39

(1) Display for the engine control module


(2) Light emitting diode (LED) indicators for the timing control
module
(3) DISPLAY SELECT switch

The timing control module uses sensors to monitor


components of the timing system. If a component
fails or if a wiring harness fails, the timing control
module will illuminate an indicator (2). Identification
for the nine indicators is adjacent to the indicators.
The diagnostic code can be displayed on display for
the engine control module (1). To view the diagnostic
code, toggle DISPLAY SELECT switch (3).
Write down all diagnostic codes that are
displayed. The display of the diagnostic code
is cleared when the DISPLAY SELECT switch
is toggled or when power is removed from the
electronic control module. Log the diagnostic
codes before clearing the codes. Logging the
diagnostic codes will help to solve engine
problems. For detailed information regarding
diagnostic codes, see the Service Manual,
Troubleshooting module.
The nine indicators that are on the timing control
module are listed in Table 12.
Table 12

LED Display On The Timing Control Module


LED

Color
(continued)

46
Operation Section
Engine Starting

SEBU6496-06

Engine Starting

Cooling System
Inspect the cooling system for leaks or loose
i02277554

Before Starting Engine

connections. Inspect the condition of all the pipes


for the cooling system. Ensure that the connections
are properly clamped.

SMCS Code: 1000; 1400; 1450

Inspect the water pumps for evidence of leaks.

Perform the required daily maintenance and other


periodic maintenance before starting the engine. This
can prevent major repairs at a later date. Refer to this
Operation and Maintenance Manual, Maintenance
Interval Schedule (Maintenance Section).

Check the coolant level. Add coolant, if necessary.

Walk-Around Inspection

Driven Equipment

NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.

If necessary, check the oil levels of the driven

To obtain maximum service life for your engine, make


a thorough inspection before starting the engine.
Make a walk-around inspection of the installation.
Look for items such as oil or coolant leaks, loose
bolts and trash buildup. Remove any trash. Make
repairs, if necessary.

For generator set engines, ensure that the main

The guards must be in the proper place. Repair


damaged guards or replace missing guards.

For information on the proper coolant to use, refer


to this Operation and Maintenance Manual, Refill
Capacities and Recommendations (Maintenance
Section).

equipment. Perform any maintenance that is


required for the driven equipment. Refer to the
literature that is provided by the OEM of the driven
equipment.

If the engine is equipped with a clutch, ensure that


the clutch is disengaged.
circuit breaker is open.

Electrical System
Inspect the wiring for the following conditions:

Loose connections

Ensure that the areas around the rotating parts are

Wiring that is worn or frayed

Air Inlet System

Inspect the gauge panel and the control panel


for good condition. Reset any shutoff or alarm
components.

clear.

Unburned gas in the air inlet and exhaust system


may ignite when the engine is started. Personal
injury and/or property damage may result.
Before starting an engine that may contain unburned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the Starting the Engine
section.

Ensure that the air inlet piping and the air filters
are in place.

Ensure that all clamps and connections are secure.

SEBU6496-06

47
Operation Section
Engine Starting

Lubrication System

Hydraulic Actuator System


Check the level of the oil in the tank for the hydraulic
actuator system. Make sure that the oil is between
the ADD and FULL marks on the oil level gauge.
For information on the proper oil to use, refer to
this Operation and Maintenance Manual, Refill
Capacities and Recommendations (Maintenance
Section).

Starting System
Ensure that the barring device is fully disengaged.
Drain moisture and sediment from the air tank and
Illustration 40

g01140341

Engine oil level gauge


(1) ADD mark
(2) RUNNING FULL mark
(3) STOPPED FULL OIL COLD NO PRELUBE mark

Check the engine oil level. Add engine oil if the

level is in the ADD zone. If the engine is running,


maintain the level in the RUNNING FULL
zone. For information on the proper engine oil
to use, refer to this Operation and Maintenance
Manual, Refill Capacities and Recommendations
(Maintenance Section).

Check for leaks at the following components:

crankshaft seals, crankcase, engine oil filters,


plugs for the engine oil gallery, sensors, and valve
covers.

Inspect the tubes, tee pieces, and clamps on the


crankcase breathers.

from any other air piping.

Check the oil level in the lubricator for the air

starting motor. Keep the lubricator at least half full.


Add oil, if necessary. Use nondetergent 10W oil
for temperatures that are greater than 0 C (32 F).
Use air tool oil for temperatures that are below
0 C (32 F).

Check the air pressure before starting. Starting

motors with vanes require air pressure in a range


of 620 to 1550 kPa (90 to 225 psi). Air turbines
require air pressure in a range of 414 to 620 kPa
(60 to 90 psi) or 690 to 1034 kPa (100 to 150 psi).

Open the air supply valve for the air starting motor.
Note: If the engine is equipped with a system for
external support, prepare the system before starting
the engine. Ensure that all of the systems for engine
support are enabled. Perform all prestart checks for
the control system.

If the engine has an air cleaner for crankcase

ventilation, inspect the air cleaner service indicator.


Service the air cleaner filter element when the
yellow diaphragm enters the red zone, or the red
piston locks in the visible position.

Fuel System
Inspect the fuel lines for loose fittings and leaks.
Ensure that the fuel lines are properly clamped.

Ensure that the fuel is supplied to the engine at the


correct pressure for the application.

Many engines use a fuel pressure of 310 14 kPa


(45 2 psi).
Some engines use a variable fuel pressure that is
based on the engine load.
For the proper fuel pressure, refer to the report from
the engine commissioning.

i00662769

Cold Weather Starting


SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
See Gas Engines Application and Installation Guide,
LEKQ7255 for more information on the following
topics:

Recommendations for the size and installation of


jacket water heaters and oil heaters

Requirements for cranking torque and air starting


motors at various temperatures

Consult your Caterpillar dealer for more information


on the starting aids that are available for cold weather
starting.

48
Operation Section
Engine Starting

SEBU6496-06

Jacket Water Heaters


Jacket water heaters are available as optional
equipment. Jacket water heaters are recommended
for improving startability in ambient temperatures
below 21 C (70 F). These heaters are recommended
for all installations that have automatic starting.

Lubricating Oil Heaters


Note: Oil pan immersion heaters are not
recommended for heating the lube oil. To ensure the
compatibility of the components, only use equipment
that is recommended by Caterpillar.
NOTICE
Heating elements that are in direct contact with the
lubricating oil can cause coking of the oil.
To aviod coking of the oil when the oil is heated, follow
these recommendations:
The temperature of the heating surface must not exceed 150 C (300 F). The maximum heat density
of the heating surface must not exceed 1.24 w/cm2
(8W/in2).

i02169979

Starting the Engine


SMCS Code: 1000; 1450

Engine exhaust contains products of combustion


which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
fuel supply and/or the ignition to the engine.

Unburned gas in the air inlet and exhaust system


may ignite when the engine is started. Personal
injury and/or property damage may result.

Oil viscosity affects the amount of torque that is


needed to crank the engine. Oil temperatures
below 10 C (50 F) require cranking torque that is
excessive. Oil heaters are recommended for heating
the lube oil to 10 C (50 F) when the ambient
conditions are below this temperature.

Before starting an engine that may contain unburned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the Starting the Engine
section.

Requirements for Starting with Air

Note: Using the EMERGENCY STOP button will


shut off both the fuel and the ignition.

To start the engine at colder temperatures, a larger


volume of starting air and/or a higher air pressure
is necessary. Ensure a sufficient supply of air
pressure for cold weather starting. Do not exceed the
maximum air pressure for the starting motor.

Do not start the engine or move any of the controls


if there is a DO NOT OPERATE warning tag or
similar warning tag attached to the start switch or to
the controls.

Water Separator

Ensure that no one will be endangered before the


engine is started and when the engine is started.

Condensation of vapor in the air supply can freeze in


cold weather. This can enable the following problems
to occur:

Perform the procedures that are described in this


Operation and Maintenance Manual, Before Starting
Engine (Operation Section).

Ice that forms in the supply lines will restrict the


air supply.

Purging Unburned Gas

If particles of ice enter the inlet of the starting

The following events cause unburned gas to remain


in the air inlet and in the exhaust manifold:

A water separator removes vapor from compressed


air prior to the air storage tank. Dry air is required for
cold weather in order to help prevent ice from forming
in the supply lines.

Emergency stop

motor, the starting motor can be damaged.

Engine overspeed

SEBU6496-06

Unsuccessful successive attempts to start the


engine

Unburned gas may remain in the air inlet and exhaust


system after several unsuccessful attempts to start
the engine. The unburned gas may increase to a
concentration that may ignite during a successive
attempt to start the engine.

49
Operation Section
Engine Starting

b. For industrial engines, unload the compressor


or pump. Disengage the clutch (if equipped).
Place the transmission and/or other
attachments for the power take-off in
NEUTRAL.

Perform the following procedure in order to purge


the unburned gas:
1. Turn the manual gas shutoff valve to the CLOSED
position.
2. Disable the ignition by grounding the G lead on
the ignition harness.
3. Turn the engine control switch to the START
position. Crank the engine for one full crank cycle
in order to purge the unburned gas.
4. Turn the engine control switch to the OFF/RESET
position.
5. Enable the ignition by disconnecting the G lead
from ground.

Illustration 41

6. Turn the manual gas shutoff valve to the OPEN


position.

(1) SPEED CONTROL potentiometer


(2) FUEL ENERGY CONTENT potentiometer
(3) Mode control switch in the START position

7. Continue with your previous procedure.

3. Verify that SPEED CONTROL potentiometer (1)


is set to an rpm that is appropriate. Verify that
the IDLE/RATED display (if equipped) indicates
IDLE.

Automatic Starting

When the engine is in the AUTOMATIC mode, the


engine can start at any moment. To avoid personal
injury, always remain clear of the the engine when
the engine is in the AUTOMATIC mode.
If the mode control switch is in the AUTO position,
the engine will automatically start when the remote
start/stop initiate contact closes. The engine will
accelerate to rated rpm when the oil pressure is
sufficient.

Manual Starting
1. Ensure that fuel is supplied to the engine. Ensure
that no gas is leaking.
2. Ensure that the driven equipment is unloaded.
a. For generator set engines, open the main
circuit breaker.

g00402399

4. Verify that FUEL ENERGY CONTENT


potentiometer (2) is set for the fuel that is being
used.
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.
5. Turn mode control switch (3) to the START
position.
NOTICE
The engine must be prelubed before the crankshaft is
rotated. Damage can result if the crankshaft is rotated
on dry bearing surfaces.

50
Operation Section
Engine Starting

Note: The prelube oil pump will operate for


approximately 30 seconds. When the oil pressure is
sufficient, the status control module will initiate the
engine start-up. If the module detects a signal that
prevents the engine from starting, the appropriate
indicator will illuminate. A diagnostic code will be
generated.

SEBU6496-06

i01934760

Starting with Jump Start


Cables
SMCS Code: 1000; 1401; 1402; 1900

6. Allow the engine to idle for three to five minutes.


The engine speed should stabilize at low idle rpm.
Perform these checks during the warm-up:

Improper jump start cable connections can cause


an explosion resulting in personal injury.

Check all of the pressure gauges.

Prevent sparks near the batteries. Sparks could


cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.

Inspect the engine for leaks.


Listen for unusual noises.
When all systems are normal, the rpm may be
increased.

If the installation is not equipped with a backup


battery system, it may be necessary to start the
engine from an external electrical source.

Ensure that the oil pressure and the fuel pressure are
in the normal ranges. After the engine has started
and the warm-up is complete, the engine can be
operated at low rpm and low load. The engine will
reach normal operating temperature faster if the
engine is operated at low rpm and with a low power
demand. This procedure is more effective than idling
the engine with no load. The engine should reach
normal operating temperature in a few minutes.

NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.

Starting Failure

When using an external electrical source to start the


engine, turn the engine control switch to the OFF
position. Turn all electrical accessories OFF before
attaching the jump start cables.

Note: If the cycle crank feature is enabled, the


status control module will attempt to start the engine
for the programmed period. If the engine fails to
start within the programmed period, the module will
execute an overcrank fault. The OVERCRANK
indicator on the module will illuminate. The module
must be reset before the engine can be started. To
reset the module, turn the mode control switch to the
OFF/RESET position.
If the engine fails to start after cranking for 30
seconds, stop cranking. Perform the Purging
Unburned Gas procedure.

Do not reverse the battery cables. The alternator can


be damaged. Attach ground cable last and remove
first.

Ensure that the main power switch is in the OFF position before attaching the jump start cables to the engine being started.
1. Turn the start switch to the OFF position. Turn off
all accessories.
2. Connect one positive end of the jump start cable
to the positive cable terminal of the discharged
battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the
electrical source.
3. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.
4. Start the engine.

SEBU6496-06

51
Operation Section
Engine Starting

5. Immediately after the stalled engine is started,


disconnect the jump start cables in reverse order.
Note: If there is a problem with the alternator or the
battery charger, the engine will not continue to run
after starting, unless the power to the engine control
module is supplied by a separate source.
i01742728

After Starting Engine


SMCS Code: 1000
Note: For new installations and engines that are
recently rebuilt, carefully monitor the engine in order
to detect any unusual engine performance.
Check the gauges during the warm-up. Complete a
walk-around inspection. Check for leaks and unusual
noises. Correct any problems before proceeding.

Engaging the Driven Equipment


Avoid detonation during loading. Generally, no load
operation to full load operation can be accomplished
in one to five minutes without any problems.
DO NOT apply a load to the engine or increase the
rpm until the engine oil pressure is a minimum of
160 kPa (23 psi) at low idle rpm.
1. Increase the engine rpm.
The minimum rpm for operating an engine with a
load is 750 rpm. The maximum rpm for operating
an engine with a load is 1000 rpm.
a. For engines with a SPEED CONTROL
potentiometer or a remote speed control, turn
the control to the engine rpm that is desired.
b. For engines with an IDLE/RATED switch,
toggle the switch to the RATED position.
Ensure that the gauges are in the normal
ranges for the engine rpm.
Note: It may be necessary to apply some load in
order to attain normal operating temperatures.
2. After verifying that the engine systems are normal,
engage the driven equipment.
Apply the load according to the requirements for
temperatures:
Before you apply a load up to 49 percent of the
rated load, the minimum temperature of the jacket
water is 38 C (100 F). The minimum engine oil
temperature is 10 C (50 F).

Before you apply a load between 50 and


100 percent of the rated load, the minimum
temperature of the jacket water is 50 C (122 F).
The minimum engine oil temperature is 50 C
(122 F).
Continue to check the gauges and the driven
equipment.
For information on partial load operation, refer to
this Operation and Maintenance Manual, Engine
Operation topic (Operation Section).
3. Adjust the load, as needed.

52
Operation Section
Engine Operation

SEBU6496-06

Engine Operation
i01765829

Engine Operation
SMCS Code: 1000
Proper operation and maintenance are key factors in
attaining the maximum service life and economy for
the engine. Follow the instructions in this Operation
and Maintenance Manual in order to minimize
operating costs and maximize the service life of the
engine.
Observe the gauges or the Caterpillar Electronic
Technician (ET) frequently while the engine is
operating. Record the data from the gauges in
a log. Average the data that is recorded during
operation and record the average values for each
day. Compare the data to the specifications for
normal engine operation. Comparing the data over
time will help to detect trends in engine performance.
Investigate any significant change in the gauge
readings. Monitor the engine operation and take
action when discrepancies are found.

Operating the Engine and the


Driven Equipment
The minimum rpm for operating an engine with a
load is 750 rpm. The maximum rpm for operating an
engine with a load is 1000 rpm.
Check the gauges and the driven equipment
frequently while the engine is operating under a load.
The engine can be operated continuously at full load.

Partial Load Operation


Extended operation at low idle or at a reduced load
will cause increased consumption of engine oil and
carbon buildup in the cylinders. Carbon buildup
results in the following effects:

Accelerated wear of components


Loss of control of the exhaust emissions
Narrow margin for detonation
Poor performance
Power loss

Caterpillar Engines can be operated at very light


loads for limited times with no harmful effects. Table
13 lists the limits for hours of operation at various
loads.
After the time limit for reduced load operation
has expired, operate the engine for a minimum of
two hours at a load that is more than 70 percent
of the rated load.
For example, an engine is operating at 20 percent of
the rated load. The engine may be operated at this
load factor for a maximum of one-half hour. After the
one-half hour, operate this engine for at least two
hours at a load factor of more than 70 percent.
To keep engine maintenance at a minimum, follow
the guidelines that are listed in Table 13.
Table 13

Time Limits for Low Load Operation

(1)

Engine Load

Time Limit

0 to 30 percent

1/2 hour

31 to 50 percent

2 hours

51 to 100 percent

Continuous

(1)

For continuous operation, the manifold air pressure must be


greater than the atmospheric pressure.

SEBU6496-06

53
Operation Section
Engine Stopping

Engine Stopping
i02158236

Emergency Stopping
SMCS Code: 1000; 7418
NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.
Ensure that any system that provides external
support to the engine is secured after the engine is
stopped. Turn off the auxiliary systems for engine
operation after the engine is stopped.
NOTICE
Do not start the engine until the problem necessitating
the emergency stop has been located and corrected.
Pressing the Emergency Stop Button may cause
unburned gas to remain in the air inlet and in the
exhaust manifold.

Unburned gas in the air inlet and exhaust system


may ignite when the engine is started. Personal
injury and/or property damage may result.
Before starting an engine that may contain unburned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the Starting the Engine
section.

Emergency Stop Button

The emergency stop button is in the OUT position for


normal engine operation. For an emergency stop,
push emergency stop button (1). The engine will not
start when the button is locked. To reset the button,
turn the button clockwise or pull the button. The
spring-loaded button will return to the OUT position.
The control panel must also be reset before the
engine will start. To reset the control panel, turn mode
control switch (2) to the OFF/RESET position.
i00670859

Manual Stop Procedure


SMCS Code: 1000; 7418
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and accelerated wear of engine components.
Excessive temperatures in the turbocharger centerhousing will cause oil coking problems.
Allow the engine to gradually cool before stopping the
engine
Note: Remove the load at a rate that will avoid
detonation.
1. Disengage or unload the driven equipment.
a. For generator set engines, open the main
circuit breaker.
b. For industrial engines, unload the compressor
or pump. Disengage the clutch (if equipped).
Place the transmission and/or other
attachments for the power take-off in
NEUTRAL.
Note: Extended idling can cause excessive oil
consumption and related problems. See this
Operation and Maintenance Manual, Engine
Operation topic (Operation Section).
2. Reduce the engine rpm to low idle.
Note: If the cooldown feature is not utilized, operate
the engine at low idle rpm for a cooldown period
before stopping the engine.
a. If the engine has been operated at a low load,
operate the engine at low idle for approximately
30 seconds before stopping the engine.

Illustration 42
(1) Emergency stop button
(2) Mode control switch in the OFF/RESET position

g00290992

b. If the engine has been operated at a high load,


operate the engine at low idle for approximately
five minutes before stopping the engine.

54
Operation Section
Engine Stopping

SEBU6496-06

3. Use one of the following methods in order to stop


the engine:

i02150753

After Stopping Engine


SMCS Code: 1000

Check the engine crankcase oil level. Maintain

the oil level between the ADD and FULL marks


on the ENGINE STOPPED side of the oil level
gauge.

If necessary, perform minor adjustments. Repair


any leaks and tighten loose bolts.

Note the service hour meter reading. Perform the


Illustration 43

g00293074

maintenance that is scheduled in this Operation


and Maintenance Manual, Maintenance Interval
Schedule (Maintenance Section).

Mode control switch in the STOP position

a. Turn the mode control switch to the STOP


position.
b. If the mode control switch is in the AUTO
position, open the remote start/stop initiate
contact.
If the cooldown feature is utilized, the engine
will operate for a programmed period of time
before the engine stops. Otherwise, the engine
will immediately shut off. When the engine
rpm is reduced to approximately 100 rpm, the
postlube cycle will operate for approximately
60 seconds. The power to the control panel
will be maintained.
The engine will coast to a stop. Ensure that any
system that provides external support to the engine
is secured after the engine is stopped. Turn off
the auxiliary systems for engine operation after the
engine is stopped.

NOTICE
Only use antifreeze/coolant mixtures recommended in
the Refill Capacities and Recommendations section of
this manual. Failure to do so can cause engine damage.

Allow the engine to cool. Check the coolant level.


If freezing temperatures are expected, check the

coolant for protection against freezing. The cooling


system must be protected against freezing to the
lowest expected outside temperature. Add the
proper coolant/water mixture, if necessary.

Perform all required periodic maintenance on all

driven equipment. Refer to the instructions that are


provided by the OEM of the driven equipment.

SEBU6496-06

55
Maintenance Section
Refill Capacities

Maintenance Section

Table 15

Approximate Refill Capacity of Crankcase

Refill Capacities

Sales Model

Liters

US Gallons

G3612

1030

272

G3616

1325

351

i02213831

Refill Capacities and


Recommendations

Hydraulic Actuator System


Hydraulic Oil

SMCS Code: 1348; 1395; 7560

Cat HYDO (Hydraulic Oil) is recommended in most


hydraulic systems. If Caterpillar oils cannot be used,
the following commercial classifications can be used
in hydraulic systems:

Lubrication System
Lubricant Recommendations
Due to significant variations in the quality and in
the performance of commercially available oils,
Caterpillar makes the following recommendations:

Cat NGEO (Natural Gas Engine Oil)


Cat NGEO EL250 (Natural Gas Engine Oil)
Cat NGEO EL350 (Natural Gas Engine Oil)
SAE 40 is the ONLY type of oil that is recommended
for Caterpillar G3600 Gas Engines. Multigrade oils
are NOT recommended for use in Caterpillar G3600
Gas Engines.
Table 14

Engine Oil Viscosity

(1)

Ambient Temperature

Cat NGEO
Grade of
Viscosity

Minimum

Maximum

SAE 40(1)

5 C (41 F)

50 C (122 F)

SAE 40 is the ONLY type of oil that is recommended for 3600


Gas engines. Multigrade oils are NOT recommended for use in
Caterpillar Gas Engines.

For further information about oils, see Special


Publication, SEBU6400, Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations.

Lubricant Capacities
The capacity of the engine crankcase includes the
capacity of the oil filters that are installed at the
factory.

CH-4 engine oils that have a minimum zinc additive


of 0.09 percent (900 ppm)

CG-4 engine oils that have a minimum zinc additive


of 0.09 percent (900 ppm)

CF-4 engine oils that have a minimum zinc additive


of 0.09 percent (900 ppm)

CF engine oils that have a minimum zinc additive


of 0.09 percent (900 ppm)

Note: Industrial hydraulic oils are not recommended


for use in Caterpillar hydraulic systems.
Caterpillar also has a biodegradable hydraulic oil
that is available for use in hydraulic systems. This
fluid is recommended for the hydraulic systems when
environmental compliance is required or desired.
For further information on choosing a hydraulic oil,
see Special Publication, SEBU6400, Caterpillar
Gas Engine Lubricant, Fuel, and Coolant
Recommendations.

Capacity of the Electrohydraulic


Actuators System
Table 16

Electrohydraulic Actuators System


Approximate Refill Capacity
Compartment or System
Hydraulic Oil Tank

Liters

US Gallons

19

56
Maintenance Section
Refill Capacities

SEBU6496-06

Fuel

Cooling System

Fuel Recommendations

Coolant Recommendations

Caterpillar gas engines will operate successfully on


a broad range of gaseous fuels. Pipeline natural
gas has been used for many years. Commercial
fuel gases are mixtures of gases. These fuels
consist primarily of hydrocarbons (combinations of
hydrogen and carbon) and some inert gases. The
compositions of these gas mixtures have extreme
variations. Fuels such as wellhead gas, bio-gas,
and manufactured gas need to be reviewed for
acceptability. Analyze the fuel in order to determine
the following characteristics:

During shipping and storage, the engine must be


protected from damage that can be caused by
freezing of the cooling system. If the engine is
shipped to a site with freezing temperatures and/or
if the engine is stored in a location with freezing
temperatures, the cooling system must contain
antifreeze that will withstand the lowest ambient
temperature. Frequently check the concentration
of glycol in the coolant/antifreeze. Make sure that
the concentration is adequate in order to prevent
freezing. Otherwise, the cooling system must be
completely drained.

Composition
Contaminants
Heat value
Methane number
Specific gravity
Field gas can have varying characteristics of
combustion. Field gas can contain numerous
harmful impurities. The impurities can alter the BTU
content. The impurities can also alter the methane
number. The impurities include everything from
water up to complex hydrocarbons that can lead to
detonation and severe engine damage. To minimize
these effects, Caterpillar recommends the following
guidelines:
1. Evaluate the fuel with the Caterpillar Methane
Number Program, LEKQ6378.
Methane values below 30 are not recommended
for use in a Caterpillar engine. Fuels with a
methane number that is below 30 must first be
processed in order to remove harmful impurities
in the fuel and raising the methane number into
the acceptable range.
2. If necessary, use an engine that is configured
for a fuel that has a high energy. Consult the
appropriate manual for the engine in order to
determine the recommended engine timing.
3. Reduce the oil change interval according to the
results of the oil analysis.
For further information on fuels, see Special
Publication, SEBU6400, Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations.

Coolant/antifreeze is normally composed of three


elements: water, glycol, and additives. Each element
must meet specific guidelines.
Water
Deionized water or distilled water is
recommended for use in engine cooling systems.
If distilled water or deionized water is not available,
use water with the properties that are listed in Table
17.
Table 17

Caterpillar Minimum Acceptable Water Requirements


Property

Maximum Limit

ASTM Test

Chloride (Cl)

40 mg/L
(2.4 grains per US gal)

D512,
D4327

Sulfate (SO4)

100 mg/L
(5.9 grains per US gal)

D516

Total Hardness

170 mg/L
(10 grains per US gal)

D1126

Total Solids

340 mg/L
(20 grains per US gal)

D1888

Acidity

pH of 5.5 to 9.0

D1293

NOTICE
Use of water that does not meet the recommendations
for the cooling system will damage the cooling system.
Do not use these types of water in the cooling system:
sea water, softened water that has been conditioned
with salt, hard water, and tap water.
Only use water that meets the recommendations for
the cooling system.
If you are not sure about the properties of your water,
consult one of the following sources for a water
analysis:

SEBU6496-06

Caterpillar dealer

57
Maintenance Section
Refill Capacities

Table 18

Local water utility company

Recommended Coolant/Antifreeze and Service


Life of the Coolant/Antifreeze

Agricultural agent

Coolant/Antifreeze
Cat NGEC

Independent laboratory
Glycol
NOTICE
Do not use Extended Life Coolant (ELC) with
Caterpillar Gas Engines.
ELC was not formulated for use in Caterpillar Gas Engines.

Cat DEAC

Two Years

Commercial Heavy-Duty
Coolant/Antifreeze that
meets ASTM D4985

One Year

Caterpillar SCA and


Water

Two Years

Commercial SCA and


Water

One Year

(1)

(1)

Three Years

Commercial Heavy-Duty
Coolant/Antifreeze that
meets ASTM D6210

Use only the coolant/antifreeze that is recommended.


Preferred Cat NGEC (Natural Gas Engine
Coolant)

Service Life

The service life of coolant is also limited by use (service hours).


Refer to the specific engines Operation and Maintenance
Manual, Maintenance Interval Schedule.

Alternatively, use Cat DEAC (Diesel Engine


Antifreeze/Coolant) or a commercial heavy-duty
coolant/antifreeze that meets ASTM D6210 or
ASTM D4985 specifications.

Additives

NOTICE
Do not use a commercial coolant/antifreeze that only
meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light duty automotive
applications.

Acceptable A commercial SCA that provides


1200 mg/L (70 grains per US gal) or 1200 ppm of
nitrites in the final mixture of coolant/antifreeze

Use only the coolant/antifreeze that is recommended.


Acceptable In applications that do not require
protection from boiling or from freezing, a mixture of
Caterpillar SCA and water that meets the properties
that are listed in Table 17 is acceptable.
Note: The preferred coolant/antifreeze and the
acceptable mixture of SCA and water require
different concentrations of SCA. Refer to the Special
Publication, SEBU6400, Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations,
Supplemental Coolant Additive (SCA) topic.
Table 18 is a list of the coolant/antifreeze that is
recommended for Caterpillar Gas Engines. The
service life of the coolant/antifreeze that is used in
Caterpillar Gas Engines is also listed. To achieve
this service life, the coolants must be properly
maintained. The maintenance program includes
SOS coolant analysis.

Preferred Caterpillar Supplemental Coolant


Additive (SCA)

Note: A 50/50 concentration of Cat NGEC or of


Cat DEAC does not require a treatment with
an SCA at the initial fill. Commercial heavy-duty
coolant/antifreeze that meets ASTM D6210
or ASTM D4985 specifications may require a
treatment with an SCA at the initial fill. Read the label
or the instructions that are provided by the OEM of
the product.
To ensure that the correct amount of SCA is in the
cooling system, the concentration of SCA must be
tested on a scheduled basis. Obtain an SOS coolant
analysis (Level 1) or use a test kit to check the
concentration of the SCA according to this Operation
and Maintenance Manual, Maintenance Interval
Schedule.
For further information on coolant, see Special
Publication, SEBU6400, Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations.

58
Maintenance Section
Refill Capacities

SEBU6496-06

Coolant Capacities
To properly maintain the cooling system, the total
cooling system capacity must be determined. The
total cooling system capacity will vary between
individual installations. The total cooling system
capacity is the sum of the capacities of the following
components: jacket water circuit, aftercooler circuit,
accessory module, and external system. The external
system capacity includes the following components:
expansion tank, heat exchanger, radiator, and piping.
Refer to the specifications that are provided by
Caterpillar or by the OEM of the equipment. Record
the total cooling system capacity in the appropriate
Tables:
Table 19

G3612 Engine Cooling System


Approximate Refill Capacities
Compartment or System

Liters

US Gallons

Jacket Water

669 L

177 US gal

Aftercooler

64 L

17 US gal

Accessory Module

345 L

91 US gal

External System
Total Cooling System
Table 20

G3616 Engine Cooling System


Approximate Refill Capacity
Compartment or System

Liters

US Gallons

Jacket Water

900

238

Aftercooler

72

19

Accessory Module

345

91

External System
Total Cooling System

SEBU6496-06

59
Maintenance Section
Maintenance Interval Schedule

i02213863

Maintenance Interval Schedule


(G3612 and G3616 Engines
That Use Bio-Gas)
SMCS Code: 1000; 4450; 7500
Before performing any operation or maintenance
procedures, ensure that the safety information,
warnings, and instructions are read and
understood.
Before each consecutive interval is performed, all
of the maintenance requirements from the previous
interval must be performed.
Note: For information on generator maintenance,
see the Operation and Maintenance Manual for the
generator.

When Required
Actuator Control Linkage - Replace ...................... 65
Barring Device - Lubricate .................................... 69
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77
Engine Air Cleaner Element (Single Element) Clean/Replace .................................................... 87
Engine Air Precleaner - Clean .............................. 91
Engine Oil - Change ............................................. 92
Engine Oil Filter - Change .................................... 93
Overhaul Considerations ..................................... 115
Valve Stem Projection - Measure/Record ........... 121

Initial 1000 Service Hours


Air Starting Motor Lines Screen - Clean ............... 67
Air Starting Motor Lubricator Bowl - Clean ........... 67
Crankcase Blowby - Measure/Record .................. 79
Cylinder Pressure - Measure/Record ................... 81
Electrohydraulic System Oil Filter - Change ......... 87
Engine Crankcase Breather - Clean ..................... 91
Engine Protective Device Connections - Inspect .. 98
Engine Valve Lash - Inspect/Adjust .................... 100
Engine Valve Rotators - Inspect ......................... 101
Magnetic Pickups - Clean/Inspect ....................... 110
Valve Stem Projection - Measure/Record ........... 121

Every 1000 Service Hours


Actuator Control Linkage - Lubricate .................... 65
Belts - Inspect/Adjust/Replace .............................. 71
Combustion Sensor - Clean/Inspect/Replace ....... 71
Hoses and Clamps - Inspect/Replace ................ 105
Ignition System Spark Plugs - Replace .............. 109
Prechamber Check Valves - Clean ...................... 117

Every 2000 Service Hours


Aftercooler Condensation - Drain ......................... 66
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77
Crankshaft Vibration Damper - Inspect ................. 80
Cylinders - Inspect ................................................ 81
Engine Crankcase Breather - Clean ..................... 91
Engine Mounts - Check ........................................ 92
Engine Valve Lash - Inspect/Adjust .................... 100
Engine Valve Rotators - Inspect ......................... 101
Valve Stem Projection - Measure/Record ........... 121

Daily

Every 5000 Service Hours

Air Starting Motor Lubricator Oil Level - Check .... 68


Air Tank Moisture and Sediment - Drain ............... 68
Control Panel - Inspect ......................................... 73
Cooling System Coolant Level - Check ................ 75
Driven Equipment - Inspect/Replace/Lubricate ... 83
Electrohydraulic System - Inspect ........................ 85
Engine Air Cleaner Service Indicator - Inspect ..... 90
Engine Oil Level - Check ...................................... 96
Fuel System Fuel Filter Differential Pressure Check ................................................................ 102
Turbocharger - Clean ........................................... 119
Walk-Around Inspection ...................................... 122

Air Starting Motor Lines Screen - Clean ............... 67


Air Starting Motor Lubricator Bowl - Clean ........... 67
Cooling System Level Switch - Inspect ................. 77
Crankcase Blowby - Measure/Record .................. 79
Cylinder Pressure - Measure/Record ................... 81
Driven Equipment - Check .................................... 82
Electrohydraulic System - Check/Adjust ............... 85
Electrohydraulic System Oil - Change .................. 86
Electrohydraulic System Oil Filter - Change ......... 87
Engine Protective Device Connections - Inspect .. 98
Engine Protective Devices - Check .................... 100
Exhaust Bypass - Recondition ............................ 102
Gas Shutoff Valve - Inspect ................................ 104
Inlet Air System - Inspect ..................................... 110
Inlet Gas Manifold and Piping - Inspect/Replace .. 110
Magnetic Pickups - Clean/Inspect ....................... 110
Prechamber Check Valves - Replace .................. 118
Starting Motor - Inspect ....................................... 118
Turbocharger - Inspect ........................................ 120
Turbocharger Cleaner Tube - Replace ............... 121

Every 125 Service Hours


Engine Oil Sample - Obtain .................................. 97

Every 250 Service Hours


Battery Electrolyte Level - Check .......................... 70
Cooling System Coolant Sample (Level 1) Obtain ................................................................. 76
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 78

Between 10 000 and 14 000 Service Hours


Gas Admission Valve Seals - Inspect/Replace ... 103

60
Maintenance Section
Maintenance Interval Schedule

Overhaul (Top End) .............................................. 114

Every 10 000 Service Hours


Alternator - Inspect ............................................... 69
Cooling System Water Temperature Regulator Replace ............................................................... 79
Electrohydraulic Actuator - Inspect ....................... 83
Engine Oil Temperature Regulator - Replace ....... 98
Exhaust Shields - Inspect ................................... 102
Gas Pressure Regulator - Inspect/Replace ........ 104
Magneto Drive Coupling - Inspect ....................... 111
Prelube Pump - Inspect ....................................... 118
Water Pump - Inspect ......................................... 122

Every 20 000 Service Hours or 3 Years


Cooling System Coolant (NGEC) - Change .......... 73

Between 27 000 and 33 000 Service Hours


Electrohydraulic Actuator - Recondition ................ 84
Gas Admission Valve - Recondition .................... 103
Overhaul (In-Frame) ............................................ 111

Between 36 000 and 44 000 Service Hours


Gas Admission Valve Seals - Inspect/Replace ... 103
Overhaul (Top End) .............................................. 114

Between 52 000 and 54 000 Service Hours


Overhaul (Major) .................................................. 113

Overhaul
Connecting Rod Bearings - Inspect/Replace ........ 73

SEBU6496-06

SEBU6496-06

61
Maintenance Section
Maintenance Interval Schedule

i02213861

Maintenance Interval Schedule


(G3612 and G3616 Engines
That Have a 10.5:1 or an 11:1
Compression Ratio and Use
Natural Gas)
SMCS Code: 1000; 4450; 7500
Before performing any operation or maintenance
procedures, ensure that the safety information,
warnings, and instructions are read and
understood.
Before each consecutive interval is performed, all
of the maintenance requirements from the previous
interval must be performed.
Note: For information on generator maintenance,
see the Operation and Maintenance Manual for the
generator.

When Required
Actuator Control Linkage - Replace ...................... 65
Barring Device - Lubricate .................................... 69
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77
Engine Air Cleaner Element (Single Element) Clean/Replace .................................................... 87
Engine Air Precleaner - Clean .............................. 91
Overhaul Considerations ..................................... 115
Valve Stem Projection - Measure/Record ........... 121

Daily
Air Starting Motor Lubricator Oil Level - Check .... 68
Air Tank Moisture and Sediment - Drain ............... 68
Control Panel - Inspect ......................................... 73
Cooling System Coolant Level - Check ................ 75
Driven Equipment - Inspect/Replace/Lubricate ... 83
Electrohydraulic System - Inspect ........................ 85
Engine Air Cleaner Service Indicator - Inspect ..... 90
Engine Oil Level - Check ...................................... 96
Fuel System Fuel Filter Differential Pressure Check ................................................................ 102
Walk-Around Inspection ...................................... 122

Every 250 Service Hours


Battery Electrolyte Level - Check ..........................
Cooling System Coolant Sample (Level 1) Obtain .................................................................
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .................................................
Engine Oil Sample - Obtain ..................................

70
76
78
97

Initial 1000 Service Hours


Air Starting Motor Lines Screen - Clean ............... 67
Air Starting Motor Lubricator Bowl - Clean ........... 67
Crankcase Blowby - Measure/Record .................. 79
Cylinder Pressure - Measure/Record ................... 81
Electrohydraulic System Oil Filter - Change ......... 87
Engine Crankcase Breather - Clean ..................... 91
Engine Protective Device Connections - Inspect .. 98
Engine Valve Lash - Inspect/Adjust .................... 100
Engine Valve Rotators - Inspect ......................... 101
Magnetic Pickups - Clean/Inspect ....................... 110
Valve Stem Projection - Measure/Record ........... 121

Every 1000 Service Hours


Actuator Control Linkage - Lubricate .................... 65
Belts - Inspect/Adjust/Replace .............................. 71
Hoses and Clamps - Inspect/Replace ................ 105
Ignition System Spark Plugs - Check/Adjust ...... 106

Every 2000 Service Hours


Aftercooler Condensation - Drain ......................... 66
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77
Crankshaft Vibration Damper - Inspect ................. 80
Engine Crankcase Breather - Clean ..................... 91
Engine Mounts - Check ........................................ 92
Engine Valve Lash - Inspect/Adjust .................... 100
Engine Valve Rotators - Inspect ......................... 101
Valve Stem Projection - Measure/Record ........... 121

Every 5000 Service Hours


Air Starting Motor Lines Screen - Clean ............... 67
Air Starting Motor Lubricator Bowl - Clean ........... 67
Combustion Sensor - Clean/Inspect/Replace ....... 71
Cooling System Level Switch - Inspect ................. 77
Crankcase Blowby - Measure/Record .................. 79
Cylinder Pressure - Measure/Record ................... 81
Driven Equipment - Check .................................... 82
Electrohydraulic System - Check/Adjust ............... 85
Electrohydraulic System Oil - Change .................. 86
Electrohydraulic System Oil Filter - Change ......... 87
Engine Oil - Change ............................................. 92
Engine Oil Filter - Change .................................... 93
Engine Protective Device Connections - Inspect .. 98
Engine Protective Devices - Check .................... 100
Exhaust Bypass - Recondition ............................ 102
Gas Shutoff Valve - Inspect ................................ 104
Ignition System Spark Plugs - Replace .............. 109
Inlet Air System - Inspect ..................................... 110
Inlet Gas Manifold and Piping - Inspect/Replace .. 110
Magnetic Pickups - Clean/Inspect ....................... 110
Prechamber Check Valves - Clean ...................... 117
Starting Motor - Inspect ....................................... 118
Turbocharger - Inspect ........................................ 120

Every 10 000 Service Hours


Alternator - Inspect ............................................... 69

62
Maintenance Section
Maintenance Interval Schedule

Cooling System Water Temperature Regulator Replace ............................................................... 79


Electrohydraulic Actuator - Inspect ....................... 83
Engine Oil Temperature Regulator - Replace ....... 98
Exhaust Shields - Inspect ................................... 102
Gas Pressure Regulator - Inspect/Replace ........ 104
Magneto Drive Coupling - Inspect ....................... 111
Prechamber Check Valves - Replace .................. 118
Prelube Pump - Inspect ....................................... 118
Water Pump - Inspect ......................................... 122

Every 15 000 Service Hours


Gas Admission Valve Seals - Inspect/Replace ... 103
Overhaul (Top End) .............................................. 114

Every 20 000 Service Hours or 3 Years


Cooling System Coolant (NGEC) - Change .......... 73

Between 45 000 and 48 000 Service Hours


Electrohydraulic Actuator - Recondition ................ 84
Gas Admission Valve - Recondition .................... 103
Overhaul (In-Frame) ............................................ 111

Between 75 000 and 80 000 Service Hours


Overhaul (Major) .................................................. 113

Overhaul
Connecting Rod Bearings - Inspect/Replace ........ 73

SEBU6496-06

SEBU6496-06

63
Maintenance Section
Maintenance Interval Schedule

i02213859

Maintenance Interval Schedule


(G3612 and G3616 Engines
That Have a 9.2:1 Compression
Ratio and Use Wellhead or
Natural Gas)
SMCS Code: 1000; 4450; 7500
Before performing any operation or maintenance
procedures, ensure that the Safety Information,
warnings, and instructions are read and
understood.
Before each consecutive interval is performed, all
of the maintenance requirements from the previous
interval must be performed.
Note: For information on generator maintenance,
see the Operation and Maintenance Manual for the
generator.

When Required
Actuator Control Linkage - Replace ...................... 65
Barring Device - Lubricate .................................... 69
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77
Engine Air Cleaner Element (Single Element) Clean/Replace .................................................... 87
Engine Air Precleaner - Clean .............................. 91
Overhaul Considerations ..................................... 115
Valve Stem Projection - Measure/Record ........... 121

Daily
Air Starting Motor Lubricator Oil Level - Check .... 68
Air Tank Moisture and Sediment - Drain ............... 68
Control Panel - Inspect ......................................... 73
Cooling System Coolant Level - Check ................ 75
Driven Equipment - Inspect/Replace/Lubricate ... 83
Electrohydraulic System - Inspect ........................ 85
Engine Air Cleaner Service Indicator - Inspect ..... 90
Engine Oil Level - Check ...................................... 96
Fuel System Fuel Filter Differential Pressure Check ................................................................ 102
Walk-Around Inspection ...................................... 122

Every 250 Service Hours


Battery Electrolyte Level - Check ..........................
Cooling System Coolant Sample (Level 1) Obtain .................................................................
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .................................................
Engine Oil Sample - Obtain ..................................

70
76
78
97

Initial 1000 Service Hours


Air Starting Motor Lines Screen - Clean ............... 67
Air Starting Motor Lubricator Bowl - Clean ........... 67
Crankcase Blowby - Measure/Record .................. 79
Cylinder Pressure - Measure/Record ................... 81
Electrohydraulic System Oil Filter - Change ......... 87
Engine Crankcase Breather - Clean ..................... 91
Engine Protective Device Connections - Inspect .. 98
Engine Valve Lash - Inspect/Adjust .................... 100
Engine Valve Rotators - Inspect ......................... 101
Magnetic Pickups - Clean/Inspect ....................... 110
Valve Stem Projection - Measure/Record ........... 121

Every 1000 Service Hours


Actuator Control Linkage - Lubricate .................... 65
Belts - Inspect/Adjust/Replace .............................. 71
Hoses and Clamps - Inspect/Replace ................ 105
Ignition System Spark Plugs - Check/Adjust ...... 106

Every 2000 Service Hours


Aftercooler Condensation - Drain ......................... 66
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77
Crankshaft Vibration Damper - Inspect ................. 80
Engine Crankcase Breather - Clean ..................... 91
Engine Mounts - Check ........................................ 92
Engine Valve Lash - Inspect/Adjust .................... 100
Engine Valve Rotators - Inspect ......................... 101
Valve Stem Projection - Measure/Record ........... 121

Every 5000 Service Hours


Air Starting Motor Lines Screen - Clean ............... 67
Air Starting Motor Lubricator Bowl - Clean ........... 67
Combustion Sensor - Clean/Inspect/Replace ....... 71
Cooling System Level Switch - Inspect ................. 77
Crankcase Blowby - Measure/Record .................. 79
Cylinder Pressure - Measure/Record ................... 81
Driven Equipment - Check .................................... 82
Electrohydraulic System - Check/Adjust ............... 85
Electrohydraulic System Oil - Change .................. 86
Electrohydraulic System Oil Filter - Change ......... 87
Engine Oil - Change ............................................. 92
Engine Oil Filter - Change .................................... 93
Engine Protective Device Connections - Inspect .. 98
Engine Protective Devices - Check .................... 100
Exhaust Bypass - Recondition ............................ 102
Gas Shutoff Valve - Inspect ................................ 104
Ignition System Spark Plugs - Replace .............. 109
Inlet Air System - Inspect ..................................... 110
Inlet Gas Manifold and Piping - Inspect/Replace .. 110
Magnetic Pickups - Clean/Inspect ....................... 110
Prechamber Check Valves - Clean ...................... 117
Starting Motor - Inspect ....................................... 118
Turbocharger - Inspect ........................................ 120

Every 10 000 Service Hours


Alternator - Inspect ............................................... 69

64
Maintenance Section
Maintenance Interval Schedule

Cooling System Water Temperature Regulator Replace ............................................................... 79


Electrohydraulic Actuator - Inspect ....................... 83
Engine Oil Temperature Regulator - Replace ....... 98
Exhaust Shields - Inspect ................................... 102
Gas Pressure Regulator - Inspect/Replace ........ 104
Magneto Drive Coupling - Inspect ....................... 111
Prechamber Check Valves - Replace .................. 118
Prelube Pump - Inspect ....................................... 118
Water Pump - Inspect ......................................... 122

Every 20 000 Service Hours or 3 Years


Cooling System Coolant (NGEC) - Change .......... 73

Every 25 000 Service Hours


Gas Admission Valve Seals - Inspect/Replace ... 103
Overhaul (Top End) .............................................. 114

Every 50 000 Service Hours


Electrohydraulic Actuator - Recondition ................ 84
Gas Admission Valve - Recondition .................... 103
Overhaul (In-Frame) ............................................ 111

Every 100 000 Service Hours


Overhaul (Major) .................................................. 113

Overhaul
Connecting Rod Bearings - Inspect/Replace ........ 73

SEBU6496-06

SEBU6496-06

65
Maintenance Section
Actuator Control Linkage - Lubricate

i02277937

Hydraulic Actuators

Actuator Control Linkage Lubricate


(If applicable)
SMCS Code: 1265-086

The linkage can move and form a pinch point


which can cause personal injury. Keep hands
away from the linkage.
Before performing this procedure, ensure that the
linkage is meant to be lubricated. If the linkage is
meant to be lubricated, this article applies to the
following: air choke actuator, fuel control actuator,
and exhaust bypass actuator.
Apply Dow Corning 41 Extreme High Temperature
Bearing Grease to the rod ends (bearings) of the
control linkage for the actuators. For more information
on grease, see the Special Publication, SEBU6400,
Caterpillar Gas Engine Lubricant, Fuel, and Coolant
Recommendations.

Heinzmann Actuators

Illustration 45

g01120800

Typical locations of grease fittings

i02277941

Actuator Control Linkage Replace


SMCS Code: 1265-510

Removal and Installation


For instructions on removal and installation of the
control linkage for the actuators, see the Disassembly
and Assembly Manual. See the Specifications
Manual for instructions on adjusting the actuators.
Consult your Caterpillar dealer for assistance.
Note: Use of a platform may be necessary to reach
the linkages.
Inspect the rod ends of the following components for
wear:

Air choke actuator


Exhaust bypass actuator
Illustration 44
Typical locations of grease fittings

g01120791

Fuel control actuator


Linkages

66
Maintenance Section
Aftercooler Condensation - Drain

SEBU6496-06

Heinzmann Actuators

Condensation can form in the passages of the


aftercooler system. Drain plugs are provided for
draining the condensation.

Illustration 48

g00788934

A drain plug is located on the right side near the rear of the engine.
(1) Plug
Illustration 46

g01120823

Typical locations of rod ends

Hydraulic Actuators

Illustration 49

g00788946

A drain plug is located on the left side near the front of the engine.
(2) Plug

1. Ensure that the engine is not running.


Illustration 47

g00799207

Typical locations of rod ends

2. Remove plugs (1) and (2).


3. Drain the moisture into suitable containers.

i01762572

Aftercooler Condensation Drain


SMCS Code: 1063
The aftercooler is similar to a radiator. Coolant
passes through the tubes in the aftercooler core. Inlet
air that is warmed by the turbocharger compressor
is directed through the aftercooler core. The air is
cooled in the aftercooler.

4. Install the plugs.

SEBU6496-06

67
Maintenance Section
Air Starting Motor Lines Screen - Clean

i01762654

Air Starting Motor Lines


Screen - Clean

Personal injury can result from removing hoses or


fittings in a pressure system.

SMCS Code: 1451-070-LI

Failure to relieve pressure can cause personal injury.


Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
1. Ensure that the air supply to the lubricator is OFF.

Illustration 50

g00789123

(1) Plug
(2) Screen

If the engine is equipped with an air starting motor,


use the following procedure:
g00745554

1. Ensure that the air supply to the air lines is OFF.

Illustration 51

2. Remove plug (1).

(1) Filler plug


(2) Bowl
(3) Drain valve

3. Carefully remove screen (2). Clean the screen


with nonflammable solvent. Inspect the screen for
damage. If the screen is damaged, replace the
damaged screen with a new screen.

2. Slowly loosen filler plug (1) in order to release the


pressure from the lubricator.

4. Install clean, dry screen (2). Clean plug (1). Install


the plug.
i02208941

Air Starting Motor Lubricator


Bowl - Clean
SMCS Code: 1451-070
If the engine is equipped with an air starting motor,
use the following procedure:

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, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
3. Place a suitable container under bowl (2) and
open drain valve (3) in order to drain the oil from
the bowl.
4. Remove bowl (2). Clean the bowl with warm water.

68
Maintenance Section
Air Starting Motor Lubricator Oil Level - Check

5. Dry the bowl. Inspect the bowl for cracks. If the


bowl is cracked, replace the damaged bowl with
a new bowl. Inspect the gasket. If the gasket is
damaged, replace the gasket.
6. Install the bowl.

SEBU6496-06

3. Remove filler plug (4). Pour oil into the lubricator


bowl. Use nondetergent SAE 10W oil for
temperatures that are greater than 0 C (32 F).
Use air tool oil for temperatures that are below
0 C (32 F).
4. Install filler plug (4).

7. Make sure that drain valve (3) is closed.


8. For instructions on filling the lubricator, see this
Operation and Maintenance Manual, Air Starting
Motor Lubricator Oil Level - Check topic.
i02213914

Air Starting Motor Lubricator


Oil Level - Check
SMCS Code: 1451-535
NOTICE
Never allow the lubricator bowl to become empty. The
air starting motor will be damaged by a lack of lubrication. Ensure that sufficient oil is in the lubricator bowl.

Adjust the Lubricator


Note: Adjust the lubricator with a constant rate of air
flow. After the adjustment, the lubricator will release
oil in proportion to variations of the air flow.
1. Ensure that the fuel supply to the engine is OFF.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
2. Operate the air starting motor. Observe the drops
of oil that are released in dome (1).
Note: Some lubricators have an adjustment screw
rather than a knob.
3. If necessary, adjust the lubricator in order
to release from one to three drops of oil per
second. To increase the rate, turn knob (2)
counterclockwise. To decrease the rate, turn the
knob clockwise.
i00351324

Air Tank Moisture and


Sediment - Drain
Illustration 52

g00745561

1. Observe the oil level in sight gauge (3). If the oil


level is less than 1/2, add oil to the lubricator bowl.

SMCS Code: 1466-543-M&S


Moisture and sediment in the air starting system can
cause the following conditions:

Freezing
Personal injury can result from removing hoses or
fittings in a pressure system.

Corrosion of internal parts


Malfunction of the air starting system

Failure to relieve pressure can cause personal injury.


Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
2. Ensure that the air supply to the lubricator is OFF.
Slowly loosen filler plug (4) in order to release
pressure from the lubricator bowl.

When opening the drain valve, wear protective


gloves, a protective face shield, protective clothing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal
injury.

SEBU6496-06

69
Maintenance Section
Alternator - Inspect

1. Open the drain valve that is on the bottom of the


air tank. Allow the moisture and sediment to drain.
2. Close the drain valve.
i02084374

Alternator - Inspect
SMCS Code: 1405-040
Inspect the alternator for the following conditions:

When the barring device is not used, the barring


device must be fully disengaged from the flywheel
and secured in the disengaged position. Refer to the
Service Manual for information on operation of the
barring device.
NOTICE
Do not operate the engine starting motor until the barring group pinion gear is fully disengaged from the flywheel ring gear. Serious damage to the engine could
result.

Proper connections

Electric Barring Device

Clean ports for cooling airflow

Note: This type of barring device may be electrically


driven or manually driven.

Proper charging of the battery


Observe the ammeter during engine operation in
order to ensure proper battery performance and/or
proper performance of the electrical system.
Make repairs, if necessary. See the Service Manual
for service procedures. Consult your Caterpillar
dealer for assistance.
i02168725

Barring Device - Lubricate


SMCS Code: 1235-086
NOTICE
Do not use an impact wrench to operate the barring
device. The use of an impact wrench will cause gear
tooth failure.

Illustration 53

g00334420

Rear view of an electrically driven barring device

Lubricating the Pinion

Guards must be in place prior to operating barring


device motor.
Remove all hand tools prior to operating barring
device motor.
Note: Prelube of the engine is required before the
crankshaft is rotated for normal maintenance.
The barring device provides a means for slowly
turning the flywheel in order to service the engine.
The barring device can also be used to prevent
rotation of the crankshaft. When the barring device is
in the engaged position, the engine starting system
is disabled.

Illustration 54

g01098831

Section view of a barring device without the electric motor


(1) Grease fitting
(2) Vent

1. Ensure that the barring device is locked in the


disengaged position.
2. Lubricate grease fitting (1) with MPGM until the
grease is visible at vent (2).

70
Maintenance Section
Battery Electrolyte Level - Check

SEBU6496-06

Lubricating the Reducer

i02213936

Battery Electrolyte Level Check


SMCS Code: 1401-535-FLV
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries
are properly charged, ammeter reading should be
very near zero.

Illustration 55

g00991445

1. Ensure that the barring device is locked in the


disengaged position.
2. Remove level plugs (2) and check the lubricant
level.
3. If necessary, remove cap (1) and add Caterpillar
4C-6767 Synthetic Oil until the oil is visible at the
level plugs.
4. Reinstall the level plugs and reinstall the cap.

Manual Barring Device

All lead-acid batteries contain sulfuric acid which


can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the filler caps. Maintain the electrolyte
level to the FULL mark on the battery.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
3. Keep the batteries clean.
Clean the battery case with one of the following
cleaning solutions:

A mixture of 0.1 kg (0.2 lb) of baking soda and


1 L (1 qt) of clean water

A mixture of 0.1 L (0.11 qt) of ammonia and 1 L


(1 qt) of clean water

Thoroughly rinse the battery case with clean water.


Illustration 56

g01098833

(1) Grease fitting


(2) Gear end

1. Ensure that the barring device is locked in the


disengaged position.
2. Lubricate grease fitting (1) with MPGM until the
grease is visible at gear end (2).

Use a fine grade of sandpaper to clean the


terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.

SEBU6496-06

71
Maintenance Section
Belts - Inspect/Adjust/Replace

i02154849

Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510

Inspection
Inspect the alternator belt and the fan drive belts for
wear and for cracking. Replace the belts if the belts
are not in good condition.
Check the belt tension according to the information in
the Service Manual, Specifications.
Slippage of loose belts can reduce the efficiency
of the driven components. Vibration of loose belts
can cause unnecessary wear on the following
components:

2. Loosen mounting bolt (1), adjusting nuts (2) and


mounting bolt (3).
3. Turn adjusting nuts (2) in order to increase or
decrease the drive belt tension.
4. Tighten adjusting nuts (2). Tighten mounting bolt
(3). Tighten mounting bolt (1). For the proper
torque, see the Service Manual, Specifications
module.
5. Reinstall the drive belt guard.
If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation at
the rated rpm.

Adjusting the Fan Drive Belt


1. Loosen the mounting bolt for the pulley.

Belts

2. Loosen the adjusting nut for the pulley.

Pulleys

3. Move the pulley in order to adjust the belt tension.

Bearings
If the belts are too tight, unnecessary stress is placed
on the components. This reduces the service life of
the components.

4. Tighten the adjusting nut.


5. Tighten the mounting bolt.

Replacement

Adjusting the Alternator Belt

For applications that require multiple drive belts,


replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.
i01765627

Combustion Sensor Clean/Inspect/Replace


SMCS Code: 1900; 1905
To provide a signal without interference to the engine
control module, the sensor must be in good condition.
The connections must be clean.

Illustration 57
(1) Mounting bolt
(2) Adjusting nuts
(3) Mounting bolt

1. Remove the drive belt guard.

g01092641

72
Maintenance Section
Combustion Sensor - Clean/Inspect/Replace

SEBU6496-06

Pressurized air can cause personal injury. When


pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.
Note: The maximum air pressure for cleaning
purposes must be below 207 kPa (30 psi).
4. The area around sensor (4) may have debris.
Thoroughly remove any debris. Use compressed
air. Ensure that the area around the sensor is
clean and free of debris.
5. Loosen sensor (4) with a 15.9 mm (5/8 inch) spark
plug socket and an extension. After the sensor
has been loosened, remove the sensor by hand in
order to detect problems with the threads.
If the sensor resists removal by hand, apply
penetrating oil to the threads. Use the wrench
and apply steady pressure to the sensor until the
sensor is loose.

Illustration 58

g00789241

Section view of a cylinder head with a combustion sensor


(1)
(2)
(3)
(4)
(5)
(6)

Harness connector
Connector
Extension
Sensor
Gasket
Discs

Note: Use of a platform may be necessary to reach


the combustion sensor.
Note: Clean the connections and polish the
connections with a clean, dry cloth. Always install
a new O-ring seal in connector (1) when the
combustion sensor is serviced.
1. Disconnect harness connector (1) from connector
(2). Remove the O-ring seal from the harness
connector. Clean the end of the harness
connector. Install a new O-ring seal.
2. Remove connector (2). Clean the inside of the
connectors adapters.
3. Remove extension (3). Clean both ends of the
extension.

Illustration 59

g00789274

Combustion sensor
(6) Terminal post
(7) Insulator
(8) Shell
(9) Gasket
(10) Electrode

6. After the sensor is removed, discard gasket (9).


7. Inspect the sensor closely for damage.
Terminal post (6) must not move. If the terminal
post can be moved by hand, discard the sensor.
Inspect insulator (7) for cracks. If a crack is found,
discard the sensor.
Inspect shell (8) for damage. Cracks can
be caused by overtightening the sensor.
Overtightening can also loosen the shell. Discard
any sensor that has a shell that is cracked or
loose.
Inspect electrode (10) for excessive wear.

SEBU6496-06

73
Maintenance Section
Connecting Rod Bearings - Inspect/Replace

Light brown deposits or beige deposits around the


electrode is produced by normal operation. White
deposits or gray deposits may be caused by the
following substances:

Connecting Rod Bearings Inspect/Replace

Excessive oil

SMCS Code: 1219-040; 1219-510

Use of the wrong oil

The condition of the connecting rod bearings will


vary depending on the engine application and
the operating conditions. During every overhaul,
bearings should be inspected in order to determine if
the bearings can be reused. Refer to Guidelines for
Reusable Parts, SEBF8009, Main and Connection
Rod Bearings for determining bearing reusability.

A substance that is introduced through the fuel


system or the air system

A buildup of ash on the electrode reduces the


efficiency of the sensor.

i02243193

8. Measure the resistance between terminal post (6)


and electrode (10).
The sensor must pass a low voltage check for
continuity between the terminal post and the
electrode (15 volts DC). The resistance must not
exceed five ohms.
9. Thoroughly clean the sensor.
Clean the shell and the electrode that is inside of
the shell. Do not use a wire brush. Glass beads
are the preferred method for cleaning. Follow
these guidelines for the use of glass beads:

Always use clean glass beads.


Use care in order to clean only the electrode
and the insulator near the electrode.

Do not use glass beads on the outside of the


shell or on the upper part of the insulator.

Ensure that the sensor is clean and free of dirt


and oil.
Note: Do not use anti-seize compound on the sensor.
Most of the heat is transferred through the threads
and the seat area of the sensor. The surfaces must
be in contact in order to provide the heat transfer that
is required.
10. Place a new 108-3515 Plug Gasket on the
sensor. Install the sensor by hand until the sensor
bottoms out. Tighten the sensor to 38 2 Nm
(28 2 lb ft).
11. Install extension (3). Make sure that discs (5)
are positioned in order to align the extensions
connectors with sensor (4) and connector (2).
12. Make sure that the O-ring seal on connector (2) is
in good condition. Install the connector.
13. Attach harness connector (1) to connector (2).

i01762721

Control Panel - Inspect


SMCS Code: 4490-040; 7451-040
Inspect the condition of the panel. If a component is
damaged, ensure that the component is repaired or
that the component is replaced. If equipped, ensure
that the electronic displays are operating properly.
Inspect the wiring for good condition. Ensure that the
wiring connections are secure.

Record the Data and Review the


Data
If equipped, check the gauges and check the
indicators frequently during normal operation. Record
the data in a log. Compare the new data to the data
that was previously recorded. Comparing the new
data to the recorded data will establish the normal
gauge readings for the engine. A gauge reading that
is abnormal may indicate a problem with operation
or with the gauge.
i02213946

Cooling System Coolant


(NGEC) - Change
SMCS Code: 1350-044
Clean the cooling system before the recommended
maintenance interval if the following conditions exist:

The engine overheats frequently.


Foaming is observed.
The oil has entered the cooling system and the
coolant is contaminated.

74
Maintenance Section
Cooling System Coolant (NGEC) - Change

SEBU6496-06

NOTICE
Use of commercially available cooling system cleaners may cause damage to cooling system components. Use only cooling system cleaners that are approved for Caterpillar engines.

Drain the Cooling System


1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the
cooling system is drained.
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.

NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tools
Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

Clean the Cooling System


1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the cooling system drain valves (if
equipped). Clean the cooling system drain plugs
and install the cooling system drain plugs.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Illustration 60

g00792409

Location of cooling system drain valves or drain plugs on the water


pumps
(1) Jacket water pump
(2) Aftercooler and oil cooler pump

3. Fill the cooling system with a mixture of clean


water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
4. Start the engine. Operate the engine for a
minimum of 30 minutes with a coolant temperature
of at least 82 C (180 F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valves (if equipped). Remove the cooling system
drain plugs. Allow the water to drain.

Illustration 61

g00901833

Location of drain plug for the jacket water system

3. Open the cooling system drain valves (if


equipped). Remove the cooling system drain
plugs. Allow the coolant to drain.

NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal components.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear water. Continue to flush the system until all signs of the
cleaning agent are gone.

SEBU6496-06

75
Maintenance Section
Cooling System Coolant Level - Check

6. Flush the cooling system with clean water until


the water that drains is clean. Close the cooling
system drain valves (if equipped). Clean the
cooling system drain plugs and install the cooling
system drain plugs.

Note: For information about the proper coolant to


use, and the capacity of the cooling system, see
this Operation and Maintenance Manual, Refill
Capacities and Recommendations (Maintenance
Section).

Cleaning a Cooling System that


has Heavy Deposits or Plugging

1. Fill the cooling system with coolant/antifreeze. Do


not install the cooling system filler cap.

Note: For the following procedure to be effective,


there must be an active flow through the cooling
system components.
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the cooling system drain valves (if
equipped). Clean the cooling system drain plugs
and install the cooling system drain plugs.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
(1 to 2 US gal) of the cooling system capacity.
Install the cooling system filler cap.
4. Start the engine. Operate the engine for a
minimum of 90 minutes with a coolant temperature
of at least 82 C (180 F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valves (if equipped). Remove the cooling system
drain plugs. Allow the water to drain.
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal components.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear water. Continue to flush the system until all signs of the
cleaning agent are gone.
6. Flush the cooling system with clean water until
the water that drains is clean. Close the cooling
system drain valves (if equipped). Clean the
cooling system drain plugs and install the cooling
system drain plugs.

Fill the Cooling System


NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute in order to avoid air locks.

2. Start the engine. Operate the engine in order to


purge the air from the cavities of the engine block.
Allow the coolant to warm and allow the coolant
level to stabilize. Stop the engine.
3. Check the coolant level. Maintain the coolant to
the proper level on the sight gauge (if equipped).
If a sight gauge is not equipped, maintain the
coolant to the level that is specified by the OEM
of the cooling system.
4. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
gaskets of the cooling system filler cap are
damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the
gaskets of the cooling system filler cap are not
damaged, use a 9S-8140 Pressurizing Pump in
order to pressure test the cooling system filler cap.
The correct pressure is stamped on the face of
the cooling system filler cap. If the cooling system
filler cap does not retain the correct pressure,
install a new cooling system filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i02158408

Cooling System Coolant Level


- Check
SMCS Code: 1350-535-FLV

Climbing equipment may be required to access


this service point. Refer to the Operation and
Maintenance Manual, Mounting and Dismounting topic for safety information.

76
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

Engines That Are Equipped With a


Sight Gauge

Illustration 62

SEBU6496-06

2. Remove the cooling system filler cap slowly in


order to relieve any pressure. Pour the proper
coolant mixture into the filler pipe.

g00750429

(1) Filler cap


(2) Sight gauge

If the engine is equipped with a sight gauge, observe


the position of the coolant in the sight gauge. At
normal operating temperature, the proper coolant
level is in the upper half of the sight gauge. If the
coolant level is low, add the proper coolant mixture.

Engines That Are Not Equipped


With a Sight Gauge

Illustration 63

g00103639

Gaskets

3. Clean the cooling system filler cap. Inspect the


gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.
4. Start the engine. Inspect the cooling system for
leaks.
i02064894

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
Check the coolant level when the engine is stopped
and cool. Check the coolant level only after the
engine has been stopped and the cooling system
filler cap is cool enough to touch with your bare hand.
Remove the cooling system filler cap slowly in order
to relieve any pressure. Maintain the coolant within
13 mm (0.5 inch) below the bottom of the filler pipe.

Add Coolant
Note: For the proper coolant mixture to use, see
this Operation and Maintenance Manual, Refill
Capacities and Recommendations (Maintenance
Section).
1. Stop the engine. Allow the engine to cool.

Cooling System Coolant


Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
For conventional heavy-duty coolant/antifreeze,
check the concentration of supplemental coolant
additive (SCA) regularly. The concentration of SCA
can be checked with an SOS coolant analysis
(Level 1).
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
to receive the full effect of SOS analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.

SEBU6496-06

77
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

Use the following guidelines for proper sampling of


the coolant:

Never collect samples from expansion bottles.


Never collect samples from the drain for a system.

Submit the sample for Level 2 analysis.


For additional information about coolant analysis,
see the Special Publication, SEBU6400, Caterpillar
Gas Engine Lubricant, Fuel, and Coolant
Recommendations or consult your Caterpillar dealer.

Keep the unused sampling bottles stored in plastic


bags.

i01519993

Keep the lids on empty sampling bottles until you

Cooling System Level Switch


- Inspect

Complete the information on the label for the

SMCS Code: 7422-040

are ready to collect the sample.

sampling bottle before you begin to take the


samples.

Obtain coolant samples directly from the coolant


sample port. You should not obtain the samples
from any other location.

In order to avoid contamination, immediately place

The low coolant level switch actuates an alarm or a


shutoff if the coolant level is low. A low coolant level
could cause the engine to overheat. This could result
in damage to the engine.
If the coolant level is low, coolant must be added to
the expansion tank or the heat exchanger.

the sample in the tube that is provided for mailing.

Submit the sample for Level 1 analysis.


Note: Level 1 results may indicate a need for
Level 2 Analysis.
For additional information about coolant analysis,
see the Special Publication, SEBU6400, Caterpillar
Gas Engine Lubricant, Fuel and Coolant
Recommendations or consult your Caterpillar dealer.
i02168823

Cooling System Coolant


Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Caterpillar dealer.
Refer to this Operation and Maintenance Manual,
Cooling System Coolant Sample (Level 1) - Obtain
(Maintenance Section) for the guidelines for proper
sampling of the coolant.

Illustration 64

g00789360

(1) Switch
(2) Lines

For proper operation of the switch, the lines and the


switch must be clean.
1. Drain the coolant to a level below lower line (2).
Drain the coolant into a clean container so that the
coolant can be reused.
2. Remove switch (1). Inspect the openings of the
inlet and the outlet for plugging. If an opening is
plugged, clean the switch.
3. Inspect lines (2) for plugging. Clean the lines, if
necessary. Pressure air or a flexible wire can be
used to clean the lines.
4. Install switch (1).

78
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

5. Pour the coolant into the cooling system. Verify


that the low coolant level switch is operating
properly. A switch that is operating properly will
activate an alarm until a sufficient amount of
coolant is added.
i02017557

Cooling System Supplemental


Coolant Additive (SCA) Test/Add
SMCS Code: 1352-045; 1395-081

SEBU6496-06

4. Add 2 to 3 drops of the NITRITE INDICATOR


SOLUTION B to the mixing bottle. Move the bottle
in a circular motion in order to mix the solution.
5. Add 1 drop of NITRITE TEST SOLUTION A to
the mixing bottle. Move the bottle in a circular
motion in order to mix the solution.
6. Repeat 5 until the solution changes color from red
to light gray, green, or blue. Record the number of
drops of NITRITE TEST SOLUTION A that were
required to cause the color change.
7. Use Table 21 to interpret the results.
Table 21

Cooling system coolant additive contains alkali.


To help prevent personal injury, avoid contact with
the skin and eyes. Do not drink cooling system
coolant additive.
Note: Caterpillar recommends an SOS coolant
analysis (Level 1).

Test the Concentration of the SCA


Coolant/Antifreeze and SCA
NOTICE
Do not exceed the recommended six percent supplemental coolant additive concentration.

Number of
Drops

Concentration
of SCA

Maintenance
Required

Less than 25

Less than the


recommended
concentration of
SCA

Add SCA.
Retest the
coolant.

25 to 30

The
recommended
concentration of
SCA

None

More than 30

More than the


recommended
concentration of
SCA

Remove the
coolant.
Replace with
water only
Retest the
coolant.

Add the SCA, If Necessary

Test the concentration of the SCA with the 8T-5296


Coolant Conditioner Test Kit. Follow the instructions
that are provided in the kit.

Water and SCA


NOTICE
Do not exceed the recommended eight percent supplemental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Use the instructions
that follow:
1. Fill the syringe to the 1.0 ml mark with the
coolant.
2. Dispense the 1.0 mL coolant sample from the
syringe into the empty mixing bottle.
3. Add tap water to the mixing bottle in order to bring
the level up to the 10 ml mark. Place the cap on
the bottle and shake the bottle.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
1. Remove the cooling system filler cap slowly.
Note: Always dispose of fluids according to local
regulations.
2. If necessary, drain some coolant in order to allow
space for the addition of the SCA.

SEBU6496-06

79
Maintenance Section
Cooling System Water Temperature Regulator - Replace

NOTICE
Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engines
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger, overheating, and/or accelerated wear of the water
pump seal.
Do not exceed the recommended amount of supplemental coolant additive concentration.
3. Add the proper amount of SCA. The concentration
of the SCA depends on the type of coolant that
is used. To determine the proper amount, see
this Operation and Maintenance Manual, Refill
Capacities and Recommendations topic.
4. Clean the cooling system filler cap. Install the
cooling system filler cap.
i02168842

Cooling System Water


Temperature Regulator Replace
SMCS Code: 1355-510
Replace the water temperature regulators for these
systems:

Jacket water
Oil cooler
Aftercooler
Replace the water temperature regulators before
the water temperature regulators fail. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulators reduces
the chances for unscheduled downtime.
A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or a seizure of the pistons.

A water temperature regulator that fails in the open


position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner. Also, a low temperature can
allow moisture to condense in the oil. This can form
damaging acids.
NOTICE
Failure to replace the water temperature regulator on
a regularly scheduled basis could cause severe engine damage.
Never operate an engine without the water temperature regulator installed.
If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature regulator is installed in the original position.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
i00708678

Crankcase Blowby Measure/Record


SMCS Code: 1317
Note: The typical crankcase blowby on a new engine
is approximately 0.02 m3/bkW h (.50 ft3/bhp h).
Measure the crankcase blowby of new engines.
Record the data. Continue to periodically measure
the crankcase blowby. Comparing the recorded
data to the new data provides information about the
condition of the engine.
Note: Crankcase blowby is one of the three factors
that help to determine the in-frame overhaul interval.
For more information, see the Operation and
Maintenance manual, Overhaul (In-Frame) topic in
the Maintenance Section.
After a new engine is used for a short time, the
crankcase blowby can decrease as the piston rings
are seated. The crankcase blowby will gradually
increase as the following components show wear:

piston rings
cylinder liners

80
Maintenance Section
Crankshaft Vibration Damper - Inspect

Note: A problem with the piston rings causes the


oil to deteriorate rapidly. Information regarding the
condition of the piston rings can be obtained from
the measurement of the crankcase blowby and the
results of oil analysis.
The crankcase blowby of a worn engine may exceed
the crankcase blowby of a new engine by two times
or more.
A sudden increase in crankcase blowby could
indicate a broken piston ring. The following conditions
are other potential sources of crankcase blowby:

Worn valve guides


A turbocharger seal that leaks
A rebuilt engine can have a high crankcase blowby
due to the following factors:

The piston rings are not seated properly.


Worn parts such as valve guides were not replaced.
Excessive crankcase blowby may indicate the need
for an overhaul. By keeping a record of the results,
a gradual increase in the amount of the crankcase
blowby will be noted until the amount of crankcase
blowby has become excessive.
Use the following tools to measure the blowby:

8T-2700 Blowby/Air Flow Indicator

SEBU6496-06

i01949731

Crankshaft Vibration Damper


- Inspect
SMCS Code: 1205-040
The crankshaft vibration damper limits the torsional
vibration of the crankshaft. The visconic damper has
a weight that is located inside a fluid filled case.
Damage to the crankshaft vibration damper or failure
of the damper can increase torsional vibrations. This
can result in damage to the crankshaft and to other
engine components. A deteriorating damper can
cause excessive gear train noise at variable points
in the speed range.
A damper that is hot is due to excessive torsional
vibration. Monitor the temperature of the damper
during operation.
The 8T-2821 Temperature Indicator or the 8T-2822
Temperature Indicator are recommended for
monitoring the temperature of the damper. Evenly
space four of the adhesive indicators around the
outer diameter of the damper.
Note: If you use an infrared thermometer to monitor
the temperature of the damper, use the thermometer
during operation with similar loads and speeds. Keep
a record of the data. If the temperature begins to rise,
reduce the interval for inspecting the damper.

1U-8860 Large Engine Blowby Pickup Group

If the temperature of the damper reaches 110 C


(230 F), consult your Caterpillar dealer.

Refer to these Special Instructions that are provided


with the tools:

Inspect the damper for evidence of dents, cracks,


and leaks of the fluid.

Special Instruction, SEHS8712, Using the

If a fluid leak is found, repair the damper or


replace the damper. The fluid in the damper is
silicone. Silicone has the following characteristics:
transparent, viscous, smooth, and sticky.

8T-2700 Blowby/Airflow Indicator Group

Special Instruction, SEHS8984, Using the

1U-8860 Large Engine Blowby Pickup Group

Record the crankcase blowby for the engine. Keep a


record of the results.
For more information, see the Service Manual,
Systems Operation/Testing and Adjusting. For
assistance, consult your Caterpillar dealer.

Inspect the damper and repair or replace the damper


for any of the following reasons.

The damper is dented, cracked, or leaking.


The paint on the damper is discolored from heat.
The engine has had a failure because of a broken
crankshaft.

An analysis of the oil has revealed that the front


bearing of the crankshaft is badly worn.

There is a large amount of gear train wear that is


not caused by a lack of oil.

SEBU6496-06

81
Maintenance Section
Cylinder Pressure - Measure/Record

Removal and Installation


Refer to the Service Manual, Disassembly and
Assembly or consult your Caterpillar dealer for
information about damper replacement.
i01520103

To measure the cylinder pressure, refer to Special


Instruction, GMG00694, Analyzing Cylinder
Condition By Measuring Air Flow. Also, use the
146-2739 Cylinder Pressure Adapter.
Illustration 65 is a graph of typical cylinder pressures
for engines with different compression ratios.

Cylinder Pressure Measure/Record


SMCS Code: 1223-082-CC; 1223; 7450-082
Measure the cylinder pressure of new engines.
Record the data. Continue to periodically measure
the cylinder pressure. Comparing the recorded data
to the new data provides information about the
condition of the engine.
Note: Cylinder pressure is one of the three factors
that help to determine the in-frame overhaul interval.
For more information, refer to this Operation
and Maintenance manual, Overhaul (In-Frame)
(Maintenance Section).
Cylinder pressure can be measured during inspection
of the spark plugs. Use the following guidelines for
checking the cylinder pressure:

Remove all of the spark plugs.


Minimize the cranking time. This will enable a

maximum consistent cranking speed for the check.


Also, the starting air or battery power will be
conserved.

A loss of cylinder pressure or a change of pressure


in one or more cylinders may indicate the following
conditions. These conditions may indicate a problem
with lubrication:

Excessive deposits
Guttering of valves
A broken valve
A piston ring that sticks
A broken piston ring
Worn piston rings
Worn cylinder liners
If the cylinder pressure has risen by one or more
compression ratios, the engine needs a top end
overhaul in order to remove deposits. Failure to
remove the deposits will increase the chance for
detonation. Severe guttering of the valves will occur.

Illustration 65

g00789376

(Y) Cylinder pressure in kPa (psi)


(X) Compression ratio
(1) Normal range for cylinder pressure

Record the pressure for each cylinder. Use Operation


and Maintenance Manual, Valve Data Sheet
(Reference Materials Section).
i01765658

Cylinders - Inspect
(Inspect the Combustion
Chamber)
SMCS Code: 1223-040; 1223
Excessive deposits can accumulate in the combustion
chambers of engines that use gas with a low BTU
such as bio-gas fuel, landfill gas, etc. The deposits
can affect the characteristics of combustion. Erratic
operation can result. The rate of recession of the
exhaust valves can increase. The risk of guttering of
the exhaust valves can increase.
Note: Use of a platform may be necessary to inspect
the combustion chamber.
Use a borescope to inspect the combustion chamber.
The inspection will provide information about the
internal condition of the engine.

82
Maintenance Section
Driven Equipment - Check

A borescope with a lens that can be rotated is


recommended. This type of borescope provides a
clear view of the combustion chamber and of the
bottom deck of the cylinder head. Photographic
documentation or video documentation is also
recommended. Consult your Caterpillar dealer for
information on available borescopes.

SEBU6496-06

i00693905

Driven Equipment - Check


SMCS Code: 3279-535

Every 5000 Service Hours

When possible, insert the borescope through the


opening in the cylinder head for the prechamber
assembly and the ignition body. This location
will provide the best possible view of the entire
combustion chamber. This requires draining the
coolant to a level below the cylinder head. If this
is not possible, insert the borescope through the
opening for the combustion sensor. Look for the
following conditions:

Engines That Are Not Attached To the


Base with a Dowel

Valve wear

Distortion of the alignment of the bore

Deposits on the valve seat

Severe damage to the engine could result. The


service life of the engine could be severely reduced.

Deposits on the valve face


Polishing of the cylinder walls
Scratching of the cylinder walls
Deposits on the cylinder walls that are above the
upper limit of the piston stroke

Deposits that are on the valve face and the valve


seat can cause guttering of the valve. Inspect the
valve seat and the valve face for excessive deposits.
If excessive deposits are found, replace the valve
and the valve seat.

If some engines are too rigidly mounted, excessive


stress may affect the internal support of the cylinder
block. This could cause the following problems:

Distortion of the bores of the main bearing

For engines that are not attached to the base with a


dowel, check the alignment after every 5000 service
hours.

Every 10,000 Service Hours


Engines That Are Attached To the Base
with a Dowel
Some engines must be more rigidly mounted. Due to
thermal expansion, a cold engine will expand after
the engine achieves operating temperature.

Determine whether the exhaust valve face has


erosion from pitting. This requires the exhaust valve
to be in the open position. To obtain as much detail
as possible, obtain a close up view of the valve
face. Erosion of the exhaust valve face can lead
to guttering of the valve. If erosion is found on the
exhaust valve face, recondition the cylinder head as
soon as possible.

Some engines are attached to the base with a dowel


in the rear mounting support. This installation forces
the thermal growth forward. The driven equipment
is also attached with a dowel in order to maintain
alignment with the engine.

Note: Operation at loads that are less than 50 percent


of the rated load can result in an excessive buildup
of carbon deposits in the combustion chamber.
The deposits can lead to detonation and premature
ignition. This condition is more obvious at certain
engine speeds and loads.

Check the Alignment

For this type of installation, check the alignment after


every 10,000 service hours.

The alignment between the engine and the driven


equipment must be maintained properly. Improper
alignment will cause damage to the engine, the
coupling, and the driven equipment.
Check the alignment according to the instructions
that are provided by the following manufacturers:

Caterpillar
OEM of the coupling
OEM of the driven equipment

SEBU6496-06

83
Maintenance Section
Driven Equipment - Inspect/Replace/Lubricate

i00935098

Driven Equipment Inspect/Replace/Lubricate


SMCS Code: 3279-040
Observe the driven equipment during operation. Look
for the following items:

Unusual noise and vibration


Loose connections
Damaged parts

Illustration 66

Perform any maintenance that is recommended


by the OEM of the driven equipment. Refer to the
literature of the OEM of the driven equipment for the
following service instructions.

Inspection
Lubricating grease and lubricating oil requirements
Specifications for adjustment
Replacement of components
Requirements for ventilation
i01610487

Electrohydraulic Actuator Inspect


SMCS Code: 1716-040

(1)
(2)
(3)
(4)

g00833473

Receptacle for the wiring harness


Solenoid
Bolt
Guards

1. Disconnect the wiring harness from receptacle (1).


Inspect the connectors for damage and corrosion.
Make repairs, if necessary.
2. Inspect the joint between solenoid (2) and the
housing for leaks.
If a leak is found between the solenoid and the
housing, replace the O-ring seal for the solenoid.
For instructions, refer to this Operation and
Maintenance Manual, Electrohydraulic Actuator Recondition.
3. Check the solenoids mounting bolts (3) for
tightness.
4. Remove guards (4).

Inspect the actuators for the fuel control, the


wastegate, and the air choke.

During operation, the linkage of the electrohydraulic actuators can form pinch points which
can cause personal injury. Shut down the engine
before you service the electrohydraulic actuators.

Illustration 67
(5) Rod end
(6) Clevis
(7) Boot

5. Disconnect rod end (5) from clevis (6).


6. Remove clevis (6).

g00833477

84
Maintenance Section
Electrohydraulic Actuator - Recondition

SEBU6496-06

7. Remove rubber boot (7). Inspect the boot for


damage. If the boot is damaged, obtain a new
boot for assembly.
There may be a small amount of hydraulic fluid
inside of the boot. Wipe off the boot and reinstall
the boot.
If an excessive amount of hydraulic fluid is found
inside the boot, the seal for the actuators shaft
is probably worn. If this is the case, replace
the piston assembly. For instructions, refer
to this Operation and Maintenance Manual,
Electrohydraulic Actuator - Recondition.
8. Install boot (7). Make sure that the outer end of
the boot folds inward when the actuators shaft
moves from the fully open position to the fully
closed position.
9. Install clevis (6). Connect rod end (5) to the clevis.
10. Install guards (4).

Illustration 68

g00833592

(1) Receptacle for the wiring harness


(2) Guards

1. Disconnect the wiring harness from receptacle (1).


Inspect the connectors for damage and corrosion.
Make repairs, if necessary.
2. Remove guards (2).

11. Connect the wiring harness to receptacle (1).

3. Disconnect the supply line (not shown) and the


return line (not shown) for the hydraulic oil.

i01610640

Electrohydraulic Actuator Recondition


SMCS Code: 1716-020
Recondition the actuators for the fuel control, the
wastegate, and the air choke. The main components
of each actuator include the housing, a piston
assembly, and a solenoid which actuates the piston.
The piston assembly and the solenoid can be
serviced separately.
Note: New parts or remanufactured parts may be
used for reconditioning the actuators.

Illustration 69
(3)
(4)
(5)
(6)

During operation, the linkage of the electrohydraulic actuators can form pinch points which
can cause personal injury. Shut down the engine
before you service the electrohydraulic actuators.

g00833594

Rod end
Clevis
Boot
Nut

4. Disconnect rod end (3) from clevis (4).


5. Remove clevis (4) and rubber boot (5). Inspect the
boot for damage. If the boot is damaged, obtain a
new boot for assembly.
Note: Handle the actuator carefully. Use care not to
damage the actuators shaft. Damage to the shaft
can result in premature failure of the O-ring seal. This
will cause hydraulic fluid to leak.
6. Remove nut (6) in order to remove the actuator
from the bracket.

SEBU6496-06

85
Maintenance Section
Electrohydraulic System - Check/Adjust

Note: Do not allow debris to enter the actuator. Seal


the openings with clean covers immediately after the
solenoid and/or the piston assembly is removed.

15. Connect the supply line and the return line for the
hydraulic oil.
16. Connect the wiring harness to receptacle (1).
i01525261

Electrohydraulic System Check/Adjust


SMCS Code: 1716-025; 1716-535

Check the Pressure Relief Valve

Illustration 70

g00833595

(7) Housing
(8) Piston assembly
(9) O-ring seal
(10) Bolt
(11) Solenoid
(12) O-ring seal

Note: The spring in the housing will be loose after


the piston assembly is removed.

Check the pressure relief valve for the hydraulic


system according to the procedure that is in Systems
Operation/Testing and Adjusting. Adjust the pressure
according to the instructions.
i02214104

Electrohydraulic System Inspect


SMCS Code: 1716-040

7. Place housing (7) in a vise. Remove piston


assembly (8). Remove O-ring seal (9) from
the joint between the piston assembly and the
housing.

Inspect the conditions of these items for the


electrohydraulic system:

Note: O-ring seal (9) is included with the piston


assembly.

Hoses, lines, connections, and components

Oil level

8. Install a new O-ring seal (9) and piston assembly


(8). Make sure that the spring in the housing is
properly aligned in the bore of the piston. Tighten
the piston assembly according to the engines
Specifications.
9. Remove bolts (10) in order to remove solenoid
(11). Remove O-ring seal (12) from the joint
between the solenoid and the housing.
10. Install a new O-ring seal (12) and solenoid (11).
Install bolts (10). Tighten the bolts according to
the engines Specifications.
Illustration 71

11. Install the actuator in the bracket with nut (6).


12. Install boot (5). Make sure that the outer end of
the boot folds inward when the actuators shaft
moves from the fully open position to the fully
closed position.
13. Install clevis (4). Connect rod end (3) to the clevis.
14. Install guards (2).

g00792283

(1) Sight gauge


(2) Hose
(3) Line

Check the Oil Level


1. Check the oil level in sight gauge (1).
The oil should be between the ADD and FULL
marks on the tank.

86
Maintenance Section
Electrohydraulic System Oil - Change

SEBU6496-06

Note: For the proper oil to use, refer to this Operation


and Maintenance Manual, Refill Capacities and
Recommendatons topic (Maintenance Section).
2. If necessary, remove the oil filler cap. Pour the
correct oil into the oil filler.
3. Clean the oil filler cap. Install the oil filler cap.

Inspect the Lines, Connections,


and Components

The linkage can move and form a pinch point


which can cause personal injury. Keep hands
away from the linkage.

Illustration 72

g00792335

(1) Oil filler cap


(2) Valve

1. Remove oil filler cap (1).


Inspect the hoses and lines for wear and leaks.
Ensure that the hoses and lines are properly
clamped. Inspect the connections for leaks. Ensure
that the connections are secure.
Inspect the following items for leaks and good
condition:

Note: Drain the oil into a suitable container. Dispose


of fluids according to local regulations.
2. Place a suitable container under valve (2). Open
the valve. Allow the oil to drain. After the oil has
drained, close the valve.
Note: For the proper oil to use, refer to this Operation
and Maintenance Manual, Refill Capacities and
Recommendations topic (Maintenance Section).

Actuators
Pressure relief valve

3. Pour the proper oil into the oil filler. Clean the oil
filler cap. Install the oil filler cap.

Pump
Make repairs, if necessary.

4. Clean up any oil that may have spilled.


i02214129

Electrohydraulic System Oil Change


SMCS Code: 1716-510-OC
Ensure that the engine cannot start during this
procedure.

SEBU6496-06

87
Maintenance Section
Electrohydraulic System Oil Filter - Change

i02246458

Electrohydraulic System Oil


Filter - Change

5. Start the engine. Check the oil level in sight gauge


(2). The oil should be between the ADD and
FULL marks on the tank. If necessary, remove
oil filler cap (4). Pour the correct oil into the oil
filler. Clean the oil filler cap. Install the oil filler cap.

SMCS Code: 1716-510-FI


i02169249

Engine Air Cleaner


Element (Single Element) Clean/Replace
SMCS Code: 1051; 1054-037

Illustration 73

g00792302

(1) Filter
(2) Sight gauge
(3) Filler cap

1. Remove filter (1) with a 1U-8760 Chain Wrench.


2. Clean the sealing surface of the filter mounting
base. Ensure that all of the old filter gasket is
removed.

NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements


Note: Use of a platform may be necessary to reach
the air cleaner element.
If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
wear. Your Caterpillar dealer has the proper air
cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.

Check the precleaner (if equipped) daily for


Illustration 74

g00103713

accumulation of dirt and debris. Remove any dirt


and debris, as needed.

Typical filter mounting base and gasket

Operating conditions (dust, dirt and debris) may

Note: For the proper oil to use, refer to this Operation


and Maintenance Manual, Refill Capacities and
Recommendations topic (Maintenance Section).

The air cleaner element may be cleaned up to

3. Apply clean hydraulic oil to the new filter gasket.


4. Install the filter by hand. Tighten the filter until the
gasket contacts the mounting base. Tighten the
filter according to the instructions that are shown
on the filter. Do not overtighten the filter.

require more frequent service of the air cleaner


element.

six times if the element is properly cleaned and


inspected.

The air cleaner element should be replaced at least


one time per year. This replacement should be
performed regardless of the number of cleanings.

88
Maintenance Section
Engine Air Cleaner Element (Single Element) - Clean/Replace

Replace the dirty paper air cleaner elements with


clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked
for tears and/or holes in the filter material. Inspect
the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner
elements for replacement purposes.
1. Remove the air cleaner cover. Remove the air
cleaner element.
Note: Refer to Cleaning the Air Cleaner Elements.

SEBU6496-06

Use clean air cleaner elements while dirty elements


are being cleaned.
NOTICE
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine
damage could result.

2. Cover the air inlet with tape in order to keep dirt


out.

Visually inspect the air cleaner elements before


cleaning. Inspect the air cleaner elements for damage
to the seal, the gaskets, and the outer cover. Discard
any damaged air cleaner elements.

3. Clean the inside of the air cleaner cover and body


with a clean, dry cloth.

There are two common methods that are used to


clean air cleaner elements:

4. Remove the tape for the air inlet. Install an air


cleaner element that is new or cleaned.

Pressurized air

5. Install the air cleaner cover.


6. Reset the air cleaner service indicator.

Cleaning the Air Cleaner Elements


NOTICE
Caterpillar recommends certified air filter cleaning services that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.

Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean air cleaner
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).

Observe the following guidelines if you attempt to


clean the filter element:
Do not tap or strike the filter element in order to remove dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
The air cleaner element can be used up to six times if
the element is properly cleaned and inspected. When
the air cleaner element is cleaned, check for rips or
tears in the filter material. The air cleaner element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.

Illustration 75

g00281692

Note: When the air cleaner elements are cleaned,


always begin with the clean side (inside) in order to
force dirt particles toward the dirty side (outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
of air directly at the air cleaner element. Dirt could be
forced further into the pleats.
Note: Refer to Inspecting the Air Cleaner Elements.

SEBU6496-06

89
Maintenance Section
Engine Air Cleaner Element (Single Element) - Clean/Replace

Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
air cleaner elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
Note: Refer to Inspecting the Air Cleaner Elements.

Inspecting the Air Cleaner Elements


Illustration 77

g00281694

Do not use paint, a waterproof cover, or plastic as a


protective covering for storage. An airflow restriction
may result. To protect against dirt and damage,
wrap the air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the air cleaner element into a box for storage.
For identification, mark the outside of the box and
mark the air cleaner element. Include the following
information:
Illustration 76

g00281693

Inspect the clean, dry air cleaner element. Use a 60


watt blue light in a dark room or in a similar facility.
Place the blue light in the air cleaner element. Rotate
the air cleaner element. Inspect the air cleaner
element for tears and/or holes. Inspect the air cleaner
element for light that may show through the filter
material. If it is necessary in order to confirm the
result, compare the air cleaner element to a new air
cleaner element that has the same part number.
Do not use an air cleaner element that has any tears
and/or holes in the filter material. Do not use an air
cleaner element with damaged pleats, gaskets or
seals. Discard damaged air cleaner elements.

Date of cleaning
Number of cleanings
Store the box in a dry location.

Crankcase Air Cleaner


Engines that are equipped with positive crankcase
ventilation have an air cleaner for crankcase
ventilation. Clean the air cleaner element or replace
the air cleaner element when the following conditions
occur:

The yellow diaphragm enters the red zone.

Storing Air Cleaner Elements

The red piston locks in a visible position.

If an air cleaner element that passes inspection will


not be used, the air cleaner element can be stored
for future use.

The air restriction reaches 0.25 kPa (1 inch of H2O).

90
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Illustration 78

g00294189

(1) Service indicator


(2) Cover

SEBU6496-06

Illustration 79

g00789538

Service indicator

1. Remove cover (2).


2. Remove the used element and dispose of the
element.
3. Clean the inside of cover (2) and clean the inside
of the body.

Observe the service indicator. Clean the air cleaner


element or replace the air cleaner element when one
of the following conditions occur:

The yellow diaphragm enters the red zone.


The red piston locks in the visible position.
The air filter restriction reaches .25 kPa

4. Install a new element. Install cover (2).

(1 inch of H2O).

5. Reset service indicator (1), if necessary.


i01520297

Engine Air Cleaner Service


Indicator - Inspect

Inspect the service indicator daily for cracks, holes, or


loose fittings. If any of these conditions are present,
repair the service indicator or replace the service
indicator.

Test the Service Indicator

SMCS Code: 7452-040

Service indicators are important instruments.

Some engines are equipped with an air cleaner for


crankcase ventilation.

Check for ease of resetting. The service indicator

This air cleaner filters air that is drawn into the


crankcase. The air dilutes the harmful fumes that
may accumulate in the crankcase. The air and the
fumes are drawn away from the crankcase.

Check the movement of the yellow core when the

should reset in less than three pushes.

engine is accelerated to the engine rated rpm.


The yellow core should latch approximately at the
greatest vacuum that is attained.

If the service indicator does not reset easily, or if the


yellow core does not latch at the greatest vacuum,
replace the service indicator. If the new service
indicator will not reset, the fitting for the service
indicator may be plugged.

SEBU6496-06

91
Maintenance Section
Engine Air Precleaner - Clean

1. Loosen clips (1). Remove cup (2).


2. Clean the inside of the cup.
3. Install the cup. Fasten the clips.
i01765695

Engine Crankcase Breather Clean


SMCS Code: 1317-070
Illustration 80

g00351792

Porous filter

A porous filter is part of a fitting that is used for


mounting of the service indicator. Inspect the filter
for cleanliness. Clean the filter, if necessary. Use
compressed air or a clean, nonflammable solvent.
The service indicator may need to be replaced
frequently in environments that are severely dusty.
Replace the service indicator annually regardless
of the operating conditions. Replace the service
indicator when the engine is overhauled, and
whenever major engine components are replaced.

If the crankcase breather is not maintained on a


regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that can shut down
the engine. Leakage of the crankshaft seal can occur.
Note: Use of a platform may be necessary to reach
the engine crankcase breather.
Perform this maintenance when the engine is
stopped.

Note: When a new service indicator is installed,


excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque
of 2 Nm (18 lb in).
i00935352

Engine Air Precleaner - Clean


SMCS Code: 1055-070

Illustration 82

Note: More frequent cleaning may be required in


dusty environments.

(1)
(2)
(3)
(4)
(5)

g00789623

Breather assembly
Tee
Hose clamp
O-ring seal
Retaining clamp

1. Loosen retaining clamps (5). Loosen hose clamps


(3). Remove breather assemblies (1) and O-ring
seals (4).
2. Wash the breather elements in clean
nonflammable solvent. Inspect tee (2) for cracks
that can be caused by vibration. Replace the old
tee with a new tee if cracking is found.
3. Install new O-ring seals (4).
Illustration 81
(1) Clip
(2) Cup

g00476231

92
Maintenance Section
Engine Mounts - Check

SEBU6496-06

4. Allow the breather elements to dry before


installation. Install the breather assemblies in the
original position. Coat the rubber parts with clean
engine oil or petroleum jelly in order to make
installation easier. Tighten the retaining clamps
and the hose clamps according to the engines
Specifications manual.

Engines That Use Bio-Gas


The oil change interval is determined by the results
of oil analysis. Change the lubrication oil when oil
analysis determines that the oil has reached the
condemning limit. Also, change the engine oil filters.

Change the Engine Oil


i01612978

Engine Mounts - Check


SMCS Code: 1152-535

Hot oil and components can cause personal injury.

Check the torque of the bolts for the mounting


plates. For the proper torque, refer to Gas Engines
Application and Installation Guide, LEKQ7252,
G3600 Mounting, Alignment.

Do not allow hot oil or components to contact


skin.

Engine vibration can be caused by the following


conditions:

Improper mounting of the engine


Deterioration of the isolators
Settling of the isolators will result in misalignment
between the engine and the driven equipment.
Inspect the condition of isolators, if necessary. Keep
the isolators clean and dry. Ensure that the isolators
are free of oil and contamination. Inspect the isolators
for deterioration.
Replace any isolator that shows deterioration.
For more information, refer to the literature that is
provided by the OEM of the isolators. Also refer to
the following publications:

Gas Engines Application and Installation Guide,


LEKQ7252, G3600 Mounting, Alignment

Special Instruction, SEHS9162, Spring Isolator

NOTICE
Ensure that the engine is stopped before performing
this procedure. Attach a DO NOT OPERATE tag to the
starting controls.
Do not drain the oil when the engine is cold. As the
oil cools, suspended waste particles settle on the
bottom of the oil pan. The waste particles are not
removed when the cold oil is drained. Drain the
crankcase with the oil warm. This draining method
allows the waste particles that are suspended in the
oil to be drained properly.
Failure to follow this recommended procedure will
allow the waste particles to be recirculated through
the engine lubrication system with the new oil.
1. After the engine has been operated at normal
operating temperature, STOP the engine.
Note: Drain the oil into a suitable container. Dispose
of fluids according to local regulations.

Group Installation and Adjustment Procedure

Consult your Caterpillar dealer for assistance.


i02158284

Engine Oil - Change


SMCS Code: 1348-044; 1348

Oil Change Interval


Considerations for the oil change interval include
the type of fuel and the engine application. An
established SOS oil analysis program enables used
oil to be evaluated. The evaluation can be used to
determine if this oil change interval is suitable for
your specific engine.

Illustration 83

g00789667

(1) Drain valve

2. Open drain valve (1) in order to drain used oil.


After the oil has drained, close drain valve (1).

SEBU6496-06

93
Maintenance Section
Engine Oil Filter - Change

Note: If a suction device is used in order to remove


the oil from the oil pan, ensure that the suction device
is clean. This will prevent dirt from entering the oil
pan. Be careful not to strike the engine oil suction
tubes or the piston cooling jets.
3. Clean the oil suction screen.
Note: Approximately 1 L (1 qt) of oil will remain in the
housing after the sump has been completely drained.
This oil will pour out of the housing when the cover
for the oil suction screen is removed. Prepare to
catch the oil in a suitable container. Clean up any
spilled oil with rags. DO NOT use absorbent particles
to clean up the oil.

NOTICE
Engine damage can occur if the crankcase is filled
above the FULL mark on the oil level gauge (dipstick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is developed and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: reduction of the oils ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. Deposits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
If the oil level is above the FULL mark on the oil level
gauge, drain some of the oil immediately.
Note: For the amount of oil to use, refer to
this Operation and Maintenance Manual, Refill
Capacities and Recommendations (Maintenance
Section).

Illustration 84

g00789729

(2) Screen assembly

a. Loosen the bolts of the cover for the oil suction


screen. Remove the cover and the gasket.
Discard the old gasket. Slide screen assembly
(2) from the tube.
b. Wash the screen assembly in clean
nonflammable solvent. Allow the screen
assembly to dry before installation.
c. Install the screen assembly. Install a new
gasket. Install the cover.
4. Change the engine oil filters. Refer to this
Operation and Maintenance Manual, Engine Oil
Filter - Change topic (Maintenance Section).
NOTICE
Only use oils that are recommended by Caterpillar.
For the proper oil to use, refer to this Operation and
Maintenance Manual, Refill Capacities and Recommendations topic (Maintenance Section).

5. Remove the oil filler cap. Fill the crankcase


through the oil filler tube only. Clean the oil filler
cap. Install the oil filler cap.
6. Follow this Operation and Maintenance Manual,
Starting The Engine procedure (Operation
Section). Operate the engine at low idle for two
minutes. Inspect the engine for oil leaks. Ensure
that the oil level is at the FULL mark on the
LOW IDLE side of the oil level gauge.
7. Stop the engine and allow the oil to drain back into
the sump for a minimum of ten minutes.
8. Remove the oil level gauge and check the oil level.
Maintain the oil level to the FULL mark on the
ENGINE STOPPED side of the oil level gauge.
i01520518

Engine Oil Filter - Change


SMCS Code: 1308-510; 1308
Replace the engine oil filters when the following
conditions are met:

Every oil change


The engine oil filter differential pressure reaches
100 kPa (15 psi).

94
Maintenance Section
Engine Oil Filter - Change

SEBU6496-06

Service tools are available to aid in the service of oil


filters. Consult your Caterpillar dealer for the part
names and the part numbers. Follow the instructions
that are supplied with the service tools. If the service
tools are not used, perform the following appropriate
procedure.

Replacing the Engine Oil Filters


With the Engine Stopped

Hot oil and components can cause personal injury.


Do not allow hot oil or components to contact
skin.

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.
3. Be alert to the spring force. The cover has a
spring force up to 240 N (54 lb). Gradually loosen
but do not remove the last two bolts or nuts that
are located at opposite ends of covers (3). Before
removing the last two bolts or nuts, pry the covers
loose or tap the covers with a rubber mallet in
order to relieve any spring pressure.

Perform the following procedure after the oil has


been drained.
Note: Use this procedure if the engine oil filters do
not have a control valve.

Illustration 86

g00789772

(5) Wire rack


(6) O-ring seal
(7) Element

Illustration 85
(1)
(2)
(3)
(4)

g00789754

Pressure gauge
Drain
Cover
Control valve

1. Connect a hose from each drain valve (2) to a


suitable container in order to catch the oil.
2. Open both drain valves (2). Allow the oil to drain.
Note: Some oil will remain in the housing after the oil
has been drained. This oil will pour out of the housing
when cover (3) is removed. Prepare to catch the oil
in a suitable container. Clean up any spilled oil with
rags. DO NOT use absorbent particles to clean up
the oil.

4. Elements (7) are mounted on wire racks (5) inside


the housing. Use a pan to catch the oil that drips
when wire racks (5) are removed. Remove wire
racks (5). Remove used elements (7). Clean up
any oil that is spilled.
NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
5. Ensure that the new oil filter elements are in good
condition. Place the elements on wire rack (5).
Install the wire rack and the elements.

SEBU6496-06

95
Maintenance Section
Engine Oil Filter - Change

6. Ensure that the surfaces for O-ring seals (6) are


clean. Inspect the O-ring seals. If the old O-ring
seals are damaged or deteriorated, replace the
old O-ring seals with new O-ring seals. Install the
O-ring seals.
7. Install covers (3). Ensure that the spring is seated
properly between elements (7) and covers (3).
Close drain valves (2).
8. Ensure that the crankcase is filled with oil. Operate
the prelube pump and rotate the control valve (if
equipped) to the FILL position for each housing.
After both of the housings are full of oil, turn the
control valve (if equipped) to the RUN position.
9. Start the engine. Check for oil leaks.

Replacing the Engine Oil Filters


During Engine Operation

Filter contains hot pressurized fluid when engine


is running.
Follow instructions on control valve to avoid personal injury.
If rapid air movement exists to blow fluid, Stop the
engine to avoid fire.

3. Open drain valve (2) and drain the lower oil filter
housing. Observe pressure gauge (1) until the
pressure is 0.
Note: Some oil will remain in the housing after the oil
has been drained. This oil will pour out of the housing
when cover (3) is removed. Prepare to catch the oil
in a suitable container. Clean up any spilled oil with
rags. DO NOT use absorbent particles to clean up
the oil.

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.
4. After zero pressure has been reached, remove
cover (3). Be alert to the spring force. The cover
has a spring force up to 240 N (54 lb). Gradually
loosen but do not remove the last two bolts or
nuts that are located at opposite ends of cover (3).
Before removing the last two bolts or nuts, pry the
cover loose or tap the cover with a rubber mallet
in order to relieve any spring pressure.

If it is necessary to replace the oil filters during engine


operation, perform the following procedure.

Illustration 88

g00789772

(5) Wire rack


(6) O-ring seal
(7) Element
Illustration 87
(1)
(2)
(3)
(4)

g00789754

Pressure gauge
Drain
Cover
Control valve

1. Connect a hose from drain valve (2) to a suitable


container in order to catch the oil.
2. Rotate control valve (4) to the LOWER SERVICE
position.

5. Elements (7) are mounted on wire rack (5) inside


the housing. Use a pan to catch the oil that drips
when wire rack (5) is removed. Remove wire rack
(5). Remove used elements (7). Clean up any oil
that is spilled.

96
Maintenance Section
Engine Oil Level - Check

NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
6. Ensure that the new oil filter elements are in good
condition. Place the elements on wire rack (5).
Install the wire rack and the elements.
7. Ensure that the surfaces for O-ring seal (6) are
clean. Inspect the O-ring seal. If the old O-ring seal
is damaged or deteriorated, replace the old O-ring
seal with a new O-ring seal. Install the O-ring seal.
8. Install cover (3). Ensure that the spring is seated
properly between element (8) and cover (3). Close
drain valve (2).

SEBU6496-06

Aluminum debris may indicate problems with the


bearings of the front gears. If aluminum is found in
the filter, inspect the crankshaft vibration damper and
the front idler gear bearing.
Due to normal wear and friction, it is not uncommon
to find small amounts of debris in the oil filter element.
If an excessive amount of debris is found in the oil
filter element, consult your Caterpillar dealer in order
to arrange for further oil analysis.
i02278259

Engine Oil Level - Check


SMCS Code: 1348-535-FLV
The most accurate check of the oil level is
performed when the engine is stopped. Perform this
maintenance on a surface that is as level as possible.

9. Rotate control valve (4) to the LOWER FILL


position. Observe pressure gauge (1). Check
cover (3) for leaks.
Note: A hydraulic stop will limit the rotation of the
control valve until the oil filter housing is full of oil.
10. After the pressure of the lower oil filter and the
upper oil filter is equal, rotate control valve (4) to
the UPPER SERVICE position. Repeat Step 1
through Step 9 for the upper oil filter.
11. After the oil filters have been serviced and after
the pressure of the lower oil filter and the upper oil
filter is equal, rotate control valve (4) to the RUN
position.

Illustration 89

g00789822

(1) Oil level gauge


(2) Oil filler

Inspect the Used Oil Filter Elements


Cut the used oil filter element open with a utility knife.
Remove the metal wrap. Cut the filter element free
from the end caps. Spread apart the pleats and
inspect the element for metal debris. An excessive
amount of debris in the element may indicate early
wear or a pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found
in the element. Ferrous metals may indicate wear
on the steel and the cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, the brass parts, or the bronze parts
of the engine. Parts that may be affected include the
following components: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.

Illustration 90

g01140702

(3) ADD mark


(4) RUNNING FULL mark
(5) STOPPED FULL OIL COLD NO PRELUBE mark

Note: For engines with powered crankcase


ventilation, remove the oil filler cap. Allow the
crankcase pressure to stabilize before checking the
engine oil level.

SEBU6496-06

97
Maintenance Section
Engine Oil Sample - Obtain

Obtain the Sample and the Analysis

1. Ensure that oil level gauge (1) is seated.


2. Remove the oil level gauge and observe the oil
level. Add engine oil if the level is in the ADD
zone. If the engine is running, maintain the level
in the RUNNING FULL zone.
NOTICE
Engine damage can occur if the crankcase is filled
above the FULL mark on the oil level gauge (dipstick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is developed and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: reduction of the oils ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. Deposits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
If the oil level is above the FULL mark on the oil level
gauge, drain some of the oil immediately.
3. If necessary, remove oil filler cap (2) and add
oil. For the correct oil to use, see this Operation
and Maintenance Manual, Refill Capacities and
Recommendations topic (Maintenance Section).
Wipe off the oil level gauge and reinstall the oil
level gauge. Clean the oil filler cap and reinstall
the oil filler cap.
4. Record the amount of oil that is added. For the
next oil sample and analysis, include the total
amount of oil that has been added since the
previous sample. This will help to provide the most
accurate oil analysis.

Hot oil and hot components can cause personal


injury. Do not allow hot oil or hot components to
contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:

Engine model
Service hours on the engine
The number of hours that have accumulated since
the last oil change

The amount of oil that has been added since the


last oil change

To ensure that the sample is representative of the


oil in the crankcase, obtain a warm, well mixed oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.

i01935337

Engine Oil Sample - Obtain


SMCS Code: 1348-554-SM
In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine. SOS oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.

98
Maintenance Section
Engine Oil Temperature Regulator - Replace

SEBU6496-06

For instructions, see Special Publication, PEHP6001,


How To Take A Good Oil Sample. Consult your
Caterpillar dealer for complete information and
assistance in establishing an SOS program for your
engine.
i00839584

Engine Oil Temperature


Regulator - Replace
SMCS Code: 1330-510
The oil temperature regulators divert the engine
oil to the oil cooler in order to maintain engine oil
temperature.
For instructions on replacing the oil temperature
regulators, see the Service Manual, Disassembly
and Assembly module.
Illustration 91
i00683610

Engine Protective Device


Connections - Inspect
SMCS Code: 7400-040
Inspect the wiring and the electrical connections for
these components:

Connectors
Control panel
Junction box
Sensors

g00449867

Typical examples of electrical connectors


(A) Military Standard connector
(1) Plug
(2) Receptacle
(B) Deutsch HD connector
(C) Phoenix terminal strip

Note: Military Standard (MS), Caterpillar


Environmental (CE), and Vehicle Environmental
(VE) connectors are similar in design. However, the
wiring is soldered to the pins and sockets of Military
Standard connectors. In CE and VE connectors,
the wiring is crimped into the pins and sockets. The
wiring is crimped into the pins and sockets of Deutsch
HD connectors also.
1. Turn the mode control switch to the OFF/RESET
position. Open the circuit breaker of the main
power supply.
2. Inspect all of the wiring for the following conditions:

Fraying
Damaged insulation
Corrosion
Make repairs, as needed.

SEBU6496-06

99
Maintenance Section
Engine Protective Device Connections - Inspect

Perform a pull test for each wire. This test will


ensure that the wiring is properly attached. Test
each wire individually.
a. Pull each wire with approximately 45 N (10 lb)
of force. Pull the wire firmly.
If a wire is loose, repair the connection. For
instructions on connecting wires, see the
Service Manual, Troubleshooting module.
4. Inspect the wiring at the relays and terminal strips
for these conditions:

Corrosion
Fraying
a. If corrosion is found, scrape large deposits.
Use cotton swabs with isopropyl alcohol to
clean any corrosion that remains.
Illustration 92

g00453241

Investigate the source of the corrosion. Correct


the condition.

Typical junction box


(1) Relay
(2) Terminal strips

If damage is found, replace the part.


b. Remove frayed strands of wire or tin the wire.
c. Perform Steps 6 and 7 for the connectors of
the control panel and the junction box.
5. Check the wiring for secure connections at these
points:

Connectors
Sensors
Perform a pull test for each wire. This test will
ensure that the wiring is properly attached. Test
each wire individually.

Illustration 93

g00453242

Typical control panel


(1) Connector for a module

3. Check the wiring for secure connections at these


points of the junction box and the control panel:

Connectors
Relays
Switches
Terminal strips

a. For wiring that is attached to a connector, hold


the body of the connector with one hand. Pull
each wire with approximately 45 N (10 lb) of
force. Pull the wire firmly.
b. Before testing the wiring of the sensors, ensure
that the sensors are securely installed. Then
pull each wire with approximately 45 N (10 lb)
of force.
If a wire is loose, repair the connection. For
instructions on connecting wires, see the
Service Manual, Troubleshooting module.
6. Disconnect the connectors at the following
locations. Inspect the connectors.

Engine sensors

100
Maintenance Section
Engine Protective Devices - Check

SEBU6496-06

Junction box
Modules of the control panel
a. Inspect each pin and each socket for corrosion
and damage.
If corrosion is found, scrape large deposits.
Use cotton swabs with isopropyl alcohol to
clean any corrosion that remains.
Investigate the source of the corrosion. Correct
the condition.
If damage is found, replace the part.
7. Reconnect the connectors.
a. For Military Standard, CE, and VE connectors,
ensure the following conditions:

NOTICE
During testing, abnormal operating conditions must be
simulated.
The tests must be performed correctly in order to prevent possible damage to the engine.
To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
perform the tests.

Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
immediately.

The connection is threaded properly.

i01765700

The connection is threaded completely. Very


little thread or no thread is visible.

b. For Deutsch HD connectors, ensure the


following conditions:

The index markings of the plug and the


receptacle are aligned.

The connection is turned fully.


The plug and the receptacle are securely
connected.

8. Close the circuit breaker of the main power supply.


i00626013

Engine Protective Devices Check


SMCS Code: 7400-535
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.
A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective
devices are functioning properly.

Engine Valve Lash Inspect/Adjust


SMCS Code: 1102-025
For instructions on the following procedures, refer to
Systems Operation/Testing and Adjusting. Consult
your Caterpillar dealer for assistance.
Note: Use of a platform may be necessary for these
procedures.

Check the Timing of the Crankshaft


and Camshaft
The timing of the crankshaft and camshaft must be
checked, and the valve bridge must be adjusted
before the valve lash is adjusted.
NOTICE
If the camshaft is rotated with the timing pin installed,
the timing pin will break. This can result in further damage. Make sure to remove the timing pin before the
camshaft is rotated.

SEBU6496-06

NOTICE
DO NOT use the starting motor to rotate the crankshaft. The lubrication oil can drain out from between
the crankshaft and the engine bearings if the engine
has not been operated for a period of time. Damage
can result if the crankshaft is rotated on dry bearing
surfaces.

101
Maintenance Section
Engine Valve Rotators - Inspect

The crankshaft and camshaft timing must be


checked, and valve bridge adjustment must be
performed before making a valve lash adjustment.
Perform the valve lash setting when the engine is
cold. After the engine has been shut down and the
valve covers are removed, the engine is considered
cold.

To prevent damage to the crankshaft bearings, DO


NOT crank the engine before prelube, especially after
this maintenance procedure.

Before performing maintenance, prevent the entry of


foreign matter into the top of the cylinder head and
the valve mechanism. Thoroughly clean the area
around the valve mechanism covers.

NOTICE
The prelube pump should not be operated continuously for extended periods of time. If, during repairs,
the prelube pump has run continuously for a period
of three hours or more, it will be necessary to remove
any oil that may have collected in the cylinders and/or
above the valves.

Gas Admission Valve

Prelube of the engine is required before the


crankshaft is rotated for normal maintenance.
Activate the prelube pump for rotating the engine
crankshaft.
NOTICE
Do not use an impact wrench to operate the barring
device. The use of an impact wrench will cause gear
tooth failure.
The barring device provides a means for slowly
turning the flywheel in order to service the engine.
The barring device can also be used to prevent
rotation of the crankshaft.

Valve Bridge
NOTICE
Do NOT attempt to adjust the valves if the crankshaft
and camshaft are not synchronized. Disregard for this
can result in engine damage such as bent valves.
Check the valve bridges. Perform the procedure for
both valve bridges for each cylinder.
After the valve bridge is checked for each cylinder,
check the valve lash for the exhaust valves, the inlet
valves, and the gas admission valves.

Engine Valve Lash


If the valve lash is within the tolerance, an adjustment
of the valve lash is NOT necessary.

Check the valve lash for the gas admission valve


when the valve lash for the inlet valves and exhaust
valves are checked. Adjust the valve lash for the gas
admission valves, if necessary.
i01765711

Engine Valve Rotators - Inspect


SMCS Code: 1109-040
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
Note: Use of a platform may be necessary to reach
the engine valve rotators.
Perform this procedure after the valve lash has been
set.
1. Mark the tops of the valve rotators with a
permanent marker. Note the position of the marks.
2. Install the valve covers. See the Service Manual
for the procedure.
3. Start the engine. Operate the engine for 5 minutes.
Stop the engine.
4. Remove the valve covers. Observe the position of
the marks that are on the valve rotators.
If a valve fails to rotate, consult your Caterpillar
dealer.

102
Maintenance Section
Exhaust Bypass - Recondition

SEBU6496-06

i01765718

Exhaust Bypass - Recondition


SMCS Code: 1057-020

NOTICE
The exhaust shields can be damaged if work is performed on the exhaust shields or around the exhaust
shields.
Remove the exhaust shields or protect the exhaust
shields before performing work on the exhaust shields
or around the exhaust shields. Handle the exhaust
shields carefully.
Do not tear the foil that is inside of the exhaust shields.
Torn foil will allow the insulation to absorb flammable
liquids and a fire can result from engine heat.

Illustration 94

g00799396

Ensure that the exhaust manifold is cool. Inspect the


exhaust shields. Replace any exhaust shield that
is damaged. Refer to the Service Manual for the
procedure to remove the exhaust shields and install
the exhaust shields.

Typical example
(1) Rod ends
(2) Cover and seal
(3) Shaft

i01763022

Note: Use of a platform may be necessary in order to


reach the components of the exhaust bypass.

Fuel System Fuel Filter


Differential Pressure - Check
SMCS Code: 1261-535

Replace the following parts:

If the engine is equipped with a fuel filter, a fuel filter


differential pressure gauge must be installed. The fuel
filter differential pressure gauge is installed in order to
determine when the fuel filter requires service. This
gauge and the fuel filter are supplied by the customer.

Rod ends (1)


Cover and seal (2)
Shaft (3)
For instructions on assembling the exhaust bypass,
refer to the Specifications.
i00457458

Exhaust Shields - Inspect


SMCS Code: 1067-040

A fuel filter differential pressure gauge indicates the


difference in fuel pressure between the inlet side
and the outlet side of the fuel filter. The differential
pressure increases as the fuel filter becomes
plugged.
Operate the engine at the rated rpm and at the
normal operating temperature. Check the fuel filter
differential pressure.
Service the fuel filter when the fuel filter differential
pressure reaches 1.7 kPa (0.25 psi).

Hot engine components can cause injury from


burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.

For instructions, refer to Special Instruction,


SEHS9298, Installation and Maintenance of
Gaseous Fuel Filters. Consult your Caterpillar dealer
for assistance.

SEBU6496-06

103
Maintenance Section
Gas Admission Valve - Recondition

i01765725

Gas Admission Valve Recondition


SMCS Code: 1105-020-GS
Note: Use of a platform may be necessary to reach
the gas admission valves.
For the procedure to remove the gas admission valve,
refer to the engines Disassembly and Assembly.

Valve guide (5) will probably have very little wear.


However, measure the inner diameter of the valve
guide at both ends and the middle. The maximum
allowable inner diameter of the valve guide at both
ends and the middle is 9.538 mm (0.3755 inch). If
any measurement exceeds this specification, replace
the valve guide. If this is not possible, replace support
assembly (6) and the valve guide.
It is unlikely for support assembly (6) to require
replacement. However, inspect the valve seat in the
support assembly.

When you disassemble the gas admission valve,


inspect the seals. Replace the seals, if necessary.
Refer to this Operation and Maintenance Manual,
Gas Admission Valve Seals - Inspect/Replace.

Illustration 96

g00833994

Angle and dimensions for the valve seat in the support assembly

If the valve seat is worn, the valve seat can be slightly


ground according to these specifications:

The angle for the valve seat is 44.75 0.5 degrees.


The gauge diameter of the valve seat within a
maximum depth of 2.0 mm (0.079 inch) from
the end of the support assembly is 39.75 mm
(1.565 inch).

Use some Prussian blue to verify complete contact of


the valve in the valve seat.
i01765734

Illustration 95

g00833978

Exploded view and section view of the parts for the gas admission
valve
(1)
(2)
(3)
(4)
(5)
(6)
(7)

Retainer locks
Valve rotator
Outer valve spring
Inner valve spring
Valve guide
Support assembly
Valve

To recondition the gas admission valve, replace


retainer locks (1), valve rotator (2), outer valve spring
(3), inner valve spring (4), and valve (7).

Gas Admission Valve Seals Inspect/Replace


SMCS Code: 1105-040-GS; 1105-510-GS
The camshaft operates the mechanism for the gas
admission valve in order to allow fuel to enter the
inlet port of the cylinder.
Note: Use of a platform may be necessary to reach
the gas admission valves.
For the procedure to remove the gas admission valve,
refer to the engines Disassembly and Assembly.

104
Maintenance Section
Gas Pressure Regulator - Inspect/Replace

SEBU6496-06

If any of those conditions are found, the gas pressure


regulator must be repaired or replaced.
For information on replacing the gas pressure
regulator, see the Service Manual. Consult your
Caterpillar dealer for assistance.
i01611465

Gas Shutoff Valve - Inspect


SMCS Code: 1329-040
The gas shutoff valve (GSOV) has a solenoid that is
operated with 24 VDC. When power is supplied to the
solenoid, fuel flows through the GSOV to the engine.
When the power is interrupted, the gas is shut off.
1. Shut off the engine.
2. Shut off the fuel supply to the GSOV.

Illustration 97

g00833829

Exploded view and section view of the parts for the gas admission
valve
(1) Upper valve stem seal
(2) Lower valve stem seal
(3, 4, and 5) O-ring seals for the support assembly

Note: The portion of the valve stem in lower valve


stem seal (2) may be slightly worn. This shallow wear
does not affect the performance of the gas admission
valve.
Inspect valve stem seals (1) and (2). Inspect O-ring
seals (3), (4), and (5). Replace the seals, if necessary.
i00679524

Gas Pressure Regulator Inspect/Replace


SMCS Code: 1550-040; 1550-510
Inspect the gas pressure regulator for the following
conditions:

Wear
Cracks
Pin holes
Improper operation

Illustration 98
(1)
(2)
(3)
(4)
(5)

g00834076

Receptacle
Gasket
Cap
Bolt
Cover

3. Disconnect the wiring harness from receptacle (1).


Inspect the connectors for damage and corrosion.
Make repairs, as needed.
4. Inspect gasket (2) for damage and wear. Replace
the gasket, if necessary.
5. Remove cap (3). Remove the washer under the
cap in order to inspect the solenoid.
6. Inspect the solenoid for damage. If the epoxy
coating is cracked or damaged, obtain a new
solenoid for assembly.
7. Inspect the cavity for the solenoid. Look for
moisture, debris, and abrasion of the wiring. Make
repairs, if necessary. Thoroughly clean the cavity.

SEBU6496-06

105
Maintenance Section
Hoses and Clamps - Inspect/Replace

8. Remove bolts (4) and cover (5) in order to inspect


the internal parts of the GSOV.
9. Clean the internal parts. Inspect the diaphragm,
the center pin for the diaphragm, and the shaft
for the solenoid. If any of the parts are damaged,
replace the entire GSOV.
10. Inspect the internal passages. Remove any
debris.
11. Reassemble the diaphragm, the center pin for the
diaphragm, and the shaft for the solenoid. Install
cover (5) with bolts (4).
12. Install cap (3). Connect the wiring harness to
receptacle (1).
13. Turn on the fuel supply to the GSOV. Use a gas
detector to check for gas leaks.
i01819486

Hoses and Clamps Inspect/Replace


SMCS Code: 7554-040; 7554-510
Inspect all hoses. Leaks can be caused by the
following conditions:

Cracking
Softness

Armoring that is embedded in the outer covering


Each installation application can be different. The
differences depend on the following factors:

Type of hose
Type of fitting material
Anticipated expansion and contraction of the hose
Anticipated expansion and contraction of the
fittings

Replace the Hoses and the Clamps


1. Service the hoses and clamps according to the
system:
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, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.

Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
NOTICE
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the recommended torque.
Check for the following conditions:

Fittings that are damaged or leaking


Outer covering that is chafed or cut
Exposed wire that is used for reinforcement
Outer covering that is ballooning locally
Flexible part of the hose that is kinked or crushed

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
a. Before servicing a coolant hose, stop the
engine. Allow the engine to cool. Loosen the
cooling system filler cap slowly in order to
relieve any pressure. Remove the cooling
system filler cap. Drain the coolant from the
cooling system to a level that is below the hose
that is being replaced.

106
Maintenance Section
Ignition System Spark Plugs - Check/Adjust

SEBU6496-06

Hot oil and components can cause personal injury.

Personal injury or death can result from improperly checking for a leak.

Do not allow hot oil or components to contact


skin.

Always use a board or cardboard when checking


for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.

b. Before servicing an oil hose, stop the engine.


Allow the engine to cool. Drain the oil from the
system to a level that is below the hose that
is being replaced.

Personal injury can result from removing hoses or


fittings in a pressure system.
Failure to relieve pressure can cause personal injury.
Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
c. Before servicing a pressurized air hose, stop
the engine. Ensure that the air supply to the
hose is OFF. Slowly release pressure from the
system.

If fluid is injected into your skin, it must be treated


immediately by a doctor familiar with this type of
injury.
c. If a pressurized air hose was serviced, restore
air pressure to the system. Check for air leaks.
i00838669

Ignition System Spark Plugs Check/Adjust


SMCS Code: 1555-535
Maintenance of the spark plugs is required in order to
obtain the following benefits:

Normal fuel consumption

2. Remove the hose clamps.

Normal levels of emissions

3. Disconnect the old hose. Discard the hose.

Maximum service life of the spark plugs

4. Install a new hose.

The service life of the spark plugs is affected by


fouling due to deposits from the oil and by peak
voltage. Maintenance of the ignition system is also
affected by voltage. Higher voltage is required by
higher inlet manifold air pressure and a higher
compression ratio. Higher voltage reduces the
service life of components such as spark plug wires
and transformers.

5. Install the hose clamps with a torque wrench.


For torques on hose clamps, see Specifications,
SENR3130, Torque Specifications, Hose
Clamps.
6. After servicing the hose, restore the system to an
operational state according to the requirements
of the system:
a. If a coolant hose was serviced, refill the cooling
system. Install the cooling system filler cap.
Start the engine. Inspect the cooling system
for leaks.
b. If an oil hose was serviced, refill the system to
the proper level. Start the engine. Inspect the
system for leaks.

SEBU6496-06

107
Maintenance Section
Ignition System Spark Plugs - Check/Adjust

Removing the Spark Plug

4. Remove transformer (3) and gasket (4). Inspect


gasket (4). If the gasket is worn or damaged,
discard the gasket and use a new gasket for
assembly.
5. Remove extension (5).

Pressurized air can cause personal injury. When


pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.

Illustration 99

g00294914

(1) Connector
(2) Bolt
(3) Transformer

1. Ensure that the mode control switch is in the


STOP or OFF/RESET position.
NOTICE
Pulling on the wiring harness may break the wires. Do
not pull on the wiring harness.
2. Disconnect the wiring harness. Use pliers to turn
connector (1) counterclockwise.
3. Remove three bolts (2).

6. Debris may have collected near the spark plug.


Thoroughly remove any debris. Use compressed
air. The maximum air pressure for cleaning
purposes must be below 207 kPa (30 psi). Ensure
that the area around the spark plug is clean and
free of dirt and debris.
7. Use a 22.23 mm (.875 inch) 4C-4601 Spark Plug
Socket and an extension to loosen spark plug (6).
After the spark plug has been loosened, remove
the spark plug by hand in order to detect problems
with the threads. After the spark plug has been
removed, discard used gasket (7).
NOTICE
The use of a thread tap will remove metal unnecessarily. This will also reduce the heat transfer for the spark
plug. This can result in a reduction of the spark plug
service life and a reduction of the detonation margin.
If the spark plug resists removal by hand, apply
penetrating oil to the threads. Use the wrench and
apply steady pressure to the spark plug until the
spark plug is loose.
Note: Cover (8) and tube (9) must be removed in
order to clean the threads.

Illustration 100
(3)
(4)
(5)
(6)
(7)
(8)
(9)

g00295199

Transformer
Gasket
Extension
Spark plug
Gasket
Cover
Tube

Note: Some engines that are certified by the


Canadian Standards Association (CSA) do not have
gasket (4).

If the spark plug cannot be removed by hand, clean


the threads with 9U-7511 Spark Plug Seat Cleaner.
This tool scrapes debris from the seat and from the
threads.

108
Maintenance Section
Ignition System Spark Plugs - Check/Adjust

SEBU6496-06

Inspecting the Spark Plug

Illustration 102
Illustration 101
(1)
(2)
(3)
(4)
(5)

g00295207

Terminal post
Insulator
Shell
Gasket
Electrode

Inspect the spark plug closely for damage. The


condition of the spark plug can indicate the operating
condition of the engine.
Terminal post (1) must not move. If the terminal post
can be moved by hand, discard the spark plug.
Inspect insulator (2) for cracks. If a crack is found,
discard the spark plug.
Faint marks may extend from shell (3) onto the
insulator. The marks may be a result of corona that
forms at the top of the shell. Corona develops when
a very high voltage potential ionizes the air that
surrounds a conductor. This is a normal condition.
This is not an indication of leakage between the shell
and the insulator.
Inspect shell (3) for damage. Cracks can be caused
by overtightening the spark plug. Overtightening can
also loosen the shell. Discard any spark plug that has
a shell that is cracked or loose.
Inspect electrode (5) for excessive wear. Flat
surfaces with sharp edges provide the best conditions
for creating a spark. An electrode will become worn
from use. The surfaces erode. A higher voltage is
required in order to produce a spark.

g00353860

(6) Precious metal pads on the electrode and the ground strap

Caterpillar spark plugs have precious metal pads (6)


on the tips of the electrode and the ground strap.
This material will gradually erode.
Replace the spark plug if the precious metal is worn
off.
A light brown or beige deposit around the electrode is
produced by normal operation. White deposits or gray
deposits may be caused by the following substances:

Excessive oil
Use of the wrong oil
A substance that is introduced through the fuel
system or the air system

A spark plug can operate despite a buildup of ash.


However, a buildup of ash can cover the electrode
gap. This will cause misfire. Large deposits may
retain heat which can cause premature fuel ignition.
This can lead to uncontrollable detonation.
A standard ohmmeter (nine volt) can be used for
measuring the resistance of the spark plug. The
ohmmeter can be used only for spark plugs with
wire-wound resistors. It is not possible to use a
standard ohmmeter (nine volt) for measuring the
resistance of other types of spark plugs. Measure the
resistance between terminal post (1) and electrode
(5). Discard any spark plug with a wire-wound resistor
if the resistance is outside the range of 1k to 1.5k
Ohms.

Cleaning the Spark Plug


Thoroughly clean the spark plug. Do not use a wire
brush. Glass beads are the preferred method for
cleaning.
Follow these guidelines for using glass beads:

SEBU6496-06

Always use clean glass beads.


Use care in order to clean only the electrode and

109
Maintenance Section
Ignition System Spark Plugs - Replace

5. Ensure that the connection points of the extension


are clean.

the insulator near the electrode.

Do not use glass beads on the outside of the shell


or on the upper part of the insulator.

Installing the Spark Plug


Note: Use the 9U-7516 Spark Plug Gauge to
measure the electrode gap. Do not use a flat feeler
gauge for measuring the electrode gap of used spark
plugs. A feeler gauge will falsely measure the actual
electrode gap due to curvature of the used precious
metal surfaces.
1. Before installing the spark plug, set the electrode
gap to 0.29 0.03 mm (.011 0.001 inch).
Adjust the electrode gap by bending the ground
electrode at the existing bend. Then bend the
strap near the weld in order to achieve proper
alignment and even spacing between the two
precious metal surfaces. Measure the electrode
gap after the alignment. Correct the electrode
gap, if necessary.
Note: Do not use anti-seize compound on spark
plugs. Most of the heat is transferred through the
threads and the seat area of the spark plug. The
surfaces must be in contact in order to provide the
heat transfer that is required.
2. Ensure that the spark plug is clean and free of
dirt and oil.
3. Always use a new gasket when a spark plug is
installed. If a used spark plug is installed, place a
new 9Y-6792 Gasket on the spark plug. Orient
the tabs of the gasket toward the electrode.
Otherwise, the gasket may not seat properly. If a
gasket for a spark plug is installed incorrectly, do
not increase the torque on the spark plug in order
to improve the seal. Do not reuse the gasket.
Install a new gasket.
NOTICE
Do not overtighten the spark plugs. The shell can be
cracked and the gasket can be deformed. The shell
can be stretched. This will loosen the seal that is between the shell and the insulator, allowing combustion
pressure to blow past the seal. Serious damage to the
engine can occur.

Illustration 103

g00451015

(1) Connection of the extension and the transformer


(2) Connection of the extension and the spark plug

a. Use a mild abrasive cleaner to clean deposits


and/or corrosion from the extension at
connection points (1) and (2).
b. Apply one of the following lubricants to the
extension at connection points (1) and (2):

4C-9504 Dielectric Grease


8T-9020 Dielectric Grease
This will help to protect the connection points
of the extension from corrosion.
6. Ensure that the internal spring exerts force on the
connection points. Install the extension onto the
spark plug.
7. Ensure that the transformer assembly is clean and
free of dirt and oil. Center the extension into the
transformer. Install the transformer.
8. Connect the wiring harness. Tighten the connector
clockwise with pliers until the connector cannot
be loosened by hand.
i01612988

Ignition System Spark Plugs Replace


SMCS Code: 1555-510

Use the proper torque.

Remove the used spark plugs. Install new spark


plugs.

4. Install the spark plug by hand until the spark plug


bottoms out. Tighten the spark plug to 68 4 Nm
(50 3 lb ft).

For instructions on removing and installing spark


plugs, refer to this Operation and Maintenance
Manual, Ignition System Spark Plugs - Check/Adjust
topic (Maintenance Section).

110
Maintenance Section
Inlet Air System - Inspect

SEBU6496-06

i01113853

Fuel lines from the source to the gas regulator

Inlet Air System - Inspect

Fuel lines from the gas regulator to the fuel inlet

SMCS Code: 1058-040; 1071-040; 1087-040

Fuel inlet

Inspect the components of the air inlet system for


the following conditions:

Control valve
Fuel manifold

Cracks

Connections of the fuel manifold and the fuel lines

Leaks

Connections of the fuel lines to the orifice

Loose connections

Connections of the fuel lines to the cylinder head

Inspect the following components:

Piping between the air cleaner and the turbocharger

Connections of the fuel lines to the precombustion


chamber

Turbocharger

Fuel pressure sensor

Piping between the turbocharger and the

Fuel temperature sensor

Aftercooler

Ensure that all of the connections are secure. Ensure


that the components of the fuel system are in good
condition.

aftercooler

Connection of the aftercooler to the air plenum


Connection of the air plenum to the cylinder head
Ensure that all of the connections are secure. Ensure
that the components are in good condition.
Make repairs, if necessary. For information regarding
removal and installation of the components, see
the Service Manual, Disassembly and Assembly
module. Consult your Caterpillar dealer for
assistance.

Make repairs, if necessary. For information regarding


removal and installation of the components, see the
Service Manual. Consult your Caterpillar dealer for
assistance.
i00683472

Magnetic Pickups Clean/Inspect


SMCS Code: 1907-040

i00683392

Inlet Gas Manifold and Piping Inspect/Replace


SMCS Code: 1550-040; 1550-510
Inspect the components of the fuel inlet system for
the following conditions:

Cracks
Deterioration
Leaks

Illustration 104

Loose connections

(1) Magnetic pickup


(2) Flywheel ring gear

Wear
Inspect the following components:

g00283415

Stop the engine in order to perform this maintenance


procedure.

SEBU6496-06

111
Maintenance Section
Magneto Drive Coupling - Inspect

1. Remove the magnetic pickup from the flywheel


housing.
2. Clean the face of the magnet. Check the condition
of the magnetic pickup.
If the magnetic pickup shows evidence of contact
with the flywheel ring gear, discard the used
magnetic pickup. Install a new magnetic pickup.
3. Install the magnetic pickup in the flywheel housing.
Turn the magnetic pickup clockwise until the
magnet contacts a tooth of the flywheel ring gear.
4. Turn the magnetic pickup counterclockwise for
5/8 turns (225 degrees). Maintain a clearance of
0.69 0.14 mm (.027 .005 inch) between the
magnetic pickup and the tooth of the flywheel
ring gear. Tighten the locknut to 47 7 Nm
(35 5 lb ft).
i00683480

Magneto Drive Coupling Inspect

i02252012

Overhaul (In-Frame)
SMCS Code: 1000-020

Scheduling an In-Frame Overhaul


Table 22 lists the approximate number of service
hours before an in-frame overhaul for different G3600
Engine applications.
Table 22

Estimated Service Hours Before An


In-Frame Overhaul
Fuel

Compression Ratio

Service
Hours

Wellhead gas or
natural gas

9.2:1

50000

Natural gas

10.5:1

45000 to
48000

Bio-gas

9.2:1

27000 to
33000

Scheduling an in-frame overhaul normally depends


on the following three conditions:

SMCS Code: 1552-040

An increase of oil consumption


An increase of crankcase blowby
A decrease and a variation of cylinder compression
Each individual condition may not indicate a need
for an overhaul. However, evaluating the three
conditions together is the most accurate method of
determining when an overhaul is necessary.

Illustration 105

g00296073

(1) Coupling

Inspect coupling (1). If any worn components are


found, replace the components.
See the service literature Specifications and
Disassembly and Assembly modules for instructions
on the following procedures:

Removing the magneto


Installing the coupling
Installing the magneto
Adjusting the timing
Consult your Caterpillar dealer for assistance.

The engine may not require an overhaul if the


engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder
compression.
Periodically measure each of the three conditions.
The first measurement should occur during the first
scheduled maintenance. This establishes a baseline
for future measurements. Additional measurements
are scheduled at regular intervals in order to
determine a schedule for the next in-frame overhaul.
The following changes in the three conditions
normally require a scheduled overhaul:

A 300 percent increase in oil consumption


A 200 percent increase in crankcase blowby
A 20 percent loss of cylinder compression

112
Maintenance Section
Overhaul (In-Frame)

Note: These indications do not require an engine


to be shut down for service. These indications
only mean that an engine should be scheduled for
service in the near future. If the engine operation
is satisfactory, an immediate overhaul is not a
requirement.
An in-frame overhaul does not typically require
the engine to be removed. Instead, the service is
performed with the engine in place.

SEBU6496-06

Replace The service life of the part is exhausted.


The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement part
may be a new part, a CAT remanufactured part, a
rebuilt part, or a used part. Various worn components
may be exchanged with your Caterpillar dealer.
Consult your Caterpillar dealer about repair options
for your engine.
Table 23

Note: The generator or the driven equipment may


also require service when the engine overhaul is
performed.

In-Frame Overhaul Information


An in-frame overhaul includes all of the work that is
done for a top end overhaul. Additionally, some other
components that wear are replaced. The condition
of components is inspected. Those components are
replaced, if necessary.
Inspect the following components according to
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, Index
of Publications on Reusability or Salvage of Used
Parts.

In-Frame Overhaul
Procedure
Inspect
Replace

(1)

Component
Aftercooler
Cylinder liners
Oil cooler
Pistons

Rebuild

Gas admission valve


Electrohydraulic actuators
Vibration damper

Replace

Camshaft bearings
Camshaft followers
Connecting rod bearings
Crankshaft seals

Your Caterpillar dealer can provide these services


and components. Your Caterpillar dealer can ensure
that the components are operating within the
appropriate specifications.

Engine oil pump


Exhaust shields
Gaskets and seals

If you elect to perform an overhaul without the


services of a Caterpillar dealer, be aware of the
following recommendations.

Electrohydraulic systems
oil pump

The following definitions explain the terminology for


the services that are performed during an overhaul:

Oil temperature regulators

Inspect Inspect the components according to


the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, Index
of Publications on Reusability or Salvage of Used
Parts. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
required if the existing parts can still be used,
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
Manual, Specifications module.

Prechamber assemblies

Rebuild The component can be reconditioned in


order to comply with reusability guidelines.

Main bearings

Piston rings

Water pumps
Water temperature
regulators
(1)

In addition to these procedures, perform the procedures for


the top end overhaul.

SEBU6496-06

113
Maintenance Section
Overhaul (Major)

i02252260

The service hours of the engine

Overhaul (Major)

The wear metal analysis of the lube oil

SMCS Code: 7595-020-MJ

An increase in the levels of noise and vibration

Scheduling a Major Overhaul

An increase of wear metals in the lube oil indicates


that the bearings and the surfaces that wear may
need to be serviced. An increase in the levels of
noise and vibration indicates that rotating parts
require service.

Table 24 lists the approximate number of service


hours before a major overhaul for different G3600
Engine applications.
Table 24

Estimated Service Hours Before a Major Overhaul


Fuel

Compression Ratio

Service
Hours

Wellhead gas or
natural gas

9.2:1

100000

Natural gas

10.5:1

75000 to
80000

Bio-gas

9.2:1

52000 to
54000

The need for a major overhaul is determined by


several factors:

An increase of oil consumption


An increase of crankcase blowby
A decrease and variation of cylinder compression
The following changes in the three conditions
normally require a scheduled overhaul:

A 300 percent increase in oil consumption


A 200 percent increase in crankcase blowby
A 20 percent loss of cylinder compression
Note: These indications do not require an engine
to be shut down for service. These indications
only mean that an engine should be scheduled for
service in the near future. If the engine operation
is satisfactory, an immediate overhaul is not a
requirement.
The engine does not require an overhaul if the
engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder
compression.
Other factors must also be considered for determining
a major overhaul:

Note: It is possible for oil analysis to indicate a


decrease of wear metals in the lube oil. The cylinder
liners may be worn so that polishing of the bore
occurs. Also, the increased use of lube oil will dilute
the wear metals.
Monitor the engine as the engine accumulates
service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.

Major Overhaul Information


A major overhaul includes all of the work that is done
for a top end overhaul. A major overhaul can also
include all of the work that is done for an in-frame
overhaul. A major overhaul includes additional parts
and labor. Additional parts and labor may be required
in order to completely rebuild the engine. In some
cases, the engine is relocated for disassembly.
For the major overhaul, bearings, seals, gaskets, and
components that wear are disassembled. The parts
are cleaned and inspected. If necessary, the parts
are replaced. The crankshaft is measured for wear.
The crankshaft may require regrinding. Alternatively,
the crankshaft may be replaced with a Caterpillar
replacement part.
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
that the components are operating within the
appropriate specifications.
If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the
following recommendations.
The following definitions explain the terminology for
the services that are performed during an overhaul:

114
Maintenance Section
Overhaul (Top End)

SEBU6496-06

Inspect Inspect the components according to


the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, Index
of Publications on Reusability or Salvage of Used
Parts. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
required if the existing parts can still be used,
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
Manual, Specifications module.
Rebuild The component can be reconditioned in
order to comply with reusability guidelines.
Replace The service life of the part is exhausted.
The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement
part may be a new part, a CAT remanufactured part,
a rebuilt part, or a used part. Some worn components
may be exchanged with your Caterpillar dealer.
Consult your Caterpillar dealer about repair options
for your engine.
Table 25

Major Overhaul(1)
Procedure
Inspect
Replace

Component
Camshafts

Crankshaft
Inlet air piping

Replace

Aftercooler
Camshaft lifters
Exhaust manifolds
Gear train bearings
Oil cooler

(1)

Estimated Service Hours Before a Top End Overhaul


Fuel

Compression Ratio

Service
Hours

Wellhead gas or
natural gas

9.2:1

25000

Natural gas

10.5:1

15000

Bio-gas

9.2:1

10000 to
14000

Top end overhauls are normally scheduled according


to the projection of exhaust valve stems. This
measurement provides an accurate indication of the
rate of valve wear. This measurement can be used to
predict when a cylinder head requires replacement.
Measure the projection of the exhaust valve stems at
the first 1000 service hours. This measurement is the
baseline. The baseline is a reference for subsequent
measurements. Continue to periodically measure
the projection.
Plan for the top end overhaul as the valve stem
projection approaches the maximum limit. Perform
the top end overhaul when the valve stem projection
has increased by a total of 2.3 mm (.09 inch). Do not
allow the projection of the exhaust valve stems
to exceed this limit.
Note: Generally, cylinder heads wear out at different
rates. In some cases, servicing the cylinder heads at
different times may be the most economic decision.
This depends on the valve stem projection of the
individual cylinders. However, this decision must
include the costs of additional downtime that is
caused by this procedure. Perform an economic
analysis in order to determine if cylinder heads should
be serviced as a group or divided into smaller groups.

Connecting rods

Rebuild

Table 26

In addition to these procedures, perform the procedures for


both the top end overhaul and the in-frame overhaul.

Note: The generator or the driven equipment may


also require service when the engine overhaul is
performed.

Top End Overhaul Information


i02238121

Overhaul (Top End)


SMCS Code: 7595-020-TE

A top end overhaul involves servicing the cylinder


heads and turbochargers. Also, some other engine
components are inspected.

Scheduling a Top End Overhaul

Top end overhauls require more tools than preventive


maintenance. The following tools are needed for
restoring the engine to factory specifications:

Table 26 lists the approximate number of service


hours before a top end overhaul for different G3600
Engine applications.

Torque wrenches
Dial indicators
Accurate measurement tools

SEBU6496-06

Cleaning equipment
Rebuilding equipment
Caterpillar dealers are equipped with these tools.
Caterpillar dealers can provide a flat rate price for
a top end overhaul.
Unexpected problems may be found during a top
end overhaul. Plan to correct these problems, if
necessary.

115
Maintenance Section
Overhaul Considerations

Replace The service life of the part is exhausted.


The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement
part may be a new part, a CAT remanufactured part,
a rebuilt part, or a used part. Some worn components
may be exchanged with your Caterpillar dealer.
Consult your Caterpillar dealer about repair options
for your engine.
Table 27

Top End Overhaul

Buildup in the cylinders from excessive oil

Procedure

consumption

Plugging of the aftercooler from coolant that is

Inspect/Replace

Seals for the gas admission


valve
Rod bearings

Rebuild

Gas pressure regulator

poorly maintained

Degradation of the oil cooler from hydrogen sulfide


in the fuel

Inspect the following components according to


the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, Index
of Publications on Reusability or Salvage of Used
Parts.

Component

Starting motor
Turbochargers
Replace

Cylinder heads and


gaskets
Oil temperature regulators
Spark plug extenders
Water temperature
regulators

Your Caterpillar dealer can provide these services


and components. Your Caterpillar dealer can ensure
that the components are operating within the
appropriate specifications.

i02250409

If you elect to perform an overhaul without the


services of a Caterpillar dealer, be aware of the
following recommendations.

Overhaul Considerations

The following definitions explain the terminology for


the services that are performed during an overhaul:

Overhaul Information

Inspect Inspect the components according to


the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, Index
of Publications on Reusability or Salvage of Used
Parts. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
required if the existing parts can still be used,
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
Manual, Specifications module.

An overhaul is replacing the major worn components


of the engine. An overhaul is a maintenance interval
that is planned. The engine is rebuilt with certain
rebuilt parts or new parts that replace the worn parts.

Rebuild The component can be reconditioned in


order to comply with reusability guidelines.

Cleaning of the internal passages of the engine

SMCS Code: 7595-043

An overhaul also includes the following maintenance:

Inspection of all the parts that are visible during


the disassembly

Replacement of the seals and gaskets that are


removed

and the engine block

116
Maintenance Section
Overhaul Considerations

Most owners will save money by overhauling the


engine at the intervals that are recommended in
the Operation and Maintenance Manual. It is not
practical to wait until the engine exhibits symptoms
of excessive wear or failure. It is not less costly to
wait. A planned overhaul before failure may be the
best value for the following reasons:

Costly unplanned downtime can be avoided.


Many original parts can be reused according to the
guidelines for reusable parts.

The service life of the engine can be extended


without the risk of a major catastrophe due to
engine failure.

Achieve the best cost/value relationship per hour


of extended service life.

Overhaul Intervals
Top end overhauls are determined by the projection
of exhaust valve stems. In-frame overhauls are
determined by cylinder compression, crankcase
blowby, and oil consumption. Major overhauls are
determined by the in-frame tests, and by results of
SOS oil analysis.
Some other factors that are important for determining
the overhaul intervals include the following
considerations:

Performance of preventive maintenance


Use of recommended lubricants
Use of recommended coolants
Use of recommended fuels
Proper installation
Operating conditions

SEBU6496-06

Bio-Gas
The overhaul intervals for engines that use bio-gas
depend on the concentration of contaminants in the
fuel. Although silicon is the primary contaminant
in bio-gas, other contaminants may cause further
reductions in the overhaul intervals. For more
information, refer to Gas Engines Application and
Installation Guide, LEKQ7260, G3600 - G3300 Low
Energy Fuels.

Overhaul Inspection
Refer to the Service Manual for the disassembly and
assembly procedures that are necessary in order
to perform the required maintenance on the items
that are listed. Consult your Caterpillar dealer for
assistance.
To determine the reusability publications that are
needed to inspect the engine, refer to Guidelines for
Reusable Parts and Salvage Operations, SEBF8029,
Index of Publications on Reusability or Salvage of
Used Parts.
The Guidelines For Reusable Parts and Salvage
Operations is part of an established Caterpillar
parts reusability program. These guidelines were
developed in order to assist Caterpillar dealers and
customers reduce costs by avoiding unnecessary
expenditures for new parts. If the engine parts comply
with the established inspection specifications, the
parts can be reused. New parts are not necessary if
the old parts can be reused, repaired, or salvaged.
If the parts are not within the inspection specifications,
the parts should be salvaged, repaired, replaced,
or exchanged. The use of out-of-spec parts could
result in unscheduled downtime and/or costly repairs.
The use of out-of-spec parts can also contribute to
increased fuel consumption and reduction of engine
efficiency.

Operation within acceptable limits

Your Caterpillar dealer can provide the parts that are


needed to rebuild the engine at the least possible
cost.

Engine load

Overhaul Programs

Engine speed

An economical way to obtain most of the parts


that are needed for overhauls is to use Caterpillar
remanufactured parts. Caterpillar remanufactured
parts are available at a fraction of the cost of new
parts. These parts have been rebuilt by Caterpillar
and certified for use. The following components are
examples of the remanufactured parts:

Note: To avoid oil problems, engines that are


turbocharged and aftercooled must be operated at a
minimum of 60 percent of rated load.
Generally, engines that are operated at a reduced
load and/or speed achieve more service life before
an overhaul. However, this is for engines that are
properly operated and maintained.

Alternators
Connecting rods

SEBU6496-06

117
Maintenance Section
Prechamber Check Valves - Clean

Crankshafts
Cylinder heads
Oil Pumps
Starting motors

i01765755

Prechamber Check Valves Clean


SMCS Code: 1550-070

Turbochargers
Water pumps
Consult your Caterpillar dealer for details and for a
list of the remanufactured parts that are available.
Your Caterpillar dealer may be offering a variety of
overhaul options.
A Flat Rate Overhaul guarantees the maximum price
that you will pay for an overhaul. Flat rate prices on
preventive maintenance programs or major repair
options are available from many servicing dealers
for all Caterpillar Engines. Consult your Caterpillar
dealer in order to schedule a before failure overhaul.
Overhaul Recommendation
Caterpillar recommends a scheduled overhaul in
order to minimize downtime. A scheduled overhaul
will provide the lowest cost and the greatest value.
Schedule an overhaul with your Caterpillar dealer.
Overhaul programs vary between dealers. To obtain
specific information about the types of overhaul
programs and services, consult your Caterpillar
dealer.

Illustration 106
(1)
(2)
(3)
(4)
(5)

g00789869

Plug
O-ring seal
Check valve assembly
O-ring seal
Gasket

Note: Use of a platform may be necessary to reach


the prechamber check valves.
Note: Refer to the engines Disassembly and
Assembly manual for instructions on removal and
installation of the check valves.
1. Remove check valve assembly (3) and gasket (5).
2. Discard gasket (5). Clean the check valve
assembly with a nonflammable solvent that will
not leave residue.
3. Clean the seat for the check valve assembly with
the 9U-5156 Tool Group. The tool group includes
instructions.
4. Before installation, inspect O-ring seals (2) and
(4) for dirt and cuts. If an O-ring seal is damaged,
discard the O-ring seal and install a new O-ring
seal.
5. Install a new gasket (5). Install the clean, dry
check valve assembly.

118
Maintenance Section
Prechamber Check Valves - Replace

SEBU6496-06

i01765759

Wear

Prechamber Check Valves Replace

Inspect the prelube pump for leaks. Replace all of the


seals if a leak is observed.

SMCS Code: 1550-510

Inspect the wiring for the following conditions:

Damage
Fraying
Ensure that the wiring is in good condition.
Inspect the electrical connections. Ensure that the
electrical connections are secure.
If repair or replacement is necessary, refer to the
engines Disassembly and Assembly manual. Consult
your Caterpillar dealer for assistance.
Illustration 107
(1)
(2)
(3)
(4)
(5)

g00789869

Plug
O-ring seal
Check valve assembly
O-ring seal
Gasket

Air Prelube Pump


Inspect all of the components in the air circuit for
the prelube pump. Inspect all of the air lines and
connections for leaks. Ensure that the components in
the air circuit are in good condition.

Note: Use of a platform may be necessary to reach


the prechamber check valves.
Note: Refer to the engines Disassembly and
Assembly manual for instructions on removal and
installation of the check valves.
1. Remove check valve assembly (3) and gasket (5).

Electric Prelube Pump


Inspect the brushes. Replace the brushes, if
necessary.
i00908982

Starting Motor - Inspect

2. Keep plug (1) for reassembly. Discard the other


parts. Obtain new parts for reassembly.

SMCS Code: 1451-040; 1453-040

3. Use the 9U-5156 Tool Group in order to clean


the check valve seat. The tool group includes
instructions.

More frequent inspection and replacement of the


starting motor may be required for the following
conditions:

4. Install the following new parts: O-ring seal (2),


check valve assembly (3), O-ring seal (4), and
gasket (5).

Operation in harsh environments

i01612991

Prelube Pump - Inspect


SMCS Code: 1319-040
Inspect the prelube pump for the following conditions:

Cracks
Pin holes
Proper operation

Applications that require frequent stops and starts


If the starting motor fails, the engine may not start in
an emergency situation. A scheduled inspection of
the starting motor is recommended.
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine
to start properly. The engine will not start if the
starting motor pinion does not engage the flywheel
ring gear. The teeth of the starting motor pinion and
the flywheel ring gear can be damaged because of
irregular engagement.

SEBU6496-06

119
Maintenance Section
Turbocharger - Clean

Inspect the starting motor for proper operation. Listen


for grinding when the engine is started. Inspect the
teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth.
Look for teeth that are broken or chipped. If damaged
teeth are found, the starting motor pinion and the
flywheel ring gear must be replaced. If damaged
teeth are found, the air circuit for the starting motor
must be examined in order to determine the cause
of the problem.

Table 28

Materials for Cleaning 3600 Engine Turbochargers


Material
Nut shell

Particle Size
1.7 mm
(1/16 inch)

Formed carbon

1 mm (1/32 inch)

Granulated carbon (70% hardness)

1.2 to 2 mm
(3/64 to 5/64 inch)

Granulated dry rice

1.7 mm
(1/16 inch)

Personal injury or death can result from improperly checking for a leak.
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of
injury.
Inspect all of the components in the air circuit for
the starting motor. Inspect all of the air lines and
connections for leaks.

Illustration 108

If repairs are needed, see the Service Manual or


consult your Caterpillar dealer.

(1)
(2)
(3)
(4)

i01765784

Turbocharger - Clean
(Cleaning with Dry Particles)
SMCS Code: 1052-070
Note: Use of a platform may be necessary to reach
the turbocharger.
If the engine has more than one turbocharger, each
turbocharger requires cleaning.
Note: The drain openings in the exhaust housing
of the turbocharger are closed during the cleaning
procedure. Some of the particles will be expelled
through the exhaust stack. The particles that are
expelled will be burned.
The materials that are listed in Table 28 are
recommended for use with this cleaning procedure.

g00833073

Air valve
Purge valve
Cap
Gate valve

Note: During normal engine operation, air valve (1),


purge valve (2), and gate valve (4) are closed.
1. Ensure that purge valve (2) is closed. Ensure that
cap (3) is secure. Open gate valve (4).
2. Open air valve (1) in order to remove deposits
that may be in the connecting pipe. After three
minutes, close air valve (1). Close gate valve (4).
3. Open purge valve (2) in order to relieve any
pressure from the container. Close purge valve
(2).
4. Remove cap (3). Pour 0.5 L (0.5 qt) of the particles
into the container. Tighten cap (3).
5. Ensure that purge valve (2) is closed. Reduce
the output of the engine so that the exhaust
temperature before the turbine is less than 577 C
(1070 F).
6. Open gate valve (4). Open air valve (1).
7. After 60 to 90 seconds, close air valve (1). Close
gate valve (4).

120
Maintenance Section
Turbocharger - Inspect

SEBU6496-06

8. Open purge valve (2) in order to relieve any


pressure from the container. Close purge valve
(2).
i00908991

Turbocharger - Inspect
SMCS Code: 1052-040
Periodic inspection and cleaning is recommended
for the turbocharger.
Fouling of the turbine wheels can contribute to loss of
engine power and overall loss of engine efficiency.
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
turbocharger compressor wheel could allow parts
from the compressor wheel to enter an engine
cylinder. This can cause additional damage to the
pistons, the valves, and the cylinder head.
NOTICE
Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
Minor leakage of a turbocharger housing under extended low idle operation should not cause problems
as long as a turbocharger bearing failure has not occurred.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
Note: Turbocharger components require clearances
that are precise. The turbocharger cartridge must be
balanced due to high rpm.
The following conditions can cause the turbocharger
to be out-of-balance:

The buildup of deposits


Chipping and/or flaking of deposits

If the turbocharger must be removed for inspection,


use caution. Do not break deposits from the turbine
wheel. Do not attempt to clean the turbine wheel. For
options regarding removal, installation, repair and
replacement, see the Service Manual or consult your
Caterpillar dealer.
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil.
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned.
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
for the inlet air (plugged air filters), which causes
the turbocharger to slobber.
Note: Deposits of ash and silicon can accumulate
on the turbine wheel. Turbine wheel will become
unbalanced when the deposits flake off. The
turbocharger cartridge must be replaced when this
occurs. However, remove deposits from the housing.
This will prevent wear on the blades of the turbine
wheel.
4. Inspect the turbine wheel and the nozzle for
deposits of ash and silicon. If deposits of 1 mm
(1/32 inch) thickness are found, the turbocharger
must be disassembled and cleaned at an
ABBrepair facility.
5. Inspect the bore of the turbine housing for
corrosion.
6. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.
7. Check the clearances of the turbocharger bearing.
Compare the clearances to the Service Manual,
Specifications. If the clearances are not within
the specifications, the turbocharger must be
repaired.

SEBU6496-06

121
Maintenance Section
Turbocharger Cleaner Tube - Replace

8. Fasten the air inlet piping and the exhaust outlet


piping to the turbocharger housing.
i01765785

Turbocharger Cleaner Tube Replace


SMCS Code: 1052-510

The exhaust valves and valve seats show the


greatest wear due to high operating temperatures.
The top end overhaul interval is normally scheduled
according to exhaust valve recession.
The actual measurement of the valve recession
inside of the cylinder head is difficult to obtain.
Two simpler methods are used to determine valve
recession:

Measure the projection of the valve stem above

the cylinder head. It is necessary to remove the


rocker arms in order to obtain this measurement.
This method is more accurate than measuring the
projection of the exhaust valve rotators. Measure
the projection of the exhaust valve stems with the
4C-2980 Cylinder Head Valve Projection Group.

Measure the projection of the valve rotator above

the cylinder head. It is not necessary to remove the


rocker arms in order to obtain this measurement.
Measure the projection of the exhaust valve
rotators with the 148-2997 Valve Recession Tool
Group.

Illustration 109
(1)
(2)
(3)
(4)

g00790542

Air valve
Purge valve
Gate valve
Tube

Note: Use of a platform may be necessary in order to


reach the cleaner tube.
1. Stop the engine.
2. Ensure that air valve (1) and gate valve (3) are
closed.
3. Open purge valve (2) in order to relieve any
pressure from the container.
4. Remove tube (4). Discard the used tube.
5. Install a new tube.
6. Close purge valve (2).

Make several copies of this Operation and


Maintenance Manual, Valve Data Sheet (Reference
Materials Section). Record the measurements on
the sheets.

Measure the projection of the inlet and exhaust

valve stems and the exhaust valve rotators at


the first 1000 service hours. This measurement
is the baseline. The baseline is a reference for
subsequent measurements.

Measure the projection of the inlet and exhaust

valve rotators when the engine valve lash is


checked. Continue this periodic measurement until
the projection of the valve rotator has increased by
a total of 1.6 mm (.063 inch). This is 70 percent of
the maximum limit. Measure the projection of the
valve stems when this occurs. This measurement
will determine the actual wear of both the valves
and the valve seats.

After 70 percent of the maximum limit has been


i00682053

Valve Stem Projection Measure/Record


SMCS Code: 1105-082
Valve Recession The valves and the valve seats
are worn over time. This causes the valves to recede
into the cylinder head. This condition is called valve
recession.

reached, measure the projection of the exhaust


valve stems at every 500 hours of operation.

Plan for the top end overhaul as the valve

stem projection approaches the maximum limit.


Perform the top end overhaul when the valve stem
projection has increased by a total of 2.3 mm
(.09 inch). Do not allow the valve recession to
exceed this limit. The valve head can break.
This will cause severe damage in the combustion
chamber and the turbocharger.

Consult your Caterpillar dealer for assistance.

122
Maintenance Section
Walk-Around Inspection

SEBU6496-06

i01492446

Walk-Around Inspection
SMCS Code: 1000-040

NEVER use a flame to check for gas leaks. Use a


gas detector.

Inspect the Engine for Leaks and


for Loose Connections

An open flame can ignite mixtures of air and fuel.


This will cause explosion and/or fire which could
result in severe personal injury or death.

A walk-around inspection should only take a few


minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.

Check the fuel system for leaks. Look for loose fuel

For maximum engine service life, thoroughly inspect


the engine room before starting the engine. Look for
items such as leaks, loose bolts, loose connections
and trash buildup. Make repairs, as needed.

The guards must be in the proper place. Repair


damaged guards or replace missing guards.

Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system


contamination.

NOTICE
For any type of leak, clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking
is suspected, check the fluid levels more often than
recommended until the leak is found or fixed, or until
the suspicion of a leak is proved to be unwarranted.

line clamps.

Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.

Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed


wires.

Inspect the ground straps for good connections


and for good condition.

Check the condition of the gauges. Replace any

gauge that is damaged. Replace any gauge that


can not be calibrated.

Inspect the exhaust system for leaks. If a leak is


found, make repairs.

i00524084

Water Pump - Inspect


NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.

Ensure that cooling lines are properly clamped.

Check for leaks. Check the condition of all pipes.

Inspect the water pumps for coolant leaks.


Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur when the engine cools and the
parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For instructions
on removal and installation of water pumps and/or
seals, refer to the Service Manual, Disassembly and
Assembly module for the engine or consult your
Caterpillar dealer.

Inspect the lubrication system for leaks at the front


crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve covers.

SMCS Code: 1361-040


A failed water pump might cause severe engine
overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential
damage to the engine.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of
the water pump seals. Refer to the Service Manual
for the disassembly and assembly procedure.
Inspect the water pump for wear, cracks, pin holes
and proper operation. Refer to the Service Manual or
consult your Caterpillar dealer if repair is needed or
replacement is needed.

SEBU6496-06

123
Reference Information Section
Customer Service

Reference Information
Section

Latin America, Mexico, Carribean


Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801

Customer Service
i02097871

Customer Assistance
SMCS Code: 1000; 4450

USA and Canada


When a problem arises concerning the operation of
an engine or concerning the service of an engine,
the problem will normally be managed by the dealer
in your area.
Your satisfaction is a primary concern to Caterpillar
and to Caterpillar dealers. If you have a problem that
has not been handled to your complete satisfaction,
follow these steps:
1. Discuss your problem with a manager from the
dealership.
2. If your problem cannot be resolved at the dealer
level without additional assistance, use the phone
number that is listed below to talk with a Field
Service Coordinator:
1-800-447-4986
The normal hours are from 8:00 to 4:30 Monday
through Friday Central Standard Time.
3. If your needs have not been met still, submit the
matter in writing to the following address:
Caterpillar Inc.
Manager, Customer Service, Engine Division
Mossville Bldg AC
P.O. Box 610
Mossville, Illinois 61552-0610
Please keep in mind: probably, your problem will
ultimately be solved at the dealership, using the
dealerships facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a
problem is experienced.

Outside of the USA and of Canada


If a problem arises outside the USA and outside
Canada, and if the problem cannot be resolved at the
dealer level, consult the appropriate Caterpillar office.

Europe, Africa, and Middle East


Caterpillar Overseas S.A.
76 Route de Frontenex
P.O. Box 6000
CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
Fax: 22-849-4544
Far East
Caterpillar Asia Pte. Ltd.
7 Tractor Road
Jurong, Singapore 627968
Republic of Singapore
Phone: 65-662-8333
Fax: 65-662-8302
China
Caterpillar China Ltd.
37/F., The Lee Gardens
33 Hysan Avenue
Causeway Bay
G.P.O. Box 3069
Hong Kong
Phone: 852-2848-0333
Fax: 852-2848-0440
Japan
Shin Caterpillar Mitsubishi Ltd.
SBS Tower
10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
Japan
Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Japan
Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Phone: 81-3-5797-4300
Fax: 81-3-5797-4359
Australia and New Zealand
Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366

124
Reference Information Section
Customer Service

SEBU6496-06

i01028392

Ordering Replacement Parts


SMCS Code: 4450; 7567

When replacement parts are required for this


product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent specifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available
from Caterpillar dealers throughout the world.
Caterpillar dealers parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following
information:

Part number
Part name
Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.

SEBU6496-06

125
Reference Information Section
Reference Materials

Reference Materials

Maintenance log
i00912149

Maintenance Records
SMCS Code: 1000; 4450
Caterpillar Inc. recommends the retention of accurate
maintenance records. Accurate maintenance records
can be used for the following purposes:

Determine operating costs.


Establish maintenance schedules for other engines
that are operated in the same environment.

Show compliance with the required maintenance


practices and maintenance intervals.

Maintenance records can be used for a variety of


other business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is well managed. Accurate
maintenance records can help your Caterpillar dealer
to fine tune the recommended maintenance intervals
in order to meet the specific operating situation. This
should result in a lower engine operating cost.
Records should be kept for the following items:
Fuel Consumption A record of fuel consumption
is essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul
intervals.
Service Hours A record of service hours is
essential to determine when the speed sensitive
components should be inspected or repaired.
Documents These items should be easy to
obtain, and these items should be kept in the engine
history file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number, and engine serial number. The following
types of documents should be kept as proof of
maintenance or repair for warranty:
Keep the following types of documents as proof of
maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:

Dealer work orders and itemized bills


Owners repair costs
Owners receipts

126
Reference Information Section
Reference Materials

SEBU6496-06

i02209903

Maintenance Log
SMCS Code: 1000; 4450
Table 29

Engine Model

Customer Identifier

Serial Number

Arrangement Number

Service
Hours

Service Item

Date

Authorization

SEBU6496-06

127
Reference Information Section
Reference Materials

i00883868

Valve Data Sheet


SMCS Code: 1000
Table 30

Engine Model
Cylinder
1

Cylinder
Pressure

Serial Number
Valve Location
Pushrod Side
Exhaust Manifold

Pushrod Side
Exhaust Manifold

Pushrod Side
Exhaust Manifold

Pushrod Side
Exhaust Manifold

Pushrod Side
Exhaust Manifold

Pushrod Side
Exhaust Manifold

Pushrod Side
Exhaust Manifold

Pushrod Side
Exhaust Manifold

Pushrod Side
Exhaust Manifold

10

Pushrod Side
Exhaust Manifold

11

Pushrod Side
Exhaust Manifold

12

Pushrod Side
Exhaust Manifold

13

Pushrod Side
Exhaust Manifold

14

Pushrod Side
Exhaust Manifold

15

Pushrod Side
Exhaust Manifold

16

Pushrod Side
Exhaust Manifold

Authorization

Service Hours
Current
Measure

Stem
Baseline

Rotator
Baseline

Wear

128
Reference Information Section
Reference Materials

SEBU6496-06

Table 31

Engine Model
Cylinder
1

Cylinder
Pressure

Serial Number
Valve Location
Pushrod Side
Inlet Manifold

Pushrod Side
Inlet Manifold

Pushrod Side
Inlet Manifold

Pushrod Side
Inlet Manifold

Pushrod Side
Inlet Manifold

Pushrod Side
Inlet Manifold

Pushrod Side
Inlet Manifold

Pushrod Side
Inlet Manifold

Pushrod Side
Inlet Manifold

10

Pushrod Side
Inlet Manifold

11

Pushrod Side
Inlet Manifold

12

Pushrod Side
Inlet Manifold

13

Pushrod Side
Inlet Manifold

14

Pushrod Side
Inlet Manifold

15

Pushrod Side
Inlet Manifold

16

Pushrod Side
Inlet Manifold

Service Hours
Current
Measure

Authorization
Stem
Baseline

Rotator
Baseline

Wear

SEBU6496-06

129
Reference Information Section
Reference Materials

i02251018

Reference Material
SMCS Code: 1000; 4450
The following literature can be obtained through any
Caterpillar dealer.

Coolants
Special Publication, PEDP7036, SOS Fluid
Analysis

Data Sheet, PEHJ0040, Cat NGEC Premix 50/50


Special Instruction, PEHP7057, Coolant Analysis

Lubricants

Data Sheet, PEHP9554, Cat DEAC

Data Sheet, NEHP6015, Cat SPG (Special

Special Publication, SEBD0518, Know Your

Special Publication, PEDP7036, SOS Fluid

Special Publication, SEBD0970, Coolant and Your

Special Publication, PEHP6001, How To Take A

Special Publication, SEBU6400, Caterpillar

Purpose Grease)
Analysis

Good Oil Sample

Data Sheet, PEHP0002, Cat MPGM

(Multi-Purpose Grease with Molybdenum)

Data Sheet, PEHP0003, Cat MPG (Multi-Purpose


Grease)

Data Sheet, PEHP0004, Cat NGEO (Natural Gas


Engine Oil)

Special Publication, SEBD0640, Oil and Your


Engine

Special Publication, SEBU6400, Caterpillar


Gas Engine Lubricant, Fuel, and Coolant
Recommendations

Fuels

Cooling System
Engine

Gas Engine Lubricant, Fuel, and Coolant


Recommendations

Miscellaneous
Special Instruction, GMG00694, Analyzing
Cylinder Condition By Measuring Air Flow

Data Sheet, LEKQ2364, US Stationary Engine


Regulations/Spark Ignited Emissions

Application and Installation Guide, LEKQ2368,

Gas Engine Application and Installation Guide

Application and Installation Guide, LEKQ7250, Air


Intake, Exhaust, Ventilation

Application and Installation Guide, LEKQ7252,


G3600 Mounting, Alignment

Special Publication, LEKQ5404, Fuels

Application and Installation Guide, LEKQ7255,

Software Program, LEKQ6378, Methane Number

Special Publication, NEHS0526, Service

Application and Installation Guide, LEKQ7256,

Special Publication, NENG2500, Caterpillar Tools

Application and Installation Guide, LEKQ7260,

Special Publication, PECP9067, One Safe

Special Publication, LEKQ9360, Internal

Special Publication, SEBF8029, Index to

Special Publication, SEBU6400, Caterpillar

Special Publication, SEBF8062, Procedure to

Specifications Changes (Only available through


www.cat.com)
Program

Fuels, Fuel Systems


Low Energy Fuels

Combustion Engine Fuel Gases (Only available


through www.cat.com)
Gas Engine Lubricant, Fuel, and Coolant
Recommendations

Special Instruction, SEHS9298, Installation and


Maintenance of Gaseous Fuel Filters

G3600 Cooling Systems, Heat Recovery,


Lubrication System
Technician Application Guide
and Shop Products Guide
Source

Guidelines for Reusable Parts and Salvage


Operations
Inspect and Clean Air Filters

Special Instruction, SEHS7332, Do Not Operate


Tag

130
Reference Information Section
Reference Materials

Special Instruction, SEHS7633, Battery Test


Procedure

Special Instruction, SEHS8622, Using the FT1984


Air-To-Air Aftercooler Leak Test Group

Special Instruction, SEHS8712, Using the


8T-2700 Blowby/Airflow Indicator Group

Special Instruction, SEHS8984, Using the

1U-8860 Large Engine Blowby Pickup Group

Special Instruction, SEHS9031, Storage


Procedure for Caterpillar Products

Special Instruction, SEHS9162, Spring Isolator


Group Installation and Adjustment Procedure

Specifications, SENR3130, Torque Specifications


Schematic, SENR5082, G3612 and G3616
Engine Electrical System

Service Manual, SENR5500, G3612 and G3616


Engines

Specifications, SENR5527, G3612 and G3616


Engines

Systems Operation/Testing and Adjusting,

SENR5528, G3612 and G3616 Engines (S/N:


1YG1-123; 4CG1-82)

Systems Operation/Testing and Adjusting,

RENR2255, G3612 and G3616 Engines (S/N:


1YG124-Up; 4CG83-Up)

Disassembly and Assembly, SENR5535, G3612


and G3616 Engines

Troubleshooting, SENR6510, G3600 Engines


Supervisory System (ESS)

Additional Reference Material


The Engine Fluids Data Book can be obtained from
the following locations: local technological society,
local library, and local college. If necessary, consult
EMA at the following address:
Engine Manufacturers Association
Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602
E-mail: ema@enginemanufacturers.org
(312) 827-8700
Facsimile: (312) 827-8737

SEBU6496-06

The Society of Automotive Engineers (SAE)


Specifications can be found in your SAE handbook.
This publication can also be obtained from the
following locations: local technological society, local
library, and local college. If necessary, consult SAE
at the following address:
SAE International
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841
The American Petroleum Institute Publication No.
1509 can be obtained from the following locations:
local technological society, local library, and local
college. If necessary, consult API at the following
address:
American Petroleum Institute
1220 L St. N.W.
Washington, DC, USA 20005
Telephone: (202) 682-8000
The International Organization for Standardization
(ISO) offers information and customer service
regarding international standards and standardizing
activities. ISO can also supply information on the
following subjects that are not controlled by ISO:
national standards, regional standards, regulations,
certification, and related activities. Consult the
member of ISO in your country.
International Organization for Standardization
(ISO)
1, rue de Varemb
Case postale 56
CH-1211 Genve 20
Switzerland
Telephone: +41 22 749 01 11
Facsimile: +41 22 733 34 30
E-mail: central@iso.ch
Web site: http://www.iso.ch
European classifications are established by the
Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).
CIMAC Central Secretariat
Lyoner Strasse 18
60528 Frankfurt
Germany
Telephone: +49 69 6603 1567
Facsimile: +49 69 6603 1566

SEBU6496-06

131
Reference Information Section
Reference Materials

i00382622

Warranty Information
SMCS Code: 1000

Engine Protection Plans


Extended Warranties and Service
Contracts
A wide variety of protection plans are available for
Caterpillar Engines. Consult your Caterpillar dealer
for detailed information on the specific programs and
coverages that are available.
Consult your Caterpillar dealer for information on a
plan that is tailored in order to fit your requirements.

132
Index Section

SEBU6496-06

Index
A
Actuator Control Linkage - Lubricate (If
applicable) ...........................................................
Heinzmann Actuators.........................................
Hydraulic Actuators............................................
Actuator Control Linkage - Replace.......................
Heinzmann Actuators.........................................
Hydraulic Actuators............................................
Removal and Installation....................................
After Starting Engine .............................................
Engaging the Driven Equipment ........................
After Stopping Engine............................................
Aftercooler Condensation - Drain ..........................
Air Starting Motor Lines Screen - Clean ................
Air Starting Motor Lubricator Bowl - Clean ............
Air Starting Motor Lubricator Oil Level - Check .....
Adjust the Lubricator ..........................................
Air Tank Moisture and Sediment - Drain................
Alternator - Inspect ................................................

65
65
65
65
66
66
65
51
51
54
66
67
67
68
68
68
69

B
Barring Device - Lubricate ..................................... 69
Electric Barring Device....................................... 69
Manual Barring Device....................................... 70
Battery Electrolyte Level - Check .......................... 70
Before Starting Engine .................................... 18, 46
Air Inlet System.................................................. 46
Cooling System.................................................. 46
Driven Equipment .............................................. 46
Electrical System ............................................... 46
Fuel System ....................................................... 47
Hydraulic Actuator System................................. 47
Lubrication System ............................................ 47
Starting System.................................................. 47
Walk-Around Inspection..................................... 46
Belts - Inspect/Adjust/Replace............................... 71
Adjusting the Alternator Belt .............................. 71
Adjusting the Fan Drive Belt .............................. 71
Inspection........................................................... 71
Replacement...................................................... 71
Burn Prevention..................................................... 15
Batteries............................................................. 15
Coolant............................................................... 15
Oils..................................................................... 15
C
Cold Weather Starting ...........................................
Jacket Water Heaters ........................................
Lubricating Oil Heaters ......................................
Requirements for Starting with Air .....................
Combustion Sensor - Clean/Inspect/Replace........
Connecting Rod Bearings - Inspect/Replace.........

47
48
48
48
71
73

Control Panel......................................................... 34
Control Panel ..................................................... 34
Engine Supervisory System............................... 34
Control Panel - Inspect .......................................... 73
Record the Data and Review the Data .............. 73
Cooling System Coolant (NGEC) - Change .......... 73
Clean the Cooling System ................................. 74
Cleaning a Cooling System that has Heavy
Deposits or Plugging ........................................ 75
Drain the Cooling System .................................. 74
Fill the Cooling System ...................................... 75
Cooling System Coolant Level - Check ................. 75
Add Coolant ....................................................... 76
Engines That Are Equipped With a Sight
Gauge .............................................................. 76
Engines That Are Not Equipped With a Sight
Gauge .............................................................. 76
Cooling System Coolant Sample (Level 1) Obtain .................................................................. 76
Cooling System Coolant Sample (Level 2) Obtain .................................................................. 77
Cooling System Level Switch - Inspect ................. 77
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add.................................................. 78
Add the SCA, If Necessary ................................ 78
Test the Concentration of the SCA..................... 78
Cooling System Water Temperature Regulator Replace................................................................ 79
Crankcase Blowby - Measure/Record ................... 79
Crankshaft Vibration Damper - Inspect ................. 80
Removal and Installation.................................... 81
Crushing Prevention and Cutting Prevention ........ 17
Customer Assistance........................................... 123
Outside of the USA and of Canada.................. 123
USA and Canada ............................................. 123
Customer Service ................................................ 123
Cylinder Pressure - Measure/Record .................... 81
Cylinders - Inspect (Inspect the Combustion
Chamber)............................................................. 81
D
Driven Equipment - Check.....................................
Check the Alignment..........................................
Every 10,000 Service Hours ..............................
Every 5000 Service Hours .................................
Driven Equipment - Inspect/Replace/Lubricate .....

82
82
82
82
83

E
Electrical System ...................................................
Grounding Practices ..........................................
Electrohydraulic Actuator - Inspect........................
Electrohydraulic Actuator - Recondition ................
Electrohydraulic System - Check/Adjust................
Check the Pressure Relief Valve .......................

19
19
83
84
85
85

SEBU6496-06

133
Index Section

Electrohydraulic System - Inspect ......................... 85


Check the Oil Level............................................ 85
Inspect the Lines, Connections, and
Components..................................................... 86
Electrohydraulic System Oil - Change................... 86
Electrohydraulic System Oil Filter - Change.......... 87
Emergency Stopping ............................................. 53
Emergency Stop Button ..................................... 53
Engine Air Cleaner Element (Single Element) Clean/Replace ..................................................... 87
Cleaning the Air Cleaner Elements.................... 88
Crankcase Air Cleaner....................................... 89
Servicing the Air Cleaner Elements ................... 87
Engine Air Cleaner Service Indicator - Inspect...... 90
Test the Service Indicator................................... 90
Engine Air Precleaner - Clean ............................... 91
Engine Crankcase Breather - Clean...................... 91
Engine Mounts - Check ......................................... 92
Engine Oil - Change .............................................. 92
Change the Engine Oil....................................... 92
Oil Change Interval ............................................ 92
Engine Oil Filter - Change ..................................... 93
Inspect the Used Oil Filter Elements.................. 96
Replacing the Engine Oil Filters During Engine
Operation ......................................................... 95
Replacing the Engine Oil Filters With the Engine
Stopped............................................................ 94
Engine Oil Level - Check ....................................... 96
Engine Oil Sample - Obtain ................................... 97
Obtain the Sample and the Analysis.................. 97
Engine Oil Temperature Regulator - Replace........ 98
Engine Operation................................................... 52
Operating the Engine and the Driven
Equipment ........................................................ 52
Partial Load Operation ....................................... 52
Engine Protective Device Connections - Inspect... 98
Engine Protective Devices - Check ..................... 100
Visual Inspection.............................................. 100
Engine Starting ................................................ 19, 46
Engine Stopping .............................................. 19, 53
Engine Valve Lash - Inspect/Adjust ..................... 100
Check the Timing of the Crankshaft and
Camshaft........................................................ 100
Engine Valve Lash ........................................... 101
Gas Admission Valve ....................................... 101
Valve Bridge..................................................... 101
Engine Valve Rotators - Inspect .......................... 101
Exhaust Bypass - Recondition............................. 102
Exhaust Shields - Inspect .................................... 102

Foreword ................................................................. 5
California Proposition 65 Warning ....................... 4
Literature Information........................................... 4
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 5
Safety................................................................... 4
Fuel System Fuel Filter Differential Pressure Check................................................................. 102

Lifting and Storage ................................................ 32

Features and Controls ...........................................


Fire Prevention and Explosion Prevention ............
Fire Extinguisher ................................................
Lines, Tubes and Hoses ....................................

34
16
17
17

G
Gas Admission Valve - Recondition .................... 103
Gas Admission Valve Seals - Inspect/Replace.... 103
Gas Pressure Regulator - Inspect/Replace ......... 104
Gas Shutoff Valve - Inspect ................................. 104
General Hazard Information .................................. 13
Asbestos Information ......................................... 14
Containing Fluid Spillage ................................... 14
Dispose of Waste Properly ................................ 15
Fluid Penetration................................................ 14
Pressure Air and Water...................................... 14
General Information............................................... 21
H
Hoses and Clamps - Inspect/Replace ................. 105
Replace the Hoses and the Clamps ................ 105
I
Ignition System Spark Plugs - Check/Adjust ....... 106
Cleaning the Spark Plug .................................. 108
Inspecting the Spark Plug ................................ 108
Installing the Spark Plug .................................. 109
Removing the Spark Plug ................................ 107
Ignition System Spark Plugs - Replace ............... 109
Ignition Systems .................................................... 18
Electronic Ignition............................................... 18
Magneto ............................................................. 18
Important Safety Information ................................... 2
Inlet Air System - Inspect...................................... 110
Inlet Gas Manifold and Piping - Inspect/Replace .. 110
L

M
Magnetic Pickups - Clean/Inspect ........................ 110
Magneto Drive Coupling - Inspect ........................ 111
Maintenance Interval Schedule (G3612 and G3616
Engines That Have a 10.5:1 or an 11:1 Compression
Ratio and Use Natural Gas)................................. 61

134
Index Section

Maintenance Interval Schedule (G3612 and G3616


Engines That Have a 9.2:1 Compression Ratio and
Use Wellhead or Natural Gas)............................. 63
Maintenance Interval Schedule (G3612 and G3616
Engines That Use Bio-Gas) ................................. 59
Maintenance Log ................................................. 126
Maintenance Records.......................................... 125
Maintenance Section ............................................. 55
Manual Stop Procedure......................................... 53
Model View Illustrations......................................... 22
Model Views and Specifications ............................ 22
Mounting and Dismounting.................................... 17
O
Operation Section.................................................. 32
Ordering Replacement Parts ............................... 124
Overhaul (In-Frame) ............................................. 111
In-Frame Overhaul Information......................... 112
Scheduling an In-Frame Overhaul .................... 111
Overhaul (Major)................................................... 113
Major Overhaul Information .............................. 113
Scheduling a Major Overhaul............................ 113
Overhaul (Top End) .............................................. 114
Scheduling a Top End Overhaul ....................... 114
Top End Overhaul Information .......................... 114
Overhaul Considerations ...................................... 115
Overhaul Information ........................................ 115

SEBU6496-06

Reference Material .............................................. 129


Additional Reference Material.......................... 130
Coolants........................................................... 129
Fuels ................................................................ 129
Lubricants ........................................................ 129
Miscellaneous .................................................. 129
Reference Materials ............................................ 125
Refill Capacities..................................................... 55
Refill Capacities and Recommendations............... 55
Cooling System.................................................. 56
Fuel .................................................................... 56
Hydraulic Actuator System................................. 55
Lubrication System ............................................ 55
S
Safety Messages ..................................................... 6
Safety Section ......................................................... 6
Specifications ........................................................ 26
Drives and Gear Trains ...................................... 27
Engine Specifications......................................... 26
Reference Weights ............................................ 28
Starting Motor - Inspect ........................................ 118
Starting the Engine ................................................ 48
Automatic Starting.............................................. 49
Manual Starting.................................................. 49
Purging Unburned Gas ...................................... 48
Starting with Jump Start Cables ............................ 50

Plate Locations and Film Locations....................... 30


Engine Identification........................................... 30
Engine Information Plate.................................... 30
Serial Number Plate........................................... 30
Prechamber Check Valves - Clean....................... 117
Prechamber Check Valves - Replace................... 118
Prelube Pump - Inspect ........................................ 118
Air Prelube Pump.............................................. 118
Electric Prelube Pump ...................................... 118
Product Description ............................................... 24
Engine Service Life ............................................ 25
Product Identification Information .......................... 30
Product Information Section .................................. 21
Product Lifting........................................................ 32
Engine Lifting with a Generator.......................... 32
Product Storage..................................................... 33
Generator Storage ............................................. 33

Table of Contents..................................................... 3
Turbocharger - Clean (Cleaning with Dry
Particles)............................................................. 119
Turbocharger - Inspect ........................................ 120
Turbocharger Cleaner Tube - Replace ................ 121

R
Reference Information ........................................... 30
Reference Information Section ............................ 123

V
Valve Data Sheet................................................. 127
Valve Stem Projection - Measure/Record............ 121
W
Walk-Around Inspection ...................................... 122
Inspect the Engine for Leaks and for Loose
Connections ................................................... 122
Warranty Information ........................................... 131
Engine Protection Plans................................... 131
Water Pump - Inspect .......................................... 122
Welding on Engines with Electronic Controls ........ 21

Product and Dealer Information


Note: For product identification plate locations, see the section Product Identification Information in the Operation
and Maintenance Manual.
Delivery Date:

Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:

Dealer Information
Name:

Branch:

Address:

Dealer Contact
Sales:
Parts:
Service:

Phone Number

Hours

2005 Caterpillar
All Rights Reserved

Printed in U.S.A.