Documente Academic
Documente Profesional
Documente Cultură
April 2010
Operation and
Maintenance
Manual
G3600 Engines
BLB1-Up (Engine)
BKE1-Up (Engine)
BEN1-Up (Engine)
4ZS1-Up (Engine)
SAFETY.CAT.COM
i03684547
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7563-09 3
Table of Contents
Operation Section
Lifting and Storage ................................................ 30
Maintenance Section
Refill Capacities .................................................... 54
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.
SEBU7563-09 5
Foreword
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.
6 SEBU7563-09
Safety Section
Safety Messages
Safety Section
i02602825
Safety Messages
SMCS Code: 1000; 7405
g01048357
Illustration 1
Right side view
SEBU7563-09 7
Safety Section
Safety Messages
g01048362
Illustration 2
Left side view
g00123168
g00299841
(2) Crankcase Covers
The safety message for the crankcase covers is
located on the rearmost crankcase covers.
Improper lift rigging can allow unit to tumble caus-
ing injury and damage.
g00123185
g00299818
i02040045
Additional Messages
SMCS Code: 1000; 7405
g01049170
Illustration 3
Right side view
SEBU7563-09 11
Safety Section
Additional Messages
g01049171
Illustration 4
Left side view
There may be several specific messages on the (1) Removal of the Prechamber
engine. The exact location of the messages and the Assembly
description of the messages are reviewed in this
section. Please become familiar with all messages.
The notices for the removal of the prechamber
assemblies are located on each valve cover.
Ensure that all of the messages are legible. Clean
the messages or replace the messages if the words
cannot be read or if the pictures are not visible. When
the messages are cleaned, use a cloth, water, and
soap. Do not use solvent, gasoline, or other harsh
chemicals to clean the messages. Solvents, gasoline,
or harsh chemicals could loosen the adhesive that
secures the messages. The messages that are
loosened could drop off of the engine. g00902999
Replace any damaged messages or missing Before the prechamber assembly is removed, drain
messages. If a message is attached to a part of the the coolant and remove the spark plugs in order to
package that is replaced, install a new message prevent damage. Tighten the nuts that are located
on the replacement part. Any Caterpillar dealer can on the wire assembly for the combustion sensor to
provide new messages. 9.5 ± .5 N·m (85 ± 5 lb in). Do not overtighten the
nuts.
12 SEBU7563-09
Safety Section
General Hazard Information
i02602865
g00702020
Illustration 6
Refer to Special Publication, NENG2500, “Caterpillar • Use exhaust ventilation on permanent machining
Dealer Service Tools Catalog” for the following items: jobs.
• Tools that are suitable for collecting fluids and • Wear an approved respirator if there is no other
equipment that is suitable for collecting fluids way to control the dust.
• Comply with applicable rules and regulations Any contact with hot coolant or with steam can cause
for the work place. In the United States, use severe burns. Allow cooling system components to
Occupational Safety and Health Administration cool before the cooling system is drained.
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”. Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
• Obey environmental regulations for the disposal
of asbestos. Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
• Stay away from areas that might have asbestos with a bare hand. Remove the filler cap slowly in
particles in the air. order to relieve pressure.
Dispose of Waste Properly 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 to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
g00706404 the eyes. Always wear protective glasses for servicing
Illustration 9
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations. i01372262
Always use leakproof containers when you drain Fire Prevention and Explosion
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
Prevention
SMCS Code: 1000; 4450; 7405
i01480768
Burn Prevention
SMCS Code: 1000; 4450; 7405
Coolant Illustration 10
g00704000
When the engine is at operating temperature, the All fuels, most lubricants, and some coolant mixtures
engine coolant is hot. The coolant is also under are flammable.
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
SEBU7563-09 15
Safety Section
Fire Prevention and Explosion Prevention
Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause deterioration. The hoses must be properly routed.
a fire. Fire may cause personal injury and property The lines and hoses must have adequate support
damage. and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after Oil filters and fuel filters must be properly installed.
an emergency shutdown. 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.
Lines, Tubes and Hoses Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
Do not bend high pressure lines. Do not strike high one will be injured by flying debris.
pressure lines. Do not install any lines that are bent
or damaged.
i01372247
Unless other maintenance instructions are provided, If the mode control switch is in the AUTOMATIC or
never attempt adjustments while the engine is START position and the wiring harness is connected,
running. the ignition system may discharge and a spark plug
will ignite. The spark plug will ignite any gas that has
Stay clear of all rotating parts and of all moving accumulated in that cylinder. The crankshaft and the
parts. Leave the guards in place until maintenance driven equipment can move. Personal injury may
is performed. After the maintenance is performed, result. The driven equipment could be damaged. Gas
reinstall the guards. that has accumulated in the exhaust system can also
be ignited.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
Turn the mode control switch to the STOP or If there is a possibility that unburned gas remains in
OFF/RESET position before connecting the wiring the exhaust system, refer to the purge procedure in
harness. When the mode control switch is in the this Operation and Maintenance Manual, “Engine
STOP or OFF/RESET position, the ignition system Starting” topic in the Operation Section.
is disabled.
Start the engine from the operator's compartment or
from the engine start switch.
i00659904
Before Starting Engine Always start the engine according to the procedure
that is described in the Operation and Maintenance
SMCS Code: 1000 Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
Inspect the engine for potential hazards. prevent major damage to the engine components.
Knowing the procedure will also help to prevent
Before starting the engine, ensure that no one is on, personal injury.
underneath, or close to the engine. Ensure that the
area is free of personnel. To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Ensure that the engine is equipped with a lighting properly, check the water temperature and the oil
system that is suitable for the conditions. Ensure that temperature during heater operation.
all lights work properly.
Engine exhaust contains products of combustion
All protective guards and all protective covers must which can be harmful to your health. Always start the
be installed if the engine must be started in order engine and operate the engine in a well ventilated
to perform service procedures. To help prevent an area. If the engine is started in an enclosed area,
accident that is caused by parts in rotation, work vent the engine exhaust to the outside.
around the parts carefully.
i00659907
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are Engine Stopping
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent SMCS Code: 1000
engine damage.
To avoid overheating of the engine and accelerated
On the initial start-up of a new engine or an engine wear of the engine components, stop the engine
that has been serviced, be prepared to stop the according to the instructions in this Operation and
engine if an overspeed condition occurs. This may Maintenance Manual, “Engine Stopping” topic
be accomplished by shutting off the fuel supply to the (Operation Section).
engine, or shutting off the ignition system.
Use the Emergency Stop Button (if equipped) ONLY
See the Service Manual for repairs and for in an emergency situation. Do not use the Emergency
adjustments. 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
i02136012
corrected.
Engine Starting On the initial start-up of a new engine or an engine
SMCS Code: 1000 that has been serviced, make provisions to stop
the engine if an overspeed occurs. This may be
If a warning tag is attached to the engine start switch accomplished by shutting off the fuel supply to the
or to the controls, DO NOT start the engine or move engine, or shutting off the ignition system.
the controls. Consult with the person that attached
the warning tag before the engine is started.
i01032810
Electrical System
SMCS Code: 1000; 1400
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.
Product Information
Section
g00892828
Illustration 12
Right hand view (in-line engine)
(1) Gas shutoff valve (4) Integrated Combustion Sensing Module (7) Crankcase pressure sensor
(2) Fuel actuator (ICSM) (8) Engine oil level gauge
(3) Ignition transformer (5) Engine oil filter (9) Engine oil filler
(6) Junction box
20 SEBU7563-09
Product Information Section
Model Views and Specifications
g00892830
Illustration 13
Left hand view (in-line engine)
(1) Exhaust bypass actuator (3) Hydraulic oil tank (5) Hydraulic oil filter
(2) Air choke actuator (4) Hydraulic oil pump
g00893222
Illustration 14
Right hand view (vee engine)
(1) Gas shutoff valve (5) Engine oil filter (10) Engine oil filler
(2) Exhaust bypass actuator (6) Junction box
(3) Fuel actuator (7) Ignition rail
(4) Integrated Combustion Sensing Module (8) Crankcase pressure sensor
(ICSM) (9) Engine oil level gauge
SEBU7563-09 21
Product Information Section
Model Views and Specifications
g00893223
Illustration 15
Left hand view (vee engine)
(1) Ignition transformer (3) Air choke actuator (6) Hydraulic oil pump
(2) Integrated Combustion Sensing Module (4) Ignition rail (7) Hydraulic oil filter
(ICSM) (5) Hydraulic oil tank
The inlet manifold air pressure is controlled by the For more detailed information on the control system,
air inlet choke and the exhaust bypass valve. The refer to Systems Operation, “Electronic Control
ECM determines the air pressure that is required to System Operation”.
maintain the correct air/fuel ratio.
The engine has two cooling circuits: a jacket water
Each cylinder has an ignition transformer. To circuit and a separate circuit for the aftercooler and
initiate combustion, the ECM sends a pulse of engine oil cooler. Water temperature regulators
approximately 108 volts to the primary coil of each are used in both circuits in order to maintain the
ignition transformer at the appropriate time and for correct operating temperatures. Water temperature
the appropriate duration. The transformer increases regulators can be installed in order to regulate the
the voltage which creates a spark across the spark inlet or outlet temperature of the water.
plug electrode.
A gear-driven centrifugal pump circulates the jacket
The electronic control system controls the ignition water coolant from an external source. The coolant
timing. The control system monitors changes in is circulated through the water jacket to the cylinder
the load. The control system modifies the timing heads. The coolant flows through water manifolds to
in response to the change in the load. The timing the outlet. The coolant flows through a remote water
can also be modified in order to compensate for temperature regulator and to a heat exchanger. The
detonation that is detected. coolant is returned to the engine.
The fuel flow is the main factor in the calculation of The engine oil and the combustion air are cooled in a
the engine load. Zero fuel flow is zero load. A fuel separate circuit. A gear-driven pump pulls the coolant
flow that is greater than zero is used to calculate a from the heat exchanger. Some of the coolant goes
percentage of the indicated load. to the engine oil cooler. Most of the coolant goes
to the aftercooler. The coolant returns to the heat
At loads that are less than 40 percent, the air/fuel exchanger.
ratio is controlled by the air choke actuator which is
trimmed by the exhaust port temperatures. A gear-driven pump pumps the engine oil. The
temperature of the engine oil is regulated. The engine
The engine has an Integrated Combustion Sensing oil is filtered prior to circulation in the cylinder block.
Module (ICSM) for each bank of cylinders. Each
cylinder exhaust port has a thermocouple that is
monitored by an ICSM. The ICSM monitors the
Engine Service Life
actual exhaust port temperatures for one bank of Engine efficiency and maximum utilization of engine
cylinders. The ICSM calculates an average exhaust
performance depend on the adherence to proper
port temperature for the bank of cylinders. The ECM
operation and maintenance recommendations. This
sends a map of the desired exhaust port temperature includes use of the recommended lubricants, fuels,
to the ICSM. The ICSM calculates the difference
and coolant/antifreezes. For additional information
between the average exhaust port temperature and
about coolant analysis, see the Special Publication,
the desired exhaust port temperature. The ICSM “Caterpillar Gas Engine Lubricant, Fuel and Coolant
communicates the information to the ECM. The ECM
Recommendations” or consult your Caterpillar dealer.
controls the air choke actuator in order to maintain
the desired exhaust temperature. For the engine maintenance that is required, see this
Operation and Maintenance Manual, “Maintenance
When the load reaches approximately 40 percent,
Interval Schedule” (Maintenance Section).
the air/fuel ratio is controlled by the exhaust bypass
actuator which is trimmed by the combustion burn
time.
i02600144
Specifications
SMCS Code: 1000
Engine Specifications
Table 1
G3600 Engine Specifications
G3606 G3608 G3612 G3616
Operating rpm 750 to 1000 750 to 1000 750 to 1000 750 to 1000
Low idle rpm 550 550 550 550
Arrangement and In-line In-line 50 degree V-12 50 degree V-16
cylinders 6 8
Bore 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch)
Stroke 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch)
Aspiration TA TA TA TA
Compression ratio 9:1 9:1 9:1 9:1
10.5:1 10.5:1
Displacement per 21.2 L (1294 in3) 21.2 L (1294 in3) 21.2 L (1294 in3) 21.2 L (1294 in3)
cylinder
Total displacement 127.2 L (7762 in3) 169.6 L (10 350 in3) 254.4 L (15 528 in3) 339.2 L (20 704 in3)
Mean velocity of the 9 m/s (1772 ft/min) 9 m/s (1772 ft/min) 9 m/s (1772 ft/min) 9 m/s (1772 ft/min)
pistons at 900 rpm
Mean velocity of the 10 m/s (1969 ft/min) 10 m/s (1969 ft/min) 10 m/s (1969 ft/min) 10 m/s (1969 ft/min)
pistons at 1000 rpm
Flywheel rotation Counterclockwise Counterclockwise Counterclockwise Counterclockwise
(standard)
Fuel, Lubricant, and See this Operation and Maintenance Manual, “Refill Capacities and Recommendations”
Coolant (Maintenance Section). Also, see the Application and Installation Guide.
Method of starting Air starting motors Air starting motors Air starting motors Air starting motors
Performance of the See the Application See the Application See the Application See the Application
cooling system and Installation Guide. and Installation and Installation Guide. and Installation Guide.
Guide.
Maximum allowable 3 kPa 3 kPa 3 kPa 3 kPa
exhaust back pressure (12 inches of H2O) (12 inches of H2O) (12 inches of H2O) (12 inches of H2O)
Maximum allowable 3.7 kPa 3.7 kPa 3.7 kPa 3.7 kPa
inlet air restriction (15 inches of H2O) (15 inches of H2O) (15 inches of H2O) (15 inches of H2O)
Air cleaners Remote Remote Remote Remote
24 SEBU7563-09
Product Information Section
Model Views and Specifications
g00891513 g00790805
Illustration 16 Illustration 19
G3606 Engine design G3616 Engine design
(A) Gas admission valves (A) Gas admission valves
(B) Inlet valves (B) Inlet valves
(C) Exhaust valves (C) Exhaust valves
g00891514
Illustration 17
G3608 Engine design
(A) Gas admission valves
(B) Inlet valves
(C) Exhaust valves g00790861
Illustration 20
SAE standard engine crankshaft rotation
In-line engines and vee engines
(1) Jacket water pump
(2) Aftercooler and oil cooler pump
(3) Oil pump
g00790801
Illustration 18
G3612 Engine design
(A) Gas admission valves
(B) Inlet valves
(C) Exhaust valves
SEBU7563-09 25
Product Information Section
Model Views and Specifications
g00790864
Illustration 21
SAE standard engine crankshaft rotation g00891685
Illustration 22
In-line engines and vee engines SAE standard engine crankshaft rotation
(4) Water outlet In-line engines and vee engines
(5) Water inlet
(1) Crankshaft
(6) Oil outlet
(2) Idler
(7) Oil inlet
(3) Idler
(4) Jacket water pump
Table 2 (5) Aftercooler and oil cooler pump
Front Drives (6) Auxiliary pump
(7) Oil pump
Component Speed(1)
Table 3
Jacket water pump 2522
Front Gear Train
Aftercooler and oil cooler pump 2522
Gear Number Of
Oil pump 1524 Teeth
(1) The speed of the component is listed for an engine that is (1) Crankshaft 96
operating at 1000 rpm. For an engine that is operating at
900 rpm, multiply the speed of the component by .9. For an (2) Idler 68
engine that is operating at 800 rpm, multiply the speed of the
component by .8. (3) Idler 67
(4) Jacket water pump 38
(5) Aftercooler and oil cooler Pump 38
(6) Auxiliary pump 43
(7) Oil pump 63
26 SEBU7563-09
Product Information Section
Model Views and Specifications
g01056736
Illustration 23
SAE standard engine crankshaft rotation
In-line engines
(1) Crankshaft
(2) Large cluster idler
(3) Small cluster idler
(4) Camshaft
g00891688
Illustration 24
SAE standard engine crankshaft rotation
Vee engines
(1) Crankshaft
(2) Large cluster idler
(3) Small cluster idler
(4) Camshaft
(5) Idler
Table 4
Reference Weights
Table 5
Module 1360 kg (2998 lb) 1410 kg (3109 lb) 1650 kg (3638 lb) 1650 kg (3638 lb)
Mounting base 7820 kg (17 240 lb)(2) 8640 kg (19 048 lb) 12 700 kg (28 000 lb) 12 700 kg (28 000 lb)
8170 kg (18 012 lb)(3)
Coupling 590 kg (1300 lb) 590 kg (1300 lb) 977 kg (2154 lb) 977 kg (2154 lb)
Total 33 750 kg (74 406 lb)(2) 39 040 kg (86 068 lb) 56 266 kg (124 045 lb) 61 074 kg (134 645 lb)
34 070 kg (75 111 lb)(3)
(1) The weights of the engines that are listed includes attachments that are mounted on the engines. The engine weights are dry weights.
(2) Single bearing generator
(3) Double bearing generator
Table 6
Engine Identification
Caterpillar engines are identified with serial numbers,
with performance specification numbers, and with Illustration 26
g00361974
arrangement numbers. In some of the cases,
modification numbers are used. These numbers The Information Plate is on the side of the cylinder
are shown on the Serial Number Plate and the block above one of the crankshaft inspection
Information Plate that are mounted on the engine. covers. The following information is stamped on
the Information Plate: engine's maximum altitude,
Caterpillar dealers need these numbers in order to horsepower, high idle, full load rpm, fuel settings, and
determine the components that were included with other information.
the engine. This permits accurate identification of
replacement part numbers.
i01519312
Table 7
Record Of Reference Numbers
Item Identification
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
30 SEBU7563-09
Operation Section
Lifting and Storage
i02046791
Product Storage
SMCS Code: 7002
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.
32 SEBU7563-09
Operation Section
Features and Controls
Monitoring System
SMCS Code: 1900; 7400; 7450; 7451
Table 8
(Table 8, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)
(Table 8, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)
Warning Always 175
E100 5
Low Engine Oil (1) On(1) kPa
Pressure(2) Engine
(Under 600 RPM) Always 100
E040 Shutdown 0
On(1) kPa
(3)
This item is not programmable.
Warning Always 400
E100 5
Low Engine Oil (1) On(1) kPa
Pressure(2) Engine
(Over 600 RPM) Always 350
E040 Shutdown 0
On(1) kPa
(3)
Warning 650
E125 On
(1) kPa
High Engine Oil 600 to 1200
Engine 25 Customer
Pressure Always 1000 kPa
E126 Shutdown
On(1) kPa
(3)
Warning 100
E129 Off 15 Customer
High Oil Filter (1) kPa
Differential Engine 0 to 350 kPa
Pressure Always 300
E130 Shutdown 25 Factory
On(1) kPa
(3)
Warning
E127 Off 5 kPa Customer
Low Oil Filter (1) 1 to 60
Differential Engine 10 0 to 150 kPa
Pressure E128 Shutdown Off 3 kPa Factory
(3)
High Fuel Warning
E223 60°C 20 0° to 60°C
Temperature (1)
Low Fuel On
Warning
Differential E864 5 kPa 60 0 to 100 kPa
(1) Customer
Pressure
High Fuel
Warning Always 160
Differential E865 30 0 to 195 kPa
(1) On(1) kPa
Pressure
High System Warning 34
E050 On 20 This item is not programmable.
Voltage (1) volts
(continued)
SEBU7563-09 35
Operation Section
Features and Controls
(Table 8, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)
(Table 8, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)
Warning Always
20 This item is not programmable.
High Inlet Air (1) On(1)
Restriction E385 Engine
(Right) This item is not
Shutdown Off 0 Customer 0 to 65
programmable.
(3) 5.23
Warning Always kPa
20 This item is not programmable.
(1) On(1)
High Inlet Air
E384 Engine This item is not
Restriction (Left)
Shutdown Off 0 Customer programmable. 0 to 65
(3)
(1) This parameter is permanently active. This parameter cannot be turned off.
(2) This event will not appear on the monitor.
Table 9
ICSM Monitoring
Delay Security Delay
System Trip Trip Point
Description Event Code State Time Level Range
Response Point Range
(Seconds) Password (Seconds)
High Exhaust Warning (1) 600°C
Temperature (Port) E801 through 100° to
Engine Off 10
E816 Shutdown 650°C 1000°C
(3)
Exhaust Port Warning (1) On 50°C 240
Temperature High E821 through
Deviation Engine
E836 Shutdown Off 100°C 600
(3) 10° to
Exhaust Port Warning (1) On 120°C 500°C
Temperature Low E841 through
Deviation Engine 300 Customer 1 to 1200
E856 Shutdown Off 400°C
(3)
High Turbo Turbine E245 (Right Warning (1) 600°C
Inlet Temperature Bank) 400 to 700
Engine
E246 (Left Shutdown 650°C °C
Bank) (3)
On 10
High Turbo Turbine E243 (Left Warning (1) 570°C
Outlet Temperature Bank) 400 to
Engine
E244 (Right Shutdown 600°C 650°C
Bank) (3)
38 SEBU7563-09
Operation Section
Features and Controls
i02600163
Control Panel
SMCS Code: 7451
g00799615
Illustration 29
Keypad
Table 13
Miscellaneous Status
Air/Fuel Ratio Status
A/F Ratio Desired A/F Fuel Quality The “Miscellaneous Status” screen displays the
Ratio parameters that are listed in Table 17.
Air Pressure Desired Air Specific Gravity Table 17
Pressure
Miscellaneous Status
Air Flow Fuel Flow Feedback Status
Detonation Level Service Hours Battery Voltage
Engine Multi Strike Engine Cylinders
Configuration Feature
Multi Strike Mode Multi Strike Multi Strike
Switch Status
40 SEBU7563-09
Operation Section
Features and Controls
Table 18
Actual Timing
Base Timing
Relay Status
Speed Status Burn Times
Mode Status
The “Burn Times” screen can display either the
E-Stop Status “Filtered Burn Times” or the “Unfiltered Burn Times”.
Driven Equipment “Filtered Burn Times” displays an average of the
combustion burn time for each bank of cylinders. The
Prelube Solenoid desired combustion burn time and the time for each
Prelube Oil Pressure Switch individual cylinder are also displayed. “Unfiltered
Burn Times” displays the actual instantaneous
Initiate Contact combustion burn time for each individual cylinder.
Start Solenoid The desired combustion burn time and the average
combustion burn time for each bank of cylinders are
Fuel Control Solenoid also displayed.
Hydrax Oil Pressure Switch
Table 21
Normal Stop
Burn Times
Filtered Unfiltered
Not Used
Even Bank Odd Bank
Option 9 of this screen is not used at this time.
Even Bank Odd Bank
Menu Desired Burn Fuel Correction
Table 22
Ignition Timing
Temperatures
The “Ignition Timing” screen displays the current Exhaust Turbo
degrees before top center for the timing of each
cylinder. The values for the programmable desired Even Bank Odd Bank
timing are listed. The current active selected timing Even Bank Odd Bank
is indicated.
Desired Temp Fuel Correction
Secondary Voltages
The “Secondary Voltages” screen display the voltage
drop across the spark plugs as a percent.
SEBU7563-09 41
Operation Section
Features and Controls
Table 24
Codes
Events and Diagnostics
g00824884
Illustration 30
Table 25 Indicators
Display Setup
The remote panel has three indicators for the status
of the engine operation.
LCD Contrast Backlighting
Offset Lights On
Metric
English
Imperial
Units
Menu
Pressing “?” returns you to the “Menu” screen.
42 SEBU7563-09
Operation Section
Features and Controls
g00824980 g00825028
Illustration 31 Illustration 32
(1) “ENGINE ON” indicator “MANUAL PRELUBE” switch and “PRELUBE ACTIVE” indicator
(2) “ACTIVE ALARM” indicator
(3) “ENGINE FAILURE” indicator
The “MANUAL PRELUBE” switch enables the
operator to prelube the engine by pressing the switch.
Illumination of green “ENGINE ON” indicator (1)
indicates normal operation. A lamp behind the switch illuminates when the
prelube is active. This is the “PRELUBE ACTIVE”
Yellow “ACTIVE ALARM” indicator (2) illuminates if indicator. If the mode control switch is in the “AUTO”
the control system initiates a warning for an event position and the remote start/stop initiate contact
or a diagnostic condition. closes, the prelube system will operate and the lamp
will illuminate. The lamp will also illuminate during
Red “ENGINE FAILURE” indicator (3) illuminates if the postlube.
the control system shuts down the engine due to
an event or a diagnostic condition. The “ENGINE Note: The ECM is programmed to provide engine
FAILURE” indicator also illuminates if an emergency lubrication after the engine is shut off. The typical
stop is performed. duration of the postlube is 180 seconds.
g00825037
Illustration 33
Mode control switch in the “AUTO” position
Engine Diagnostics
i03681549
Configuration Parameters
SMCS Code: 1000; 1900; 1901; 1902
• Ensure that the areas around the rotating parts are • Wiring that is worn or frayed
clear.
Inspect the gauge panel and the control panel
for good condition. Reset any shutoff or alarm
Air Inlet System components.
• Ensure that the air inlet piping and the air filters
are in place.
Starting System
• Ensure that the barring device is fully disengaged.
• Drain moisture and sediment from the air tank and
g01140341 from any other air piping.
Illustration 35
Engine oil level gauge
• Check the oil level in the lubricator for the air
(1) “ADD” mark starting motor. Keep the lubricator at least half full.
(2) “RUNNING FULL” mark Add oil, if necessary. Use nondetergent “10W” oil
(3) “STOPPED FULL OIL COLD NO PRELUBE” mark
for temperatures that are greater than 0 °C (32 °F).
Use air tool oil for temperatures that are below
• Check the engine oil level. Add engine oil if 0 °C (32 °F).
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 • Check the air pressure before starting. Starting
motors with vanes require air pressure in a range
oil to use, refer to this Operation and Maintenance of 620 to 1550 kPa (90 to 225 psi). Air turbines
Manual, “Refill Capacities and Recommendations”
require air pressure in a range of 414 to 620 kPa
(Maintenance Section).
(60 to 90 psi) or 690 to 1034 kPa (100 to 150 psi).
• Check for leaks at the following components: • Open the air supply valve for the air starting motor.
crankshaft seals, crankcase, engine oil filters,
plugs for the engine oil gallery, sensors, and valve Note: If the engine is equipped with a system for
covers.
external support, prepare the system before starting
the engine. Ensure that all of the systems for engine
• Inspect the tubes, tee pieces, and clamps on the support are enabled. Perform all prestart checks for
crankcase breathers.
the control system.
• If the engine has an air cleaner for crankcase
ventilation, inspect the air cleaner service indicator. i02601106
Service the air cleaner filter element when the
yellow diaphragm enters the red zone, or the red Cold Weather Starting
piston locks in the visible position.
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Fuel System See Gas Engines Application and Installation Guide,
LEBW4980 for more information on the following
• Inspect the fuel lines for loose fittings and leaks. topics:
Ensure that the fuel lines are properly clamped.
• Recommendations for the size and installation of
• Ensure that the fuel is supplied to the engine at the jacket water heaters and oil heaters
correct pressure for the application.
Requirements for Starting with Air Note: 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 Do not start the engine or move any of the controls
is necessary. Ensure a sufficient supply of air if there is a “DO NOT OPERATE” warning tag or
pressure for cold weather starting. Do not exceed the similar warning tag attached to the start switch or to
maximum air pressure for the starting motor. the controls.
• The engine control is set to the STOP mode and b. For industrial engines, unload the compressor
the gas shutoff valve does not close. or pump. Disengage the clutch (if equipped).
Place the transmission and/or other
• Unsuccessful successive attempts to start the attachments for the power take-off in
engine NEUTRAL.
4. Continue with your previous procedure. 4. Observe the “Configuration” screen on Caterpillar
Electronic Technician (ET) or on the Advisor
panel. Verify that the “FUEL ENERGY CONTENT”
Automatic Starting and the “SPECIFIC GRAVITY” are correct.
2. Ensure that the driven equipment is unloaded. The engine speed should stabilize at low idle rpm.
Perform these checks during the warm-up:
a. For generator set engines, open the main
circuit breaker. • Check all of the pressure gauges.
• Inspect the engine for leaks.
• Listen for unusual noises.
SEBU7563-09 49
Operation Section
Engine Starting
When all systems are normal, the rpm may be Apply the load according to the requirements for
increased. temperatures:
Ensure that the oil pressure and the fuel pressure are Before you apply a load up to 49 percent of the
in the normal ranges. After the engine has started rated load, the minimum temperature of the jacket
and the warm-up is complete, the engine can be water is 38 °C (100 °F). The minimum engine oil
operated at rated rpm and low load. The engine will temperature is 10 °C (50 °F).
reach normal operating temperature faster if the
engine is operated at low rpm and with a low power Before you apply a load between 50 and
demand. This procedure is more effective than idling 100 percent of the rated load, the minimum
the engine with no load. The engine should reach temperature of the jacket water is 50 °C (122 °F).
normal operating temperature in a few minutes. The minimum engine oil temperature is 50 °C
(122 °F).
i02606873
Continue to check the gauges and the driven
After Starting Engine equipment.
Table 27
BSOC for G3600 Engines
0.304 g/bkw h (.00052 lb/bhp h)
52 SEBU7563-09
Operation Section
Engine Stopping
i02601387
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.
NOTICE
Do not start the engine until the problem necessitating
the emergency stop has been located and corrected. Illustration 37
g00792865
i01748696
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of engine components.
1. Disengage or unload the driven equipment. The engine will coast to a stop. Ensure that any
system that provides external support to the engine
a. For generator set engines, open the main is secured after the engine is stopped. Turn off
circuit breaker. the auxiliary systems for engine operation after the
engine is stopped.
b. For industrial engines, unload the compressor
or pump. Disengage the clutch (if equipped). The power to the control panel will be maintained
Place the transmission and/or other until the engine control switch is turned to the
attachments for the power take-off in “OFF/RESET” position.
NEUTRAL.
i02508920
Note: Extended idling can cause excessive oil
consumption and related problems. See this
Operation and Maintenance Manual, “Engine
After Stopping Engine
Operation” topic (Operation Section). SMCS Code: 1000
2. Reduce the engine rpm to low idle.
• Check the engine crankcase oil level. Maintain the
oil level between the “ADD” and “FULL” marks
Note: If the cooldown feature is not utilized, operate on the “ENGINE STOPPED” side of the oil level
the engine at low idle rpm for a cooldown period of gauge.
approximately one to two minutes before stopping
the engine.
• If necessary, perform minor adjustments. Repair
any leaks and tighten loose bolts.
3. Use one of the following methods in order to stop
the engine:
• Note the service hour reading. Perform the
maintenance that is scheduled in this Operation
and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section).
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Refill Capacities and Recommendations section of
this manual. Failure to do so can cause engine dam-
age.
Table 28
i03679347
Approximate Refill Capacity of Crankcase
Refill Capacities and Sales Model Liters US Gallons
Recommendations G3606 708 187
G3608 912 241
SMCS Code: 1348; 1395; 7560
G3612 1030 272
NOTICE G3616 1325 351
Every attempt is made to provide accurate, up to date
information. By use of this document you agree that
Caterpillar Inc. is not responsible for errors or omis- Hydraulic Actuator System
sions. The information that is provided are the latest
recommendations for Cat gas engines. This informa- Hydraulic Oil
tion supersedes all previous recommendations which
have been published for Cat gas engines. Special flu- Caterpillar offers two hydraulic oil products:
ids may be required for some engines and it will be
necessary to continue to use these special products.
Refer to the applicable Operation and Maintenance
• Cat HYDO Advanced 10
Manual.
• Cat Bio HYDO Advanced
NOTICE Cat HYDO Advanced 10 (Hydraulic Oil)
These recommendations are subject to change with-
out notice. Consult your local Caterpillar dealer for the CatHYDO Advanced 10 fully replaced CatHYDO oil.
most up to date recommendations. CatHYDO is no longer available.
• Cat Natural Gas Engine Oil (NGEO) EL350 • Cat Arctic TDTO
Cat Bio HYDO Advanced (Hydraulic Oil) Permissible fuels must be analyzed in order to
determine the following characteristics:
Cat Bio HYDO Advanced is biodegradable non-toxic
hydraulic oil that is recommended for use in hydraulic • Composition
systems when environmental compliance is required
or desired. Cat Bio HYDO Advanced has a renewable • Contaminants
content that exceeds 90% and complies with the
European Eco-Label. Consult Federal, state, or • Heat value
local authorities for guidance on hydraulic oils
environmental requirements in your area. • 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 value.
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. In order to minimize
these effects, Caterpillar recommends the following
guidelines:
Machines with this symbol are filled with • Methane values below 30 are not recommended
biodegradable hydraulic oil. This symbol is located for use in a Cat engine. Fuels with a methane
on the hydraulic tank. number that is below 30 must first be processed in
order to remove harmful impurities in the fuel and
Capacity of the Electrohydraulic raising the methane number into the acceptable
range.
Actuator's System
Table 29 • If necessary, use an engine that is configured for a
fuel that has a high energy. Consult the appropriate
G3600 Electrohydraulic Actuator System manual for the engine in order to determine the
Approximate Refill Capacity recommended engine timing.
Compartment or System Liters US Gallons
Hydraulic Oil Tank 19 5
• Reduce the oil change interval according to the
results of the oil analysis.
Coolant/antifreeze is normally composed of three Use only the coolant/antifreeze that is recommended.
elements: water, glycol, and additives. Each element
must meet specific guidelines.
Preferred – Cat NGEC (Natural Gas Engine
Water Coolant)
Deionized water or distilled water is Alternatively, use Cat DEAC (Diesel Engine
recommended for use in engine cooling systems. Antifreeze/Coolant) or a commercial heavy-duty
If distilled water or deionized water is not available, antifreeze/coolant that meets “ASTM D6210” or
use water with the properties that are listed in Table “ASTM D4985” specifications.
30.
NOTICE
Table 30 Do not use a commercial coolant/antifreeze that only
Caterpillar Minimum Acceptable Water Requirements meets the ASTM “D3306” specification. This type of
coolant/antifreeze is made for light duty automotive
Property Maximum Limit ASTM Test applications.
40 mg/L “D512”,
Chloride (Cl)
(2.4 grains per US gal) “D4327” Use only the coolant/antifreeze that is recommended.
100 mg/L
Sulfate (SO4) “D516”
(5.9 grains per US gal) Acceptable – In applications that do not require
170 mg/L protection from boiling or from freezing, a mixture of
Total Hardness “D1126” Caterpillar SCA and water that meets the properties
(10 grains per US gal)
that are listed in Table 30 is acceptable.
340 mg/L
Total Solids “D1888”
(20 grains per US gal) Note: The preferred coolant/antifreeze and the
Acidity pH of 5.5 to 9.0 “D1293” acceptable mixture of SCA and water require
different concentrations of SCA. Refer to the Special
Publication, SEBU6400, “Caterpillar Gas Engine
NOTICE Lubricant, Fuel, and Coolant Recommendations”,
Use of water that does not meet the recommendations “Supplemental Coolant Additive (SCA)” topic.
for the cooling system will damage the cooling system.
Table 31 is a list of the coolant/antifreeze that is
Do not use these types of water in the cooling system: recommended for Caterpillar Gas Engines. The
sea water, softened water that has been conditioned service life of the coolant/antifreeze that is used in
with salt, hard water, and tap water. Caterpillar Gas Engines is also listed. To achieve
this service life, the coolants must be properly
Only use water that meets the recommendations for maintained. The maintenance program includes
the cooling system. S·O·S coolant analysis.
Table 31 Table 32
Recommended Coolant/Antifreeze and Service G3606 Engine Cooling System
Life of the Coolant/Antifreeze Approximate Refill Capacities
Coolant/Antifreeze Service Life (1) Compartment or System Liters US Gallons
Cat NGEC Jacket Water 340 90
Three Years
Cat DEAC Aftercooler 61 16
Commercial Heavy-Duty Accessory Module 345 91
Antifreeze/Coolant that Two Years
meets “ASTM D6210” External System
i03681563
NOTICE
To relieve the pressure from the coolant system, turn
Because the strength of the frame may decrease,
off the engine. Allow the cooling system pressure cap
some manufacturers do not recommend welding onto
to cool. Remove the cooling system pressure cap
a chassis frame or rail. Consult the OEM of the equip-
slowly in order to relieve pressure.
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
Fuel System
Proper welding procedures are necessary in
To relieve the pressure from the fuel system, turn off order to avoid damage to the engine's electronic
the engine. control module (ECM), sensors, and associated
components. When possible, remove the component
High Pressure Fuel Lines (If Equipped) from the unit and then weld the component. If
removal of the component is not possible, the
following procedure must be followed when you weld
on a unit that is equipped with a Caterpillar Electronic
Engine. The following procedure is considered to be
Contact with high pressure fuel may cause fluid
the safest procedure to weld on a component. This
penetration and burn hazards. High pressure fu-
procedure should provide a minimum risk of damage
el spray may cause a fire hazard. Failure to fol-
to electronic components.
low these inspection, maintenance and service in-
structions may cause personal injury or death.
NOTICE
Do not ground the welder to electrical components
The high pressure fuel lines are the fuel lines that such as the ECM or sensors. Improper grounding can
are between the high pressure fuel pump and the cause damage to the drive train bearings, hydraulic
high pressure fuel manifold and the fuel lines that are components, electrical components, and other com-
between the fuel manifold and cylinder head. These ponents.
fuel lines are different from fuel lines on other fuel
systems. Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
This is because of the following differences: as possible to the weld. This will help reduce the pos-
sibility of damage.
• The high pressure fuel lines are constantly charged
with high pressure.
1. Stop the engine. Turn the switched power to the
• The internal pressures of the high pressure fuel OFF position.
lines are higher than other types of fuel system.
2. Disconnect the negative battery cable from the
Before any service or repair is performed on the battery. If a battery disconnect switch is provided,
engine fuel lines, perform the following tasks: open the switch.
SEBU7563-09 59
Maintenance Section
Maintenance Recommendations
3. Disconnect the J1/P1 and J2/P2 connectors from 5. Protect the wiring harness from welding debris
the ECM. Move the harness to a position that will and spatter.
not allow the harness to accidentally move back
and make contact with any of the ECM pins. 6. Use standard welding practices to weld the
materials.
g01075639
Illustration 40
Use the example above. The current flow from the welder to
the ground clamp of the welder will not cause damage to any
associated components.
(1) Engine
(2) Welding rod
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Maximize distance between the component that is being
welded and any electrical/electronic component.
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
i02601608 i02236400
Before performing this procedure, ensure that the • Exhaust bypass actuator
linkage is meant to be lubricated. If the linkage is
meant to be lubricated, this article applies to the • Fuel control actuator
following: air choke actuator, fuel control actuator,
and exhaust bypass actuator. • Linkages
If necessary, replace the rod ends.
Apply Dow Corning 41 Extreme High Temperature
Bearing Grease to the rod ends (bearings) of the
control linkage for the actuator. For more information Removal and Installation
on grease, see the Special Publication, SEBU6400,
“Caterpillar Gas Engine Lubricant, Fuel, and Coolant
Recommendations”.
Hydraulic Actuators
g00799207
Illustration 42
Typical example of rod ends on an actuator and on the linkage
for an actuator
g01120800
Illustration 41
Typical locations of grease fittings
SEBU7563-09 67
Maintenance Section
Aftercooler Condensation - Drain
i01762572 i01762654
g00789123
Illustration 45
(1) Plug
(2) Screen
i02654935
NOTICE
Never allow the lubricator bowl to become empty. The
air starting motor will be damaged by a lack of lubrica-
tion. Ensure that sufficient oil is in the lubricator bowl.
g01333332
Illustration 46
(1) Filler plug
(2) Bowl
(3) Drain valve
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- g01333366
Illustration 47
ing any compartment or disassembling any compo-
nent containing fluids. 1. Observe the oil level in sight gauge (3). If the oil
level is less than 1/2, add oil to the lubricator bowl.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Personal injury can result from removing hoses or
Dispose of all fluids according to local regulations and fittings in a pressure system.
mandates.
Failure to relieve pressure can cause personal in-
jury.
3. Place a suitable container under bowl (2) and
open drain valve (3) in order to drain the oil from Do not disconnect or remove hoses or fittings un-
the bowl. til all pressure in the system has been relieved.
4. Remove bowl (2). Clean the bowl with warm water.
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.
SEBU7563-09 69
Maintenance Section
Air Tank Moisture and Sediment - Drain
3. Remove filler plug (4). Pour oil into the lubricator 1. Open the drain valve that is on the bottom of the
bowl. Use nondetergent SAE 10W oil for air tank. Allow the moisture and sediment to drain.
temperatures that are greater than 0 °C (32 °F).
Use air tool oil for temperatures that are below 2. Close the drain valve.
0 °C (32 °F).
i02601719
4. Install filler plug (4).
Alternator - Inspect
Adjust the Lubricator
SMCS Code: 1405-040
Note: Adjust the lubricator with a constant rate of air
flow. After the adjustment, the lubricator will release Inspect the alternator for the following conditions:
oil in proportion to variations of the air flow.
• Proper connections
1. Ensure that the fuel supply to the engine is OFF.
• Clean ports for cooling airflow
NOTICE
Do not crank the engine continuously for more than • Proper charging of the battery
30 seconds. Allow the starting motor to cool for two
Observe battery voltage on the Advisor panel or
minutes before cranking the engine again.
Cat ET during engine operation to evaluate the
performance of the alternator.
2. Operate the air starting motor. Observe the drops
of oil that are released in dome (1). Make repairs, if necessary. See the Service Manual
for service procedures. Consult your Caterpillar
Note: Some lubricators have an adjustment screw dealer for assistance.
rather than a knob.
i02601741
3. If necessary, adjust the lubricator in order
to release from one to three drops of oil per Barring Device - Lubricate
second. To increase the rate, turn knob (2)
counterclockwise. To decrease the rate, turn the SMCS Code: 1235-086
knob clockwise.
NOTICE
i00351324 Do not use an impact wrench to operate the barring
device. The use of an impact wrench will cause gear
Air Tank Moisture and tooth failure.
Sediment - Drain
SMCS Code: 1466-543-M&S
Guards must be in place prior to operating barring
Moisture and sediment in the air starting system can device motor.
cause the following conditions:
Remove all hand tools prior to operating barring
• Freezing device motor.
• Corrosion of internal parts
Note: Prelube of the engine is required before the
• Malfunction of the air starting system crankshaft is rotated for normal maintenance.
g00991445
Illustration 50
g01098831 g01098833
Illustration 49 Illustration 51
Section view of a barring device without the electric motor (1) Grease fitting
(1) Grease fitting (2) Gear end
(2) Vent
1. Ensure that the barring device is locked in the
1. Ensure that the barring device is locked in the disengaged position.
disengaged position.
2. Lubricate grease fitting (1) with Cat Advanced
2. Lubricate grease fitting (1) with Cat Advanced 3Moly Grease until the grease is visible at gear
3Moly Grease until the grease is visible at vent (2). end (2).
SEBU7563-09 71
Maintenance Section
Battery Electrolyte Level - Check
i02601752 i02601764
g01092641
Illustration 52
Typical alternator
(1) Mounting bolt
(2) Adjusting nuts
(3) Mounting bolt
Replacement
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
g00789241
drive belt to carry more load because the older drive Illustration 53
belts are stretched. The additional load on the new Section view of a cylinder head with a combustion sensor
drive belt could cause the new drive belt to fail. (1) Harness connector
(2) Connector
(3) Extension
i02601781 (4) Sensor
(5) Gasket
Combustion Sensor - (6) Discs
6. After the sensor is removed, discard gasket (9). Note: Do not use anti-seize compound on the sensor.
Most of the heat is transferred through the threads
7. Inspect the sensor closely for damage. and the seat area of the sensor. The surfaces must
be in contact in order to provide the heat transfer that
Terminal post (6) must not move. If the terminal is required.
post can be moved by hand, discard the sensor.
10. Place a new 108-3515 Plug Gasket on the
Inspect insulator (7) for cracks. If a crack is found, sensor. Install the sensor by hand until the sensor
discard the sensor. bottoms out. Tighten the sensor to 38 ± 2 N·m
(28 ± 2 lb ft).
Inspect shell (8) for damage. Cracks can
be caused by overtightening the sensor. 11. Install extension (3). Make sure that discs (5)
Overtightening can also loosen the shell. Discard are positioned in order to align the extension's
any sensor that has a shell that is cracked or connectors with sensor (4) and connector (2).
loose.
12. Make sure that the O-ring seal on connector (2) is
Inspect electrode (10) for excessive wear. in good condition. Install the connector.
i01762721
Data Location of cooling system drain valves or drain plugs on the water
pumps
If equipped, check the gauges and check the (1) Jacket water pump
indicators frequently during normal operation. Record (2) Aftercooler and oil cooler pump
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.
i02601979
• The engine overheats frequently. 3. Open the cooling system drain valves (if
equipped). Remove the cooling system drain
• Foaming is observed. plugs. Allow the coolant to drain.
• The oil has entered the cooling system and the NOTICE
coolant is contaminated.
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
NOTICE coolant for reuse in engine cooling systems. The full
Use of commercially available cooling system clean- distillation procedure is the only method acceptable by
ers may cause damage to cooling system compo- Caterpillar to reclaim the used coolant.
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
Drain the Cooling System dealer or consult Caterpillar Dealer Service Tools
Group:
1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the Outside Illinois: 1-800-542-TOOL
cooling system is drained. Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
SEBU7563-09 75
Maintenance Section
Cooling System Coolant (NGEC) - Change
Clean the Cooling System 2. Close the cooling system drain valves (if
equipped). Clean the cooling system drain plugs
1. Flush the cooling system with clean water in order and install the cooling system drain plugs.
to remove any debris.
3. Fill the cooling system with a mixture of clean
2. Close the cooling system drain valves (if water and Caterpillar Fast Acting Cooling System
equipped). Clean the cooling system drain plugs Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
and install the cooling system drain plugs. (1 to 2 US gal) of the cooling system capacity.
Install the cooling system filler cap.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) 4. Start the engine. Operate the engine for a
per minute in order to avoid air locks. Proper venting minimum of 90 minutes with a coolant temperature
of the cooling system is essential to fill at this rate. of at least 82 °C (180 °F).
Note: For the following procedure to be effective, 1. Fill the cooling system with coolant/antifreeze. Do
there must be an active flow through the cooling not install the cooling system filler cap.
system components.
2. Start the engine. Operate the engine in order to
1. Flush the cooling system with clean water in order purge the air from the cavities of the engine block.
to remove any debris. Allow the coolant to warm and allow the coolant
level to stabilize. Stop the engine.
76 SEBU7563-09
Maintenance Section
Cooling System Coolant Level - Check
3. Check the coolant level. Maintain the coolant to If the engine is equipped with a sight gauge, observe
the proper level on the sight gauge (if equipped). the position of the coolant in the sight gauge. At
If a sight gauge is not equipped, maintain the normal operating temperature, the proper coolant
coolant to the level that is specified by the OEM level is in the upper half of the sight gauge. If the
of the cooling system. coolant level is low, add the proper coolant mixture.
4. Clean the cooling system filler cap. Inspect Engines That Are Not Equipped
the gaskets of the cooling system filler cap. If
the gaskets of the cooling system filler cap are With a Sight Gauge
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. Pressurized System: Hot coolant can cause seri-
The correct pressure is stamped on the face of ous burns. To open the cooling system filler cap,
the cooling system filler cap. If the cooling system stop the engine and wait until the cooling system
filler cap does not retain the correct pressure, components are cool. Loosen the cooling system
install a new cooling system filler cap. pressure cap slowly in order to relieve the pres-
sure.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature. 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
i02062976
filler cap is cool enough to touch with your bare hand.
Cooling System Coolant Level
Remove the cooling system filler cap slowly in order
- Check to relieve any pressure. Maintain the coolant within
13 mm (0.5 inch) below the bottom of the filler pipe.
SMCS Code: 1350-535-FLV
Add Coolant
Note: For the proper coolant mixture to use, see
Climbing equipment may be required to access this Operation and Maintenance Manual, “Refill
this service point. Refer to the Operation and Capacities and Recommendations” (Maintenance
Maintenance Manual, “Mounting and Dismount- Section).
ing” topic for safety information.
1. Stop the engine. Allow the engine to cool.
Engines That Are Equipped With a 2. Remove the cooling system filler cap slowly in
Sight Gauge order to relieve any pressure. Pour the proper
coolant mixture into the filler pipe.
g00750429
Illustration 57 g00103639
Illustration 58
(1) Filler cap
(2) Sight gauge Gaskets
SEBU7563-09 77
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
3. Clean the cooling system filler cap. Inspect the • In order to avoid contamination, immediately place
gaskets of the cooling system filler cap. If the the sample in the tube that is provided for mailing.
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler Submit the sample for Level 1 analysis.
cap. Install the cooling system filler cap.
Note: Level 1 results may indicate a need for
4. Start the engine. Inspect the cooling system for Level 2 Analysis.
leaks.
For additional information about coolant analysis,
see the Special Publication, SEBU6400, “Caterpillar
i02064894
Gas Engine Lubricant, Fuel and Coolant
Cooling System Coolant Recommendations” or consult your Caterpillar dealer.
If the coolant level is low, coolant must be added to Note: Caterpillar recommends an S·O·S coolant
the expansion tank or the heat exchanger. analysis (Level 1).
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
Illustration 59
g00789360 Water and SCA
(1) Switch
(2) Lines NOTICE
Do not exceed the recommended eight percent sup-
For proper operation of the switch, the lines and the plemental coolant additive concentration.
switch must be clean.
1. Drain the coolant to a level below lower line (2). Test the concentration of the SCA with the 8T-5296
Drain the coolant into a clean container so that the Coolant Conditioner Test Kit. Use the instructions
coolant can be reused. that follow:
2. Remove switch (1). Inspect the openings of the 1. Fill the syringe to the “1.0 ml” mark with the
inlet and the outlet for plugging. If an opening is coolant.
plugged, clean the switch.
2. Dispense the 1.0 mL coolant sample from the
3. Inspect lines (2) for plugging. Clean the lines, if syringe into the empty mixing bottle.
necessary. Pressure air or a flexible wire can be
used to clean the lines. 3. Add tap water to the mixing bottle in order to bring
the level up to the “10 ml” mark. Place the cap on
4. Install switch (1). the bottle and shake the bottle.
5. Pour the coolant into the cooling system. Verify 4. Add 2 to 3 drops of the “NITRITE INDICATOR
that the low coolant level switch is operating SOLUTION B” to the mixing bottle. Move the bottle
properly. A switch that is operating properly will in a circular motion in order to mix the solution.
activate an alarm until a sufficient amount of
coolant is added. 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.
i02017557
6. Repeat 5 until the solution changes color from red
Cooling System Supplemental to light gray, green, or blue. Record the number of
Coolant Additive (SCA) - drops of “NITRITE TEST SOLUTION A” that were
required to cause the color change.
Test/Add
7. Use Table 36 to interpret the results.
SMCS Code: 1352-045; 1395-081
Note: If only the water temperature regulators are Excessive crankcase blowby may indicate the need
replaced, drain the coolant from the cooling system to for an overhaul. By keeping a record of the results,
a level that is below the water temperature regulator a gradual increase in the amount of the crankcase
housing. blowby will be noted until the amount of crankcase
blowby has become excessive.
i02602965
Use the 1U-8860 Large Engine Blowby Pickup
Crankcase Blowby - Group to measure the blowby. Refer to Special
Instruction, SEHS8984, “1U-8860 Large Engine
Measure/Record Blowby Pickup Group” that is provided with the tool.
SMCS Code: 1317 Record the crankcase blowby for the engine. Keep a
record of the results.
Note: The typical crankcase blowby on a new engine
is approximately 0.02 m3/bkW h (.50 ft3/bhp h). For more information, see the Service Manual,
“Systems Operation/Testing and Adjusting”. For
Measure the crankcase blowby of new engines. assistance, consult your Caterpillar dealer.
Record the data. Continue to periodically measure
the crankcase blowby. Comparing the recorded
data to the new data provides information about the i02062446
Note: A problem with the piston rings causes the A damper that is hot is due to excessive torsional
oil to deteriorate rapidly. Information regarding the vibration. Monitor the temperature of the damper
condition of the piston rings can be obtained from during operation.
the measurement of the crankcase blowby and the
results of oil analysis. The 8T-2821 Temperature Indicator or the 8T-2822
Temperature Indicator are recommended for
The crankcase blowby of a worn engine may exceed monitoring the temperature of the damper. Evenly
the crankcase blowby of a new engine by two times space four of the adhesive indicators around the
or more. outer diameter of the damper.
A sudden increase in crankcase blowby could Note: If you use an infrared thermometer to monitor
indicate a broken piston ring. The following conditions the temperature of the damper, use the thermometer
are other potential sources of crankcase blowby: during operation with similar loads and speeds. Keep
a record of the data. If the temperature begins to rise,
• Worn valve guides reduce the interval for inspecting the damper. It is
important to regularly monitor the temperature of the
• A turbocharger seal that leaks damper. It is important to document the temperature
of the damper when it increases and decreases. This
A rebuilt engine can have a high crankcase blowby will verify that damper service is necessary.
due to the following factors:
If the temperature of the damper reaches 110 °C
• The piston rings are not seated properly. (230 °F), consult your Caterpillar dealer.
• Worn parts such as valve guides were not replaced. Inspect the damper for evidence of dents, cracks,
and leaks of the fluid.
SEBU7563-09 81
Maintenance Section
Cylinder Pressure - Measure/Record
If a fluid leak is found, determine the type of fluid. • Minimize the cranking time. This will enable a
The fluid in the damper is silicone. Silicone has maximum consistent cranking speed for the check.
the following characteristics: transparent, viscous, Also, the starting air or battery power will be
smooth, and sticky. If leaking silicone is found, repair conserved.
the damper or replace the damper.
A loss of cylinder pressure or a change of pressure
If the fluid leak is oil, inspect the crankshaft seal for in one or more cylinders may indicate the following
leaks. If a leak is observed, replace the seal. conditions. These conditions may indicate a problem
with lubrication:
Inspect the damper and repair or replace the damper
for any of the following reasons. • Excessive deposits
• The damper is dented, cracked, or leaking. • Guttering of valves
• The paint on the damper is discolored from heat. • A broken valve
• The engine has had a failure because of a broken • A piston ring that sticks
crankshaft.
• A broken piston ring
• An analysis of the oil has revealed that the front
bearing of the crankshaft is badly worn. • Worn piston rings
• There is a large amount of gear train wear that is • Worn cylinder liners
not caused by a lack of oil.
If the cylinder pressure has risen by one or more
compression ratios, the engine needs a top end
Removal and Installation overhaul in order to remove deposits. Failure to
Refer to the Service Manual, “Disassembly and remove the deposits will increase the chance for
detonation. Severe guttering of the valves will occur.
Assembly” or consult your Caterpillar dealer for
information about damper replacement.
To measure the cylinder pressure, refer to Special
Instruction, GMG00694, “Analyzing Cylinder
i02602007 Condition By Measuring Air Flow”. Also, use the
146-2739 Cylinder Pressure Adapter.
Cylinder Pressure -
Measure/Record Illustration 60 is a graph of typical cylinder pressures
for engines with different compression ratios.
SMCS Code: 1223-082-CC; 1223; 7450-082
• Valve wear
• Deposits on the valve seat
• Deposits on the valve face
• Polishing of the cylinder walls
• Scratching of the cylinder walls
• Deposits on the cylinder walls that are above the
Illustration 60
g00789376 upper limit of the piston stroke
(Y) Cylinder pressure in kPa (psi)
(X) Compression ratio Deposits that are on the valve face and the valve
(1) Normal range for cylinder pressure seat can cause guttering of the valve. Inspect the
valve seat and the valve face for excessive deposits.
Record the pressure for each cylinder. Use Operation If excessive deposits are found, replace the valve
and Maintenance Manual, “Valve Data Sheet” and the valve seat.
(Reference Materials Section).
Determine whether the exhaust valve face has
erosion from pitting. This requires the exhaust valve
i01765658 to be in the open position. To obtain as much detail
Cylinders - Inspect as possible, obtain a close up view of the valve
face. Erosion of the exhaust valve face can lead
(Inspect the Combustion to guttering of the valve. If erosion is found on the
exhaust valve face, recondition the cylinder head as
Chamber) soon as possible.
SMCS Code: 1223-040; 1223
Note: Operation at loads that are less than 50 percent
of the rated load can result in an excessive buildup
Excessive deposits can accumulate in the combustion
of carbon deposits in the combustion chamber.
chambers of engines that use gas with a low BTU
The deposits can lead to detonation and premature
such as bio-gas fuel, landfill gas, etc. The deposits
ignition. This condition is more obvious at certain
can affect the characteristics of combustion. Erratic
engine speeds and loads.
operation can result. The rate of recession of the
exhaust valves can increase. The risk of guttering of
the exhaust valves can increase. i02602013
A borescope with a lens that can be rotated is Engines That Are Not Attached To the
recommended. This type of borescope provides a Base with a Dowel
clear view of the combustion chamber and of the
bottom deck of the cylinder head. Photographic If some engines are too rigidly mounted, excessive
documentation or video documentation is also stress may affect the internal support of the cylinder
recommended. Consult your Caterpillar dealer for block. This could cause the following problems:
information on available borescopes.
SEBU7563-09 83
Maintenance Section
Driven Equipment - Inspect/Replace/Lubricate
• Distortion of the bores of the main bearing • Unusual noise and vibration
• Distortion of the alignment of the bore • Loose connections
Severe damage to the engine could result. The • Damaged parts
service life of the engine could be severely reduced.
Perform any maintenance that is recommended
For engines that are not attached to the base with a by the OEM of the driven equipment. Refer to the
dowel, check the following: literature of the OEM of the driven equipment for the
following service instructions.
• Check the alignment after every 5000 service
hours. • Inspection
• Inspect the drive coupling according to the • Lubricating grease and lubricating oil requirements
specifications of the OEM.
• Specifications for adjustment
Every 10,000 Service Hours
• Replacement of components
Engines That Are Attached To the Base • Requirements for ventilation
with a Dowel
i01610487
Some engines must be more rigidly mounted. Due to
thermal expansion, a cold engine will expand after
the engine achieves operating temperature.
Electrohydraulic Actuator -
Inspect
Some engines are attached to the base with a dowel
in the rear mounting support. This installation forces SMCS Code: 1716-040
the thermal growth forward. The driven equipment
is also attached with a dowel in order to maintain Inspect the actuators for the fuel control, the
alignment with the engine. wastegate, and the air choke.
• Caterpillar
• OEM of the coupling
• OEM of the driven equipment
i00935098
Inspect/Replace/Lubricate (1)
(2)
Receptacle for the wiring harness
Solenoid
(3) Bolt
SMCS Code: 3279-040 (4) Guards
1. Disconnect the wiring harness from receptacle (1). 10. Install guards (4).
Inspect the connectors for damage and corrosion.
Make repairs, if necessary. 11. Connect the wiring harness to receptacle (1).
g00833477
Illustration 62
(5) Rod end
(6) Clevis
(7) Boot
g00833594
9. Remove bolts (10) in order to remove solenoid
Illustration 64 (11). Remove O-ring seal (12) from the joint
(3) Rod end between the solenoid and the housing.
(4) Clevis
(5) Boot
(6) Nut 10. Install a new O-ring seal (12) and solenoid (11).
Install bolts (10). Tighten the bolts according to
4. Disconnect rod end (3) from clevis (4). the engine's Specifications.
5. Remove clevis (4) and rubber boot (5). Inspect the 11. Install the actuator in the bracket with nut (6).
boot for damage. If the boot is damaged, obtain a
new boot for assembly. 12. Install boot (5). Make sure that the outer end of
the boot folds inward when the actuator's shaft
Note: Handle the actuator carefully. Use care not to moves from the fully open position to the fully
damage the actuator's shaft. Damage to the shaft closed position.
can result in premature failure of the O-ring seal. This
will cause hydraulic fluid to leak. 13. Install clevis (4). Connect rod end (3) to the clevis.
6. Remove nut (6) in order to remove the actuator 14. Install guards (2).
from the bracket.
15. Connect the supply line and the return line for the
Note: Do not allow debris to enter the actuator. Seal hydraulic oil.
the openings with clean covers immediately after the
solenoid and/or the piston assembly is removed. 16. Connect the wiring harness to receptacle (1).
i01525261
Electrohydraulic System -
Check/Adjust
SMCS Code: 1716-025; 1716-535
i02214104 Inspect the hoses and lines for wear and leaks.
Ensure that the hoses and lines are properly
Electrohydraulic System - clamped. Inspect the connections for leaks. Ensure
Inspect that the connections are secure.
SMCS Code: 1716-040 Inspect the following items for leaks and good
condition:
Inspect the conditions of these items for the
electrohydraulic system: • Actuators
i02603161
g00792283
Illustration 66
(1) Sight gauge
(2) Hose
(3) Line
Note: For the proper oil to use, refer to this Operation Illustration 67
g00792335
and Maintenance Manual, “Refill Capacities and
(1) Oil filler cap
Recommendatons” topic (Maintenance Section). (2) Valve
2. If necessary, remove the oil filler cap. Pour the 1. Remove oil filler cap (1).
correct oil into the oil filler.
Note: Drain the oil into a suitable container. Dispose
3. Clean the oil filler cap. Install the oil filler cap. of fluids according to local regulations.
Inspect the Lines, Connections, 2. Place a suitable container under valve (2). Open
the valve. Allow the oil to drain. After the oil has
and Components drained, close the valve.
i02246458 5. Start the engine. Check the oil level in sight gauge
(2). The oil should be between the “ADD” and
Electrohydraulic System Oil “FULL” marks on the tank. If necessary, remove
Filter - Change 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
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
Illustration 68
g00792302 engine causes premature wear and damage to engine
(1) Filter
components. Air cleaner elements help to prevent air-
(2) Sight gauge borne debris from entering the air inlet.
(3) Filler cap
4. Install the filter by hand. Tighten the filter until the • The air cleaner element should be replaced at least
gasket contacts the mounting base. Tighten the one time per year. This replacement should be
filter according to the instructions that are shown performed regardless of the number of cleanings.
on the filter. Do not overtighten the filter.
88 SEBU7563-09
Maintenance Section
Engine Air Cleaner Element (Single Element) - Clean/Replace
Replace the dirty paper air cleaner elements with Use clean air cleaner elements while dirty elements
clean air cleaner elements. Before installation, the are being cleaned.
air cleaner elements should be thoroughly checked
for tears and/or holes in the filter material. Inspect NOTICE
the gasket or the seal of the air cleaner element for Do not clean the air cleaner elements by bumping or
damage. Maintain a supply of suitable air cleaner tapping. This could damage the seals. Do not use el-
elements for replacement purposes. ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
1. Remove the air cleaner cover. Remove the air damage could result.
cleaner element.
Note: Refer to “Cleaning the Air Cleaner Elements”. Visually inspect the air cleaner elements before
cleaning. Inspect the air cleaner elements for damage
2. Cover the air inlet with tape in order to keep dirt to the seal, the gaskets, and the outer cover. Discard
out. any damaged air cleaner elements.
3. Clean the inside of the air cleaner cover and body There are two common methods that are used to
with a clean, dry cloth. clean air cleaner elements:
4. Remove the tape for the air inlet. Install an air • Pressurized air
cleaner element that is new or cleaned.
• Vacuum cleaning
5. Install the air cleaner cover.
Pressurized Air
6. Reset the air cleaner service indicator.
Pressurized air can be used to clean air cleaner
Cleaning the Air Cleaner Elements 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
NOTICE pressure of 207 kPa (30 psi).
Caterpillar recommends certified air filter cleaning ser-
vices that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
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.
g00281694
Illustration 72
Storing Air Cleaner Elements • The red piston locks in a visible position.
If an air cleaner element that passes inspection will • The air restriction reaches 0.25 kPa (1 inch of H2O).
not be used, the air cleaner element can be stored
for future use.
90 SEBU7563-09
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
g00294189 g00789538
Illustration 73 Illustration 74
(1) Service indicator Service indicator
(2) Cover
Observe the service indicator. Clean the air cleaner
1. Remove cover (2). element or replace the air cleaner element when one
of the following conditions occur:
2. Remove the used element and dispose of the
element. • The yellow diaphragm enters the red zone.
3. Clean the inside of cover (2) and clean the inside • The red piston locks in the visible position.
of the body.
• 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. 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
i01520297
indicator.
Engine Air Cleaner Service
Indicator - Inspect Test the Service Indicator
SMCS Code: 7452-040 Service indicators are important instruments.
Some engines are equipped with an air cleaner for • Check for ease of resetting. The service indicator
crankcase ventilation. should reset in less than three pushes.
This air cleaner filters air that is drawn into the • Check the movement of the yellow core when the
crankcase. The air dilutes the harmful fumes that engine is accelerated to the engine rated rpm.
may accumulate in the crankcase. The air and the The yellow core should latch approximately at the
fumes are drawn away from the crankcase. greatest vacuum that is attained.
i01765695
g00351792
If the crankcase breather is not maintained on a
Illustration 75 regular basis, the crankcase breather will become
Porous filter plugged. A plugged crankcase breather will cause
excessive crankcase pressure that can shut down
A porous filter is part of a fitting that is used for the engine. Leakage of the crankshaft seal can occur.
mounting of the service indicator. Inspect the filter
for cleanliness. Clean the filter, if necessary. Use Note: Use of a platform may be necessary to reach
compressed air or a clean, nonflammable solvent. the engine crankcase breather.
The service indicator may need to be replaced Perform this maintenance when the engine is
frequently in environments that are severely dusty. stopped.
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.
i00935352
g00476231
Illustration 76
(1) Clip
(2) Cup
92 SEBU7563-09
Maintenance Section
Engine Mounts - Check
4. Allow the breather elements to dry before Engines That Use Bio-Gas
installation. Install the breather assemblies in the
original position. Coat the rubber parts with clean The oil change interval is determined by the results
engine oil or petroleum jelly in order to make of oil analysis. Change the lubrication oil when oil
installation easier. Tighten the retaining clamps analysis determines that the oil has reached the
and the hose clamps according to the engine's condemning limit. Also, change the engine oil filters.
Specifications manual.
Change the Engine Oil
i01612978
i02602019
3. Clean the oil suction screen. An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
Note: Approximately 1 L (1 qt) of oil will remain in the oped and also force air bubbles into the oil. These
housing after the sump has been completely drained. bubbles (foam) can cause the following problems: re-
This oil will pour out of the housing when the cover duction of the oil's ability to lubricate, reduction of oil
for the oil suction screen is removed. Prepare to pressure, inadequate cooling, oil blowing out of the
catch the oil in a suitable container. Clean up any crankcase breathers, and excessive oil consumption.
spilled oil with rags. DO NOT use absorbent particles
to clean up the oil. Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
posits 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.
a. Loosen the bolts of the cover for the oil suction 6. Follow this Operation and Maintenance Manual,
screen. Remove the cover and the gasket. “Starting The Engine” procedure (Operation
Discard the old gasket. Slide screen assembly Section). Operate the engine at low idle for two
(2) from the tube. minutes. Inspect the engine for oil leaks. Ensure
that the oil level is at the “FULL” mark on the
b. Wash the screen assembly in clean “LOW IDLE” side of the oil level gauge.
nonflammable solvent. Allow the screen
assembly to dry before installation. 7. Stop the engine and allow the oil to drain back into
the sump for a minimum of ten minutes.
c. Install the screen assembly. Install a new
gasket. Install the cover. 8. Remove the oil level gauge and check the oil level.
Maintain the oil level above the “ADD” mark.
4. Change the engine oil filters. Refer to this
Operation and Maintenance Manual, “Engine Oil i01520518
Filter - Change” topic (Maintenance Section).
Engine Oil Filter - Change
NOTICE
Only use oils that are recommended by Caterpillar. SMCS Code: 1308-510; 1308
For the proper oil to use, refer to this Operation and
Maintenance Manual, “Engine Oil” topic (Maintenance Replace the engine oil filters when the following
Section). conditions are met:
g00789772
Illustration 81
(5) Wire rack
(6) O-ring seal
(7) Element
6. Ensure that the surfaces for O-ring seals (6) are 3. Open drain valve (2) and drain the lower oil filter
clean. Inspect the O-ring seals. If the old O-ring housing. Observe pressure gauge (1) until the
seals are damaged or deteriorated, replace the pressure is “0”.
old O-ring seals with new O-ring seals. Install the
O-ring seals. Note: Some oil will remain in the housing after the oil
has been drained. This oil will pour out of the housing
7. Install covers (3). Ensure that the spring is seated when cover (3) is removed. Prepare to catch the oil
properly between elements (7) and covers (3). in a suitable container. Clean up any spilled oil with
Close drain valves (2). rags. DO NOT use absorbent particles to clean up
the oil.
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 Personal injury can result from parts and/or cov-
control valve (if equipped) to the “RUN” position. ers under spring pressure.
9. Start the engine. Check for oil leaks. Spring force will be released when covers are re-
moved.
Replacing the Engine Oil Filters
Be prepared to hold spring loaded covers as the
During Engine Operation bolts are loosened.
g00789772
Illustration 83
(5) Wire rack
(6) O-ring seal
(7) Element
Illustration 82
g00789754 5. Elements (7) are mounted on wire rack (5) inside
the housing. Use a pan to catch the oil that drips
(1) Pressure gauge
(2) Drain when wire rack (5) is removed. Remove wire rack
(3) Cover (5). Remove used elements (7). Clean up any oil
(4) Control valve that is spilled.
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.
g00789822
Illustration 84
11. After the oil filters have been serviced and after
the pressure of the lower oil filter and the upper oil (1) Oil level gauge
(2) Oil filler
filter is equal, rotate control valve (4) to the “RUN”
position.
1. Ensure that oil level gauge (1) is seated. Obtain the Sample and the Analysis
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. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip- Before you take the oil sample, complete the Label,
stick). PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
An overfull crankcase can cause the crankshaft to dip the following information:
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These • Engine model
bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil • Service hours on the engine
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption. • The number of hours that have accumulated since
the last oil change
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De- • The amount of oil that has been added since the
posits in the combustion chamber lead to the following last oil change
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner. To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
If the oil level is above the “FULL” mark on the oil level sample.
gauge, drain some of the oil immediately.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
3. If necessary, remove oil filler cap (2) and add samples must be clean.
oil. For the correct oil to use, see this Operation
and Maintenance Manual, “Refill Capacities and Caterpillar recommends using the sampling valve
Recommendations” topic (Maintenance Section). in order to obtain oil samples. The quality and the
Wipe off the oil level gauge and reinstall the oil consistency of the samples are better when the
level gauge. Clean the oil filler cap and reinstall sampling valve is used. The location of the sampling
the oil filler cap. valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
4. Record the amount of oil that is added. For the
next oil sample and analysis, include the total The 169-8373 Fluid Sampling Bottle is
amount of oil that has been added since the recommended for use with the sampling valve. The
previous sample. This will help to provide the most fluid sampling bottle includes the parts that are
accurate oil analysis. needed for obtaining oil samples. Instructions are
also provided.
Note: Some engines are equipped with an automatic
oil level controller. The oil level should still be
checked on a daily basis with the oil level gauge. NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
i03542996 Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
Engine Oil Sample - Obtain contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
SMCS Code: 1348-554-SM dealers and customers.
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil If the engine is not equipped with a sampling valve,
analysis at regularly scheduled intervals in order use the 1U-5718 Vacuum Pump. The pump is
to monitor the condition of the engine and the designed to accept sampling bottles. Disposable
maintenance requirements of the engine. S·O·S oil tubing must be attached to the pump for insertion
analysis provides infrared analysis, which is required into the sump.
for determining nitration and oxidation levels.
98 SEBU7563-09
Maintenance Section
Engine Oil Temperature Regulator - Replace
i00839584
• Fraying
• Damaged insulation
• Corrosion
Make repairs, as needed.
SEBU7563-09 99
Maintenance Section
Engine Protective Device Connections - Inspect
• Corrosion
• Fraying
a. If corrosion is found, scrape large deposits.
Use cotton swabs with isopropyl alcohol to
clean any corrosion that remains.
g01302112
Illustration 87
Inside of control panel (front)
Investigate the source of the corrosion. Correct
the condition.
• Connectors
• Sensors
Perform a pull test for each wire. This test will
ensure that the wiring is properly attached. Test
each wire individually.
• Engine sensors
100 SEBU7563-09
Maintenance Section
Engine Protective Devices - Check
• Junction box
NOTICE
• Modules of the control panel During testing, abnormal operating conditions must be
simulated.
a. Inspect each pin and each socket for corrosion
and damage. The tests must be performed correctly in order to pre-
vent possible damage to the engine.
If corrosion is found, scrape large deposits.
Use cotton swabs with isopropyl alcohol to
clean any corrosion that remains. To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
Investigate the source of the corrosion. Correct perform the tests.
the condition.
Visual Inspection
If damage is found, replace the part.
Visually check the condition of all gauges, sensors
7. Reconnect the connectors. and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
a. For Military Standard, CE, and VE connectors, or components should be repaired or replaced
ensure the following conditions: immediately.
i00626013
6. Install the sensor. Make sure that the sensor is Prelube of the engine is required before the
properly seated. Tighten bolt (2). crankshaft is rotated for normal maintenance.
Activate the prelube pump for rotating the engine
7. Inspect the wiring harness. Make sure that the crankshaft.
connector is in good condition. Attach the wiring
harness to the sensor. Make sure that the mating NOTICE
of the connectors is proper. Do not use an impact wrench to operate the barring
device. The use of an impact wrench will cause gear
tooth failure.
i01765700
Engine Valve Lash - The barring device provides a means for slowly
turning the flywheel in order to service the engine.
Inspect/Adjust The barring device can also be used to prevent
rotation of the crankshaft.
SMCS Code: 1102-025
Check the Timing of the Crankshaft Check the valve bridges. Perform the procedure for
and Camshaft both valve bridges for each cylinder.
The timing of the crankshaft and camshaft must be After the valve bridge is checked for each cylinder,
checked, and the valve bridge must be adjusted check the valve lash for the exhaust valves, the inlet
before the valve lash is adjusted. valves, and the gas admission valves.
Check the valve lash for the gas admission valve Exhaust Bypass - Recondition
when the valve lash for the inlet valves and exhaust
valves are checked. Adjust the valve lash for the gas SMCS Code: 1057-020
admission valves, if necessary.
i01765711
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
g00799396
and cylinder head damage. Illustration 90
Typical example
(1) Rod ends
Note: Use of a platform may be necessary to reach (2) Cover and seal
the engine valve rotators. (3) Shaft
Perform this procedure after the valve lash has been Note: Use of a platform may be necessary in order to
set. reach the components of the exhaust bypass.
1. Mark the tops of the valve rotators with a Replace the following parts:
permanent marker. Note the position of the marks.
• Rod ends (1)
2. Install the valve covers. See the Service Manual
for the procedure. • Cover and seal (2)
3. Start the engine. Operate the engine for 5 minutes. • Shaft (3)
Stop the engine.
For instructions on assembling the exhaust bypass,
4. Remove the valve covers. Observe the position of refer to the Specifications.
the marks that are on the valve rotators.
i01765725
NOTICE
The exhaust shields can be damaged if work is per-
Gas Admission Valve -
formed on the exhaust shields or around the exhaust Recondition
shields.
SMCS Code: 1105-020-GS
Remove the exhaust shields or protect the exhaust
shields before performing work on the exhaust shields Note: Use of a platform may be necessary to reach
or around the exhaust shields. Handle the exhaust the gas admission valves.
shields carefully.
For the procedure to remove the gas admission valve,
Do not tear the foil that is inside of the exhaust shields. refer to the engine's Disassembly and Assembly.
Torn foil will allow the insulation to absorb flammable
liquids and a fire can result from engine heat. When you disassemble the gas admission valve,
inspect the seals. Replace the seals, if necessary.
Refer to this Operation and Maintenance Manual,
Ensure that the exhaust manifold is cool. Inspect the
“Gas Admission Valve Seals - Inspect/Replace”.
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.
i02602064
g00833994
Illustration 92
g00833829
Angle and dimensions for the valve seat in the support assembly Illustration 93
Exploded view and section view of the parts for the gas admission
If the valve seat is worn, the valve seat can be slightly valve
ground according to these specifications: (1) Upper valve stem seal
(2) Lower valve stem seal
(3, 4, and 5) O-ring seals for the support assembly
• The angle for the valve seat is 44.75 ± 0.5 degrees.
Note: The portion of the valve stem in lower valve
• The gauge diameter of the valve seat within a stem seal (2) may be slightly worn. This shallow wear
maximum depth of 2.0 mm (0.079 inch) from
does not affect the performance of the gas admission
the end of the support assembly is 39.75 mm
valve.
(1.565 inch).
Inspect valve stem seals (1) and (2). Inspect O-ring
Use some Prussian blue to verify complete contact of
seals (3), (4), and (5). Replace the seals, if necessary.
the valve in the valve seat.
i00679524
i01765734
The camshaft operates the mechanism for the gas Inspect the gas pressure regulator for the following
admission valve in order to allow fuel to enter the conditions:
inlet port of the cylinder.
• Wear
Note: Use of a platform may be necessary to reach
the gas admission valves. • Cracks
For the procedure to remove the gas admission valve, • Pin holes
refer to the engine's Disassembly and Assembly.
• Improper operation
SEBU7563-09 105
Maintenance Section
Gas Shutoff Valve - Inspect
If any of those conditions are found, the gas pressure 8. Remove bolts (4) and cover (5) in order to inspect
regulator must be repaired or replaced. the internal parts of the GSOV.
For information on replacing the gas pressure 9. Clean the internal parts. Inspect the diaphragm,
regulator, see the Service Manual. Consult your the center pin for the diaphragm, and the shaft
Caterpillar dealer for assistance. for the solenoid. If any of the parts are damaged,
replace the entire GSOV.
i01611465
10. Inspect the internal passages. Remove any
Gas Shutoff Valve - Inspect debris.
SMCS Code: 1329-040 11. Reassemble the diaphragm, the center pin for the
diaphragm, and the shaft for the solenoid. Install
The gas shutoff valve (GSOV) has a solenoid that is cover (5) with bolts (4).
operated with 24 VDC. When power is supplied to the
solenoid, fuel flows through the GSOV to the engine. 12. Install cap (3). Connect the wiring harness to
When the power is interrupted, the gas is shut off. receptacle (1).
1. Shut off the engine. 13. Turn on the fuel supply to the GSOV. Use a gas
detector to check for gas leaks.
2. Shut off the fuel supply to the GSOV.
i03847809
• Flexible part of the hose that is kinked or crushed Replace the Hoses and the Clamps
• Armoring that is embedded in the outer covering NOTICE
Care must be taken to ensure that fluids are contained
• Hoses which exhibit signs of leakage which are not during performance of inspection, maintenance, test-
the result of loose couplings or clamps
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
Inspect all clamps for the following conditions.
ing any compartment or disassembling any compo-
Replace any clamp which exhibits signs of any of the
nent containing fluids.
following conditions.
Refer to Special Publication, NENG2500, “Caterpillar
• Cracking Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and
• Looseness Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
• Damage
Dispose of all fluids according to local regulations and
Inspect all couplings for leaks. Replace any coupling
mandates.
which exhibits signs of leaks.
• Type of hose
• Type of fitting material Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
• Anticipated expansion and contraction of the hose stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
• Anticipated expansion and contraction of the pressure cap slowly in order to relieve the pres-
fittings sure.
7. Disconnect the old hose. Note: High pressure fuel lines may be installed
between the high pressure fuel pump and the fuel
8. Replace the old hose with a new hose. injectors. High pressure fuel lines are constantly
charged with high pressure. Do not check the high
9. Install hose clamps which have been inspected or pressure fuel lines with the engine or the starting
install new hose clamps. Refer to Specifications, motor in operation. Wait for 10 minutes after the
SENR3130, “Torque Specifications”, “Hose engine stops before you perform any service or repair
Clamps” for information about selecting and on high pressure fuel lines in order to allow pressure
installing the proper hose clamps. to be purged.
10. Refill the cooling system. 1. Drain the fuel from the fuel system to a level that
is below the hose that is being replaced.
11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap 2. Remove the hose clamps.
if the gaskets are damaged. Install the filler cap.
3. Disconnect the old hose.
12. Start the engine. Inspect the cooling system for
leaks. 4. Replace the old hose with a new hose.
Contact with high pressure fuel may cause fluid 8. Start the engine. Inspect the fuel system for leaks.
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol- Lubrication System
low these inspection, maintenance and service in-
structions may cause personal injury or death.
6. Refill the lubrication system. Refer to this Removing the Spark Plug
Operation and Maintenance Manual, “Engine
Oil Level - Check” in order to ensure that the
lubrication system is filled with the proper amount
of engine oil.
Air System
1. Remove the hose clamps.
5. Start the engine. Inspect the air lines for leaks. 1. Ensure that the mode control switch is in the
“STOP” or “OFF/RESET” position.
i03915150
NOTICE
Ignition System Spark Plugs - Pulling on the wiring harness may break the wires. Do
not pull on the wiring harness.
Check/Adjust
SMCS Code: 1555-535 2. Remove the lockwire. Disconnect harness
connector (1). Use pliers to turn the connector
Maintenance of the spark plugs is required in order to counterclockwise.
obtain the following benefits:
3. Remove bolts (2).
• Normal fuel consumption
4. Remove transformer (3). Inspect O-ring seal (4).
• Normal levels of emissions If the O-ring seal is worn or damaged, discard
the O-ring seal and use a new O-ring seal for
• Maximum service life of the spark plugs assembly.
The service life of the spark plugs is affected by 5. Remove extension (5).
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 Pressurized air can cause personal injury. When
service life of components such as spark plug wires pressurized air is used for cleaning, wear a pro-
and transformers. tective face shield, protective clothing, and pro-
tective shoes.
7. Use a 4C-4601 Spark Plug Socket and an Faint marks may extend from shell (3) onto the
extension to loosen spark plug (6). After the spark insulator. The marks may be a result of corona that
plug has been loosened, remove the spark plug by forms at the top of the shell. The corona develops
hand in order to detect problems with the threads. when a high voltage potential ionizes the air that
After the spark plug has been removed, discard surrounds a conductor, which is a normal condition.
the used gasket. This condition is not an indication of leakage between
the shell and the insulator.
NOTICE
The use of a thread tap will remove metal unnecessar- Inspect shell (3) for damage. Cracks can be caused
ily. This will also reduce the heat transfer for the spark by overtightening the spark plug. Overtightening can
plug. This can result in a reduction of the spark plug also loosen the shell. Discard any spark plug that has
service life and a reduction of the detonation margin. a shell that is cracked or loose.
g00760569
Illustration 97
(6) Precious metal pads on the electrode and the ground strap
Illustration 96
g00838300 Replace the spark plug if the precious metal is worn
off.
(1) Terminal post
(2) Insulator
(3) Shell Light brown deposits or beige deposits around the
(4) Gasket electrode are produced by normal operation. White
(5) Electrode deposits or gray deposits may be caused by the
following substances:
Inspect the spark plug closely for damage. The
condition of the spark plug can indicate the operating • Excessive oil
condition of the engine.
• Use of the wrong oil
Terminal post (1) must not move. If the terminal post
can be moved by hand, discard the spark plug. • A substance that is introduced through the fuel
system or the air system
Inspect insulator (2) for cracks. If a crack is found,
discard the spark plug. A spark plug can operate despite a buildup of
ash. However, a buildup of ash can cover the
electrode gap. The buildup will cause misfire. Large
deposits may retain heat which can cause premature
fuel ignition. Premature fuel ignition can lead to
uncontrollable detonation.
110 SEBU7563-09
Maintenance Section
Ignition System Spark Plugs - Check/Adjust
• Use care in order to clean only the electrode and Use the proper torque.
the insulator near the electrode.
• Do not use glass beads on the outside of the shell 4. Install the spark plug by hand until the spark
or on the upper part of the insulator. plug bottoms out. For the 301-6663 Spark Plug,
tighten the spark plug to 48 ± 5 N·m (35 ± 4 lb ft).
For the 243-4291 Spark Plug, tighten the spark
Installing the Spark Plug plug to 45 ± 5 N·m (33 ± 3 lb ft).
Note: Use the 9U-7516 Spark Plug Gauge to 5. Inspect the extension and clean the extension.
measure the electrode gap. Do not use a flat feeler
gauge for measuring the electrode gap of used
spark plugs. A feeler gauge will produce a false
measurement because the used precious metal
surfaces will be curved.
7. Ensure that the transformer assembly is clean and Make repairs, if necessary. For information regarding
free of dirt and oil. Assemble the extension into removal and installation of the components, refer
the transformer. Install the transformer. to Service Manual, “Disassembly and Assembly”.
Consult your Caterpillar dealer for assistance.
8. Connect the wiring harness. Tighten the connector
clockwise with pliers until the connector cannot be
i00683392
loosened by hand. Replace the lockwire.
Inlet Gas Manifold and Piping -
i01612988 Inspect/Replace
Ignition System Spark Plugs - SMCS Code: 1550-040; 1550-510
Replace
Inspect the components of the fuel inlet system for
SMCS Code: 1555-510 the following conditions:
SMCS Code: 1058-040; 1071-040; 1087-040 • Fuel lines from the source to the gas regulator
Use of a platform may be necessary to inspect the • Fuel lines from the gas regulator to the fuel inlet
following components of the air inlet system:
• Fuel inlet
• Piping between the air cleaner and the turbocharger
• Control valve
• Rubber hoses in the air lines
• Fuel manifold
• Turbocharger
• Connections of the fuel manifold and the fuel lines
• Piping between the turbocharger and the
aftercooler • Connections of the fuel lines to the orifice
• Connection of the aftercooler to the air plenum • Connections of the fuel lines to the precombustion
chamber
• Connection of the air plenum to the cylinder head
• Fuel pressure sensor
Inspect the components for the following conditions:
• Fuel temperature sensor
• Cracks Ensure that all of the connections are secure. Ensure
that the components of the fuel system are in good
• Leaks condition.
• Loose connections Make repairs, if necessary. For information regarding
removal and installation of the components, see the
• Debris Service Manual. Consult your Caterpillar dealer for
Ensure that all of the connections are secure. Ensure assistance.
that the components are in good condition and free
of debris.
112 SEBU7563-09
Maintenance Section
Overhaul (In-Frame)
Each individual condition may not indicate a need If you elect to perform an overhaul without the
for an overhaul. However, evaluating the three services of a Caterpillar dealer, be aware of the
conditions together is the most accurate method of following recommendations.
determining when an overhaul is necessary.
The following definitions explain the terminology for
The engine may not require an overhaul if the the services that are performed during an overhaul:
engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder Inspect – Inspect the components according to
compression. the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Periodically measure each of the three conditions. Parts and Salvage Operations, SEBF8029, “Index
The first measurement should occur during the first of Publications on Reusability or Salvage of Used
scheduled maintenance. This establishes a baseline Parts”. The guidelines were developed in order to
for future measurements. Additional measurements help Caterpillar dealers and customers to avoid
are scheduled at regular intervals in order to unnecessary expenditures. New parts are not
determine a schedule for the next in-frame overhaul. required if the existing parts can still be used,
reconditioned, or repaired. If the components are
The following changes in the three conditions not in the reusability guidelines, refer to the Service
normally require a scheduled overhaul: Manual, “Specifications” module.
• A 300 percent increase in oil consumption Rebuild – The component can be reconditioned in
order to comply with reusability guidelines.
• A 200 percent increase in crankcase blowby
• A 20 percent loss of cylinder compression
SEBU7563-09 113
Maintenance Section
Overhaul (Major)
• The service hours of the engine Inspect – Inspect the components according to
the instructions that are in Caterpillar reusability
• The wear metal analysis of the lube oil publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
• An increase in the levels of noise and vibration of Publications on Reusability or Salvage of Used
Parts”. The guidelines were developed in order to
An increase of wear metals in the lube oil indicates help Caterpillar dealers and customers to avoid
that the bearings and the surfaces that wear may unnecessary expenditures. New parts are not
need to be serviced. An increase in the levels of required if the existing parts can still be used,
noise and vibration indicates that rotating parts reconditioned, or repaired. If the components are
require service. not in the reusability guidelines, refer to the Service
Manual, “Specifications” module.
Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder Rebuild – The component can be reconditioned in
liners may be worn so that polishing of the bore order to comply with reusability guidelines.
occurs. Also, the increased use of lube oil will dilute
the wear metals. Replace – The service life of the part is exhausted.
The part may fail before the next maintenance
Monitor the engine as the engine accumulates interval. The part must be replaced with a part that
service hours. Consult your Caterpillar dealer about meets functional specifications. The replacement
scheduling a major overhaul. part may be a new part, a CAT remanufactured part,
a rebuilt part, or a used part. Some worn components
Note: The driven equipment may also require service may be exchanged with your Caterpillar dealer.
when the engine is overhauled. Refer to the literature Consult your Caterpillar dealer about repair options
that is provided by the OEM of the driven equipment. for your engine.
Table 40
Major Overhaul Information
Major Overhaul(1)
A major overhaul includes all of the work that is done Procedure Component
for a top end overhaul. A major overhaul can also
include all of the work that is done for an in-frame Inspect Camshafts
overhaul. A major overhaul includes additional parts Replace
Connecting rods
and labor. Additional parts and labor may be required
in order to completely rebuild the engine. In some Crankshaft
cases, the engine is relocated for disassembly. Rebuild Inlet air piping
For the major overhaul, bearings, seals, gaskets, and Replace Aftercooler
components that wear are disassembled. The parts Camshaft lifters
are cleaned and inspected. If necessary, the parts
are replaced. The crankshaft is measured for wear. Exhaust manifolds
The crankshaft may require regrinding. Alternatively, Gear train bearings
the crankshaft may be replaced with a Caterpillar
replacement part. Oil cooler
(1) In addition to these procedures, perform the procedures for
Your Caterpillar dealer can provide these services both the top end overhaul and the in-frame overhaul.
and components. Your Caterpillar dealer can ensure
that the components are operating within the
i03247357
appropriate specifications.
The following definitions explain the terminology for Scheduling a Top End Overhaul
the services that are performed during an overhaul:
Table 41 lists the approximate number of service
hours before a top end overhaul for different G3600
Engine applications.
SEBU7563-09 115
Maintenance Section
Overhaul (Top End)
• Torque wrenches
• Dial indicators
• Accurate measurement tools
116 SEBU7563-09
Maintenance Section
Overhaul Considerations
Replace – The service life of the part is exhausted. • Costly unplanned downtime can be avoided.
The part may fail before the next maintenance
interval. The part must be replaced with a part that • Many original parts can be reused according to the
meets functional specifications. The replacement guidelines for reusable parts.
part may be a new part, a Cat remanufactured part, a
rebuilt part, or a used part. Some worn components • The service life of the engine can be extended
may be exchanged with your Caterpillar dealer. without the risk of a major catastrophe due to
Consult your Caterpillar dealer about repair options engine failure.
for your engine.
• Achieve the best cost/value relationship per hour
Table 42 of extended service life.
Top End Overhaul
Procedure Component
Overhaul Intervals
Inspect/Replace Seals for the gas admission Top end overhauls are determined by the projection
valve of exhaust valve stems. In-frame overhauls are
Precombustion chambers determined by cylinder compression, crankcase
Drive coupling blowby, and oil consumption. Major overhauls are
Rebuild Gas pressure regulator determined by the in-frame tests, and by results of
Starting motor S·O·S oil analysis.
Turbochargers
Some other factors that are important for determining
Replace Connecting rod bearings
Cylinder heads and
the overhaul intervals include the following
gaskets considerations:
Oil temperature regulators
Spark plug extenders • Performance of preventive maintenance
Water temperature
regulators • Use of recommended lubricants
• Use of recommended coolants
i02250409
• Use of recommended fuels
Overhaul Considerations
• Proper installation
SMCS Code: 7595-043
• Operating conditions
Overhaul Information
• Operation within acceptable limits
An overhaul is replacing the major worn components
of the engine. An overhaul is a maintenance interval • Engine load
that is planned. The engine is rebuilt with certain
rebuilt parts or new parts that replace the worn parts. • Engine speed
An overhaul also includes the following maintenance: Note: To avoid oil problems, engines that are
turbocharged and aftercooled must be operated at a
• Inspection of all the parts that are visible during minimum of 60 percent of rated load.
the disassembly
Generally, engines that are operated at a reduced
• Replacement of the seals and gaskets that are load and/or speed achieve more service life before
removed an overhaul. However, this is for engines that are
properly operated and maintained.
• Cleaning of the internal passages of the engine
and the engine block
Bio-Gas • Crankshafts
The overhaul intervals for engines that use bio-gas • Cylinder heads
depend on the concentration of contaminants in the
fuel. Although silicon is the primary contaminant • Oil Pumps
in bio-gas, other contaminants may cause further
reductions in the overhaul intervals. For more • Starting motors
information, refer to Gas Engines Application and
Installation Guide, LEKQ7260, “G3600 - G3300 Low • Turbochargers
Energy Fuels”.
• Water pumps
Overhaul Inspection
Consult your Caterpillar dealer for details and for a
Refer to the Service Manual for the disassembly and list of the remanufactured parts that are available.
assembly procedures that are necessary in order
to perform the required maintenance on the items Your Caterpillar dealer may be offering a variety of
that are listed. Consult your Caterpillar dealer for overhaul options.
assistance.
A Flat Rate Overhaul guarantees the maximum price
To determine the reusability publications that are that you will pay for an overhaul. Flat rate prices on
needed to inspect the engine, refer to Guidelines for preventive maintenance programs or major repair
Reusable Parts and Salvage Operations, SEBF8029, options are available from many servicing dealers
“Index of Publications on Reusability or Salvage of for all Caterpillar Engines. Consult your Caterpillar
Used Parts”. dealer in order to schedule a before failure overhaul.
Overhaul Programs
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:
• Alternators
• Connecting rods
118 SEBU7563-09
Maintenance Section
Prechamber - Clean/Inspect
i02602727 i02602093
g00789869
Illustration 100
(1) Plug
(2) O-ring seal
(3) Check valve assembly
(4) O-ring seal
g01302648 (5) Gasket
Illustration 99
i02602222 Inspect the prelube pump for leaks. Replace all of the
seals if a leak is observed.
Prechamber Check Valves -
Replace Inspect the wiring for the following conditions:
Note: Problems with the electric starting motor can Turbocharger - Clean
be caused by the following conditions: malfunction of (Cleaning with Dry Particles)
the solenoid and malfunction of the electric starting
system. SMCS Code: 1052-070
Inspect the electrical system for the following Note: Use of a platform may be necessary to reach
conditions: the turbocharger.
• Loose connections If the engine has more than one turbocharger, each
turbocharger requires cleaning.
• Corrosion
Note: The drain openings in the exhaust housing
• Wires that are worn or frayed of the turbocharger are closed during the cleaning
procedure. Some of the particles will be expelled
• Cleanliness through the exhaust stack. The particles that are
expelled will be burned.
Make repairs, if necessary.
The materials that are listed in Table 43 are
Air Starting Motor recommended for use with this cleaning procedure.
Table 43
Materials for Cleaning 3600 Engine Turbochargers
Personal injury or death can result from improp- Material Particle Size
erly checking for a leak. Nut shell 1.7 mm
(1/16 inch)
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure, Formed carbon 1 mm (1/32 inch)
even a pin-hole size leak, can penetrate body tis- Granulated carbon (70% hardness) 1.2 to 2 mm
sue causing serious injury, and possible death. (3/64 to 5/64 inch)
If fluid is injected into your skin, it must be treated Granulated dry rice 1.7 mm
(1/16 inch)
immediately by a doctor familiar with this type of
injury.
5. Inspect the bore of the turbine housing for Note: Use of a platform may be necessary in order to
corrosion. reach the cleaner tube.
i00682053
• Check the fuel system for leaks. Look for loose fuel
line clamps.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
i02624237
i01028392
• 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.
i00912149
Maintenance Records
SMCS Code: 1000; 4450
i03905196
Maintenance Log
SMCS Code: 1000; 4450
Table 44
Engine Model Customer Identifier
Serial Number Arrangement Number
Service
Service Item Date Authorization
Hours
SEBU7563-09 129
Reference Information Section
Reference Materials
i00769479
Table 45
Engine Model Serial Number Service Hours Authorization
Cylinder Valve Location Current Stem Rotator
Cylinder Wear
Pressure Measure Baseline Baseline
1 Pushrod Side
Exhaust Manifold
2 Pushrod Side
Exhaust Manifold
3 Pushrod Side
Exhaust Manifold
4 Pushrod Side
Exhaust Manifold
5 Pushrod Side
Exhaust Manifold
6 Pushrod Side
Exhaust Manifold
7 Pushrod Side
Exhaust Manifold
8 Pushrod Side
Exhaust Manifold
9 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
130 SEBU7563-09
Reference Information Section
Reference Materials
• Special Instruction, SEHS7332, “Do Not Operate The International Organization for Standardization
Tag” (ISO) offers information and customer service
regarding international standards and standardizing
• Special Instruction, SEHS7633, “Battery Test activities. ISO can also supply information on the
Procedure” following subjects that are not controlled by ISO:
national standards, local standards, regulations,
• Special Instruction, SEHS8622, “Using the FT1984 certification, and related activities. Consult the
Air-To-Air Aftercooler Leak Test Group” member of ISO in your country.
i00382622
Warranty Information
SMCS Code: 1000
Index
A Control Panel......................................................... 38
Advisor II ........................................................... 38
Actuator Control Linkage - Lubricate (If “DESIRED SPEED” Potentiometer .................... 43
applicable) ........................................................... 66 “EMERGENCY STOP” Button ........................... 41
Hydraulic Actuators............................................ 66 Indicators ........................................................... 41
Actuator Control Linkage - Replace....................... 66 “MANUAL PRELUBE” Switch and “PRELUBE
Removal and Installation.................................... 66 ACTIVE” Indicator ............................................ 42
Additional Messages ............................................. 10 Mode Control Switch.......................................... 42
After Starting Engine ............................................. 49 Control Panel - Inspect .......................................... 74
Engaging the Driven Equipment ........................ 49 Record the Data and Review the Data .............. 74
After Stopping Engine............................................ 53 Cooling System Coolant (NGEC) - Change .......... 74
Aftercooler Condensation - Drain .......................... 67 Clean the Cooling System ................................. 75
Air Starting Motor Lines Screen - Clean ................ 67 Cleaning a Cooling System that has Heavy
Air Starting Motor Lubricator Bowl - Clean ............ 67 Deposits or Plugging ........................................ 75
Air Starting Motor Lubricator Oil Level - Check ..... 68 Drain the Cooling System .................................. 74
Adjust the Lubricator .......................................... 69 Fill the Cooling System ...................................... 75
Air Tank Moisture and Sediment - Drain................ 69 Cooling System Coolant Level - Check ................. 76
Alternator - Inspect ................................................ 69 Add Coolant ....................................................... 76
Engines That Are Equipped With a Sight
Gauge .............................................................. 76
B Engines That Are Not Equipped With a Sight
Gauge .............................................................. 76
Barring Device - Lubricate ..................................... 69 Cooling System Coolant Sample (Level 1) -
Electric Barring Device....................................... 70 Obtain .................................................................. 77
Manual Barring Device....................................... 70 Cooling System Coolant Sample (Level 2) -
Battery Electrolyte Level - Check .......................... 71 Obtain .................................................................. 77
Before Starting Engine .................................... 17, 45 Cooling System Level Switch - Inspect ................. 77
Air Inlet System.................................................. 45 Cooling System Supplemental Coolant Additive
Cooling System.................................................. 45 (SCA) - Test/Add.................................................. 78
Driven Equipment .............................................. 45 Add the SCA, If Necessary ................................ 79
Electrical System ............................................... 45 Test the Concentration of the SCA..................... 78
Fuel System ....................................................... 46 Cooling System Water Temperature Regulator -
Hydraulic Actuator System................................. 46 Replace................................................................ 79
Lubrication System ............................................ 46 Crankcase Blowby - Measure/Record ................... 80
Starting System.................................................. 46 Crankshaft Vibration Damper - Inspect ................. 80
Walk-Around Inspection..................................... 45 Removal and Installation.................................... 81
Belts - Inspect/Adjust/Replace............................... 71 Crushing Prevention and Cutting Prevention ........ 16
Adjusting the Alternator Belt .............................. 71 Customer Assistance........................................... 125
Adjusting the Fan Drive Belt .............................. 72 Outside of the USA and of Canada.................. 125
Inspection........................................................... 71 USA and Canada ............................................. 125
Replacement...................................................... 72 Customer Service ................................................ 125
Burn Prevention..................................................... 14 Cylinder Pressure - Measure/Record .................... 81
Batteries............................................................. 14 Cylinders - Inspect (Inspect the Combustion
Coolant............................................................... 14 Chamber)............................................................. 82
Oils..................................................................... 14
D
C
Driven Equipment - Check..................................... 82
Cold Weather Starting ........................................... 46 Check the Alignment.......................................... 83
Jacket Water Heaters ........................................ 47 Every 10,000 Service Hours .............................. 83
Lubricating Oil Heaters ...................................... 47 Every 5000 Service Hours ................................. 82
Requirements for Starting with Air ..................... 47 Driven Equipment - Inspect/Replace/Lubricate ..... 83
Combustion Sensor - Clean/Inspect/Replace........ 72
Configuration Parameters...................................... 44
134 SEBU7563-09
Index Section
E F
M R
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
©2010 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge Printed in U.S.A.
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.