SEBU7563-02

June 2002

Operation and
Maintenance
Manual
G3600 Engines
4ZS1-Up (Engine)
BEN1-Up (Engine)
BKE1-Up (Engine)
BLB1-Up (Engine)
 i01658146

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents Maintenance Interval Schedule (Engines that use

Bio-Gas) .............................................................. 69

Foreword ................................................................. 4 Maintenance Interval Schedule (Engines with a

10.5:1 Compression Ratio that use Wellhead Gas or
Natural Gas) ........................................................ 71
Safety Section
Safety Signs and Labels ......................................... 6 Reference Information Section

General Hazard Information ................................. 12 Customer Service ............................................... 123

Burn Prevention .................................................... 15 Reference Materials ............................................ 125

Fire Prevention and Explosion Prevention ............ 15 Index Section

Crushing Prevention and Cutting Prevention ........ 17 Index ................................................................... 130

Mounting and Dismounting ................................... 17

Ignition Systems ................................................... 17

Before Starting Engine .......................................... 18

Engine Starting ..................................................... 18

Engine Stopping ................................................... 18

Electrical System .................................................. 18

Product Information Section

Model Views and Specifications ........................... 20

Product Identification Information ........................ 29

Operation Section
Engine Lifting and Storage ................................... 31

Features and Controls .......................................... 33

Engine Starting ..................................................... 42

Engine Operation .................................................. 46

Engine Stopping ................................................... 47

Maintenance Section
Lubricant Specifications ........................................ 49

Fuel Specifications ................................................ 54

Cooling System Specifications ............................. 58

Refill Capacities .................................................... 66

Maintenance Interval Schedule (Engines with a

9:1 Compression Ratio that use Wellhead Gas or
Natural Gas) ........................................................ 68
4
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.
English is the primary language for all Caterpillar
publications. The English used facilitates translation
and consistency in electronic media delivery.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Caterpillar dealer for the latest
available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance
and repair on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting,
operating and stopping the engine. This section
also includes a discussion of electronic diagnostic
information.
Maintenance
The maintenance section is a guide to engine
care. The illustrated, step-by-step instructions are
grouped by service hours and/or calendar time
maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions
that follow.
Use service hours to determine intervals. Calendar
intervals shown (daily, annually, etc) may be used
instead of service meter intervals if they provide
more convenient schedules and approximate the
indicated service meter reading.
Recommended service should always be
performed at the service hour interval. The actual
operating environment of the engine also governs
the maintenance schedule. Therefore, under
extremely severe, dusty, wet or freezing cold
operating conditions, more frequent lubrication and
maintenance than is specified in the maintenance
schedule may be necessary.
The maintenance schedule items are organized
for a preventive maintenance management
program. If the preventive maintenance program
is followed, a periodic tune-up is not required.
The implementation of a preventive maintenance
management program should minimize operating
costs through cost avoidances resulting from
reductions in unscheduled downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples
of the original requirement. Each level and/or
individual items in each level should be shifted
ahead or back depending upon your specific
maintenance practices, operation and application.
We recommend that the maintenance schedules
be reproduced and displayed near the engine as
a convenient reminder. We also recommend that a
maintenance record be maintained as part of the
engines permanent record.
See the section in the Operation and Maintenance
Manual, Maintenance Records for information
regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized
Caterpillar dealer can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
California Proposition 65 Warning
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
 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
Safety Section
Safety Signs and Labels

Safety Section
i01749840

Safety Signs and Labels

SMCS Code: 1000; 4450; 7405
 7
Safety Section
Safety Signs and Labels

g00901952
Illustration 1
8
Safety Section
Safety Signs and Labels

g00901955
Illustration 2

There may be several specific safety signs on the

engine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Please become familiar with all safety signs.
 9
Safety Section
Safety Signs and Labels

Ensure that all of the safety signs are legible. Clean (2) Removal of the Prechamber
the safety signs or replace the safety signs if the
words cannot be read or if the pictures are not
Assembly
visible. When the safety signs are cleaned, use a
The notices for the removal of the prechamber
cloth, water, and soap. Do not use solvent, gasoline,
assemblies are located on each valve cover.
or other harsh chemicals to clean the safety signs.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety signs. The
safety signs that are loosened could drop off of
the engine.

Replace any damaged safety signs or missing

safety signs. If a safety sign is attached to a part of
the package that is replaced, install a new safety g00902999
sign on the replacement part. Any Caterpillar dealer
can provide new safety signs. NOTICE

To prevent damage, drain the coolant and remove

Do not operate or work on this engine unless you
have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.
The safety signs and notices that may be attached
on the engine are illustrated and described below.
the spark plugs before removing the prechamber.
Tighten the combustion sensor wire assembly nuts
to 9.5 .5 Nm (85 5 lb in). Do not overtighten.
(3) Oil Filter
This information is for engines that have a control
valve for the oil filters. The warning label for the oil
filters is located on the oil filter covers.

(1) Lifting Eye

The notices for the lifting eyes are located on the
bases of the lifting eyes.
g00123170

Filter contains hot pressurized fluid when engine

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

g00902989

NOTICE

For lifting engine only, use a 50.8 anchor shackle.

10
Safety Section
Safety Signs and Labels

This information is for engines that do not have a (5) Read the Manual
control valve for the oil filters. The warning label for
the oil filters is located on the oil filter covers. The warning label for reading the manual is located
on the cover of the junction box.

g00296929

Filter contains hot pressurized fluid when engine

is running.

To avoid personal injury, stop engine before re- g00903032

moving filter cover.

(4) Pinch Point (Linkage)
The warning labels for the pinch point (linkage) are
located on the covers of the fuel control actuator,
the air choke actuator, and the bracket of the
exhaust bypass actuator .
Do not operate or work on this engine unless you
have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.

g00123168

During operation, the linkage of the electrohy-

draulic actuators can form pinch points which
can cause personal injury. Shut down the engine
before you service the electrohydraulic actuators.

(6) Barring Device
The warning label for the barring device is located
on the guard of the barring device.
g00902932
Guards must be in place prior to operating barring
device motor.
Remove all hand tools prior to operating barring
device motor.
NOTICE
The barring device must be disengaged before
starting the engine.
Tighten nut to 270 Nm max. (200 lb ft) to lock
barring device.
Refer to the operations and maintenance manual for
further operating instructions.
11
Safety Section
Safety Signs and Labels
(7) Crankcase Covers
The warning label for the crankcase covers is
located on the rearmost crankcase covers.
g00123185
Flash fire may result in personal injury, if
crankcase covers are removed within fifteen
minutes after emergency shut down. Do not
restart engine until cause for shutdown has been
corrected.
12
Safety Section
General Hazard Information
(8) Engine Lifting (Label On the
Number Three Camshaft Cover
and On the Number Four Camshaft
Cover)
Warning labels for engine lifting are located on the
camshaft cover of the number three cylinder and on
the camshaft cover of the number four cylinder.
g00299841
Improper lift rigging can allow unit to tumble caus-
ing injury and damage.
1. Use a proper spreader bar, as shown.
2. Attach two properly rated cables to the spreader
bar from the engine lift shackles.
(9) Engine Lifting (Label On the
Number One Camshaft Cover and
On the Number Two Camshaft
Cover)
Warning labels for engine lifting are located on the
camshaft cover of the number one cylinder and on
the camshaft cover of the number two cylinder.
g00299818
Improper lift rigging can allow unit to tumble caus-
ing injury and damage.
1. Use a proper spreader bar, as shown.
2. Attach two properly rated cables to the spreader
bar from the engine lift shackles.
i01359759
General Hazard Information
SMCS Code: 1000; 4450; 7405
g00104545
Illustration 3

Attach a Do Not Operate warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine
is repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine
and to each operator control station. When it is
appropriate, disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Engine exhaust contains products of combustion
which may be harmful to your health. Always
start the engine and operate the engine in a well
ventilated area. If the engine is in an enclosed area,
vent the engine exhaust to the outside.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
Filler caps
Grease fittings
Pressure taps
Breathers
Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order
to relieve any spring pressure or other pressure.
g00702020
Illustration 4
Wear a hard hat, protective glasses, and other
protective equipment, as required.
When work is performed around an engine that
is operating, wear protective devices for ears in
order to help prevent damage to hearing.
13
Safety Section
General Hazard Information
Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.
Ensure that all protective guards and all covers
are secured in place on the engine.
Never put maintenance fluids into glass
containers. Glass containers can break.
Use all cleaning solutions with care.
Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
The engine is stopped. Ensure that the engine
cannot be started.
Disconnect the batteries when maintenance
is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
Do not attempt any repairs that are not
understood. Use the proper tools. Replace
any equipment that is damaged or repair the
equipment.
California Proposition 65 Warning
Some engine exhaust constituents are known to the
State of California to cause cancer, birth defects,
and other reproductive harm.
Pressure Air and Water
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result
in personal injury.
When pressure air and/or pressure water is used
for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be
below 275 kPa (40 psi).
14
Safety Section
General Hazard Information
Fluid Penetration
g00687600
Illustration 5
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak
can cause severe injury. If fluid is injected into your
skin, you must get treatment immediately. Seek
treatment from a doctor that is familiar with this type
of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Tools and
Shop Products Guide for the following items:
Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.
Asbestos Information
g00702022
Illustration 6
Caterpillar equipment and replacement parts that
are shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine
Caterpillar replacement parts. Use the following
guidelines when you handle any replacement parts
that contain asbestos or when you handle asbestos
debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that
contain asbestos fibers. Inhaling this dust can
be hazardous to your health. The components
that may contain asbestos fibers are brake pads,
brake bands, lining material, clutch plates, and
some gaskets. The asbestos that is used in these
components is usually bound in a resin or sealed in
some way. Normal handling is not hazardous unless
airborne dust that contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
Never use compressed air for cleaning.
Avoid brushing materials that contain asbestos.
Avoid grinding materials that contain asbestos.
Use a wet method in order to clean up asbestos
materials.
A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
Use exhaust ventilation on permanent machining
jobs.
Wear an approved respirator if there is no other
way to control the dust.

Comply with applicable rules and regulations
for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in 29 CFR 1910.1001.
Obey environmental regulations for the disposal
of asbestos.
Stay away from areas that might have asbestos
particles in the air.
Dispose of Waste Properly
g00706404
Illustration 7
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01480768
Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
15
Safety Section
Burn Prevention
Any contact with hot coolant or with steam
can cause severe burns. Allow cooling system
components to cool before the cooling system is
drained.
Check the coolant level after the engine has
stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing
the filler cap. The filler cap must be cool enough
to touch with a bare hand. Remove the filler cap
slowly in order to relieve pressure.
Cooling system conditioner contains alkali. Alkali
can cause personal injury. Do not allow alkali to
contact the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil 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 the eyes. Always wear protective glasses
for servicing batteries. Wash hands after touching
the batteries and connectors. Use of gloves is
recommended.
i01372262
Fire Prevention and Explosion
Prevention
SMCS Code: 1000; 4450; 7405
Illustration 8
g00704000
All fuels, most lubricants, and some coolant mixtures
are flammable.
16
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.

If the application involves the presence of

combustible gases, consult your Caterpillar dealer
for additional information about suitable protection
devices.

Remove all flammable materials such as fuel, oil,

and debris from the engine. Do not allow any
flammable materials to accumulate on the engine.

Store fuels and lubricants in properly marked

containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.

Do not expose the engine to any flame. g00704135

Illustration 9

Exhaust shields (if equipped) protect hot exhaust

Gases from a battery can explode. Keep any open
components from oil or fuel spray in case of a line,
flames or sparks away from the top of a battery. Do
a hose, or a seal failure. Exhaust shields must be
not smoke in battery charging areas.
installed correctly.
Never check the battery charge by placing a metal
Do not weld on lines or tanks that contain flammable
object across the terminal posts. Use a voltmeter or
fluids. Do not flame cut lines that contain flammable
a hydrometer.
fluid. Clean any such lines thoroughly with a
nonflammable solvent prior to welding or flame
Improper jumper cable connections can cause
cutting.
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
Wiring must be kept in good condition. All electrical
instructions.
wires must be properly routed and securely
attached. Check all electrical wires daily. Repair any
Do not charge a frozen battery. This may cause
wires that are loose or frayed before you operate
an explosion.
the engine. Clean all electrical connections and
tighten all electrical connections.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
Eliminate all wiring that is unattached or
recommended cables, connections, and battery
unnecessary. Do not use any wires or cables that
box covers when the engine is operated.
are smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Fire Extinguisher
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly Make sure that a fire extinguisher is available. Be
maintained battery cables will help to prevent arcing familiar with the operation of the fire extinguisher.
or sparking. Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not
use your bare hand to check for leaks. Use a
board or cardboard to check for leaks. Tighten all
connections to the recommended torque.
Replace the parts if any of the following conditions
are present:
End fittings are damaged or leaking.
Outer coverings are chafed or cut.
Wires are exposed.
Outer coverings are ballooning.
Flexible part of the hoses are kinked.
Outer covers have embedded armoring.
End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
i01359666
Crushing Prevention and
Cutting Prevention
SMCS Code: 1000; 4450; 7405
Support the component properly when work
beneath the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The
fan blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
17
Safety Section
Crushing Prevention and Cutting Prevention
Chips or other debris may fly off objects when
objects are struck. Before objects are struck, ensure
that no one will be injured by flying debris.
i01372247
Mounting and Dismounting
SMCS Code: 1000; 4450; 7405
Inspect the steps, the handholds, and the work
area before mounting the engine. Keep these items
clean and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use
any controls as handholds.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a
hand line to raise and lower tools or supplies.
i01519141
Ignition Systems
SMCS Code: 1550
Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and
wiring.
Do not inspect the valve mechanism or the
transformers while the engine is operating. Personal
injury or death may result.
If the mode control switch is in the AUTOMATIC
or START position and the wiring harness is
connected, the ignition system may discharge and
a spark plug will ignite. The spark plug will ignite
any gas that has accumulated in that cylinder. The
crankshaft and the driven equipment can move.
Personal injury may result. The driven equipment
could be damaged. Gas that has accumulated in
the exhaust system can also be ignited.
18
Safety Section
Before Starting Engine
Turn the mode control switch to the STOP or
OFF/RESET position before connecting the wiring
harness. When the mode control switch is in the
STOP or OFF/RESET position, the ignition system
is disabled.
i00659904
Before Starting Engine
SMCS Code: 1000
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
Ensure that the engine is equipped with a lighting
system that is suitable for the conditions. Ensure
that all lights work properly.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits
are provided in order to help prevent personal
injury. The circuits are also provided in order to help
prevent engine damage.
On the initial start-up of a new engine or an engine
that has been serviced, be prepared to stop the
engine if an overspeed condition occurs. This may
be accomplished by shutting off the fuel supply to
the engine, or shutting off the ignition system.
See the Service Manual for repairs and for
adjustments.
i00572000
Engine Starting
SMCS Code: 1000
If a warning tag is attached to the engine start
switch or to the controls, DO NOT start the engine
or move the controls. Consult with the person that
attached the warning tag before the engine is
started.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine from the operators compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, Engine Starting topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge
and the oil temperature gauge during the heater
operation.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
i00659907
Engine Stopping
SMCS Code: 1000
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to the instructions in this Operation and
Maintenance Manual, Engine Stopping topic
(Operation Section).
Use the Emergency Stop Button (if equipped)
ONLY in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop
the engine if an overspeed occurs. This may be
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
i01032810
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
 19
Safety Section
Electrical System

Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires
before the engine is operated. Repair all frayed
electrical wires before the engine is started.

Grounding Practices
Proper grounding is necessary for optimum engine
performance and reliability. Improper grounding will
result in uncontrolled electrical circuit paths and in
unreliable electrical circuit paths.

Uncontrolled electrical circuit paths can result in

damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
Uncontrolled electrical circuit paths can also cause
electrical activity that may degrade the engine
electronics and communications.

Ensure that all grounds are secure and free of

corrosion.

The engine alternator must be grounded to the

negative - battery terminal with a wire that is
adequate to carry the full charging current of the
alternator.

For the starting motor, do not attach the battery

negative terminal to the engine block.

Ground the engine block with a ground strap that

is furnished by the customer. Connect this ground
strap to the ground plane.

Use a separate ground strap to ground the battery

negative terminal for the control system to the
ground plane.

If rubber couplings connect the steel piping of the

cooling system and the radiator, the piping and the
radiator can be electrically isolated. Ensure that the
piping and the radiator are continuously grounded
to the engine. Use ground straps that bypass the
rubber couplings.
20
Product Information Section
Model Views and Specifications

Product Information
Section

Model Views and

Specifications
i01744053

Model View Illustrations

SMCS Code: 1000; 4450

The illustrations show various typical features of

G3600 Engines. The illustrations do not show all of
the options that are available.

g00892828
Illustration 10
Right hand view (in-line engine)
(1) Gas shutoff valve (5) Engine oil filter
(2) Fuel actuator (6) Junction box
(3) Ignition transformer (7) Crankcase pressure sensor
(4) Integrated Combustion Sensing Module (8) Engine oil level gauge
(ICSM) (9) Engine oil filler

Illustration 11
Left hand view (in-line engine)
(1) Exhaust bypass actuator
(2) Air choke actuator
Illustration 12
Right hand view (vee engine)
(1) Gas shutoff valve
(2) Exhaust bypass actuator
(3) Fuel actuator
(4) Integrated Combustion Sensing Module
(ICSM)
21
Product Information Section
Model Views and Specifications
g00892830
(3) Hydraulic oil tank (5) Hydraulic oil filter
(4) Hydraulic oil pump
g00893222
(5) Engine oil filter (10) Engine oil filler
(6) Junction box
(7) Ignition rail
(8) Crankcase pressure sensor
(9) Engine oil level gauge
22
Product Information Section
Model Views and Specifications
Illustration 13
Left hand view (vee engine)
(1) Ignition transformer (4)
(2) Integrated Combustion Sensing Module (5)
(ICSM) (6)
(3) Air choke actuator (7)
Product Description
SMCS Code: 1000; 4450
The G3600 Family of Engines is designed to provide
power for the following applications:
Electrical power generation
Gas compression
Industrial air compression
Petroleum
The engines incorporate advanced technology that
is essential for obtaining high output, low emissions,
and thermal efficiency.
Precise control of the engine parameters enable
optimum engine performance. The engines are
capable of using a variety of fuels in various
ambient conditions.
The Engine Control Module (ECM) controls most
of the functions of the engine. The module is an
environmentally sealed unit that is mounted in a
junction box on the engine. The ECM monitors
various inputs from sensors in order to activate
relays, solenoids, etc at the appropriate levels.
g00893223
Ignition rail
Hydraulic oil tank
Hydraulic oil pump
Hydraulic oil filter
i01522356 The ECM monitors the actual engine speed. The
ECM calculates the difference between the actual
engine speed and the desired engine speed. The
ECM controls the fuel actuator in order to maintain
the desired engine speed.
The fuel, the inlet air, and the exhaust bypass
are regulated by the ECM through control of
three electrohydraulic actuators. The actuators are
electronically controlled and hydraulically actuated.
The hydraulic oil is in a circuit that is separate from
the engine oil. The hydraulic oil is circulated by a
gear-driven pump.
The ECM operates the fuel actuator in order to
allow fuel to enter the gas manifold. Fuel flows from
the manifold through an orifice. Some of the gas
is routed through an adjustable needle valve and
into a precombustion chamber. The rest of the gas
is routed through a gas admission valve that is
actuated by the camshaft. This allows fuel to enter
the inlet port in the cylinder head.
Air for combustion flows from the turbocharger to
an air inlet choke. The ECM operates the air choke
actuator in order to allow air to enter the inlet air
manifold. The air flows through the aftercooler to the
air plenum and into the cylinder head inlet port. The
air is mixed with gas in the cylinder head. The rich
fuel in the precombustion chamber is ignited by the
spark plug. This provides the ignition for the air/fuel
mixture in the cylinder.

The inlet manifold air pressure is controlled by the
air inlet choke and the exhaust bypass valve. The
ECM determines the air pressure that is required to
maintain the correct air/fuel ratio.
Each cylinder has an ignition transformer. To
initiate combustion, the ECM sends a pulse of
approximately 108 volts to the primary coil of each
ignition transformer at the appropriate time and for
the appropriate duration. The transformer increases
the voltage which creates a spark across the spark
plug electrode.
The electronic control system controls the ignition
timing. The control system monitors changes in
the load. The control system modifies the timing
in response to the change in the load. The timing
can also be modified in order to compensate for
detonation that is detected.
The fuel flow is the main factor in the calculation of
the engine load. Zero fuel flow is zero load. A fuel
flow that is greater than zero is used to calculate a
percentage of the indicated load.
At loads that are less than 40 percent, the air/fuel
ratio is controlled by the air choke actuator which is
trimmed by the exhaust port temperatures.
The engine has an Integrated Combustion Sensing
Module (ICSM) for each bank of cylinders. Each
cylinder exhaust port has a thermocouple that
is monitored by an ICSM. The ICSM monitors
the actual exhaust port temperatures for one
bank of cylinders. The ICSM calculates an
average exhaust port temperature for the bank of
cylinders. The ECM sends a map of the desired
exhaust port temperature to the ICSM. The ICSM
calculates the difference between the average
exhaust port temperature and the desired exhaust
port temperature. The ICSM communicates the
information to the ECM. The ECM controls the air
choke actuator in order to maintain the desired
exhaust temperature.
When the load reaches approximately 40 percent,
the air/fuel ratio is controlled by the exhaust bypass
actuator which is trimmed by the combustion burn
time.
Each ICSM calculates an average combustion burn
time for all of the cylinders in one bank. The ECM
sends a map of the desired combustion burn time
to the ICSM. The ICSM calculates the difference
between the average combustion burn time and the
desired combustion burn time. The ICSM sends a
fuel correction factor to the ECM. The ECM controls
the exhaust bypass actuator in order to maintain
the desired combustion burn time.
23
Product Information Section
Model Views and Specifications
For more detailed information on the control system,
refer to Systems Operation, Electronic Control
System Operation.
The engine has two cooling circuits: a jacket water
circuit and a separate circuit for the aftercooler
and engine oil cooler. Water temperature regulators
are used in both circuits in order to maintain the
correct operating temperatures. Water temperature
regulators can be installed in order to regulate the
inlet or outlet temperature of the water.
A gear-driven centrifugal pump circulates the jacket
water coolant from an external source. The coolant
is circulated through the water jacket to the cylinder
heads. The coolant flows through water manifolds to
the outlet. The coolant flows through a remote water
temperature regulator and to a heat exchanger. The
coolant is returned to the engine.
The engine oil and the combustion air are cooled
in a separate circuit. A gear-driven pump pulls
the coolant from the heat exchanger. Some of the
coolant goes to the engine oil cooler. Most of the
coolant goes to the aftercooler. The coolant returns
to the heat exchanger.
A gear-driven pump pumps the engine oil. The
temperature of the engine oil is regulated. The
engine oil is filtered prior to circulation in the
cylinder block.
Engine Service Life
Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. This
includes use of the recommended lubricants, fuels,
and coolant/antifreezes.
For the engine maintenance that is required, see this
Operation and Maintenance Manual, Maintenance
Interval Schedule (Maintenance Section).
24
Product Information Section
Model Views and Specifications
Specifications
SMCS Code: 1000
Engine Specifications
Table 1
Operating rpm
Low idle rpm
Arrangement and
cylinders
Bore
Stroke
Aspiration
Compression ratio
Displacement per
cylinder
Total displacement
Mean velocity of the
pistons at 900 rpm
Mean velocity of the
pistons at 1000 rpm
Flywheel rotation
(standard)
Fuel
Method of starting
Performance of the
cooling system
Maximum allowable
exhaust back pressure
Maximum allowable
inlet air restriction
Air cleaners
Valve lash (gas
admission valve)(1)
Inlet valve lash
Exhaust valve lash
(1) This measurement is for newer engines. For earlier engines, the valve lash is set by turning an adjusting screw and counting the clicks.
i01758379
G3600 Engine Specifications
G3606 G3608 G3612 G3616
750 to 1000 750 to 1000 750 to 1000 750 to 1000
550 550 550 550
In-line In-line 50 degree V-12 50 degree V-16
6 8
300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch)
300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch)
TA TA TA TA
9:1 9:1 9:1 9:1
10.5:1 10.5:1
21.2 L (1294 in3) 21.2 L (1294 in3) 21.2 L (1294 in3) 21.2 L (1294 in3)
127.2 L (7762 in3) 169.6 L (10 350 in3) 254.4 L (15 528 in3) 339.2 L (20 704 in3)
9 m/s (1772 ft/min) 9 m/s (1772 ft/min) 9 m/s (1772 ft/min) 9 m/s (1772 ft/min)
10 m/s (1969 ft/min) 10 m/s (1969 ft/min) 10 m/s (1969 ft/min) 10 m/s (1969 ft/min)
Counterclockwise Counterclockwise Counterclockwise Counterclockwise
See this Operation and Maintenance Manual, Fuel Recommendations (Maintenance Section).
Also, see the Application and Installation Guide.
Air starting motors Air starting motors Air starting motors Air starting motors
See the Application See the Application See the Application See the Application
and Installation Guide. and Installation Guide. and Installation Guide. and Installation Guide.
3 kPa 3 kPa 3 kPa 3 kPa
(12 inches of H2O) (12 inches of H2O) (12 inches of H2O) (12 inches of H2O)
3.7 kPa 3.7 kPa 3.7 kPa 3.7 kPa
(15 inches of H2O) (15 inches of H2O) (15 inches of H2O) (15 inches of H2O)
Remote Remote Remote Remote
0.64 mm (.025 inch) 0.64 mm (.025 inch) 0.64 mm (.025 inch) 0.64 mm (.025 inch)
0.50 mm (.020 inch) 0.50 mm (.020 inch) 0.50 mm (.020 inch) 0.50 mm (.020 inch)
1.25 mm (.050 inch) 1.25 mm (.050 inch) 1.25 mm (.050 inch) 1.25 mm (.050 inch)
 25
Product Information Section
Model Views and Specifications

g00891513 g00790805
Illustration 14 Illustration 17
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

Drives and Gear Trains

Front Drives

g00891514
Illustration 15
G3608 Engine design
(A) Gas admission valves
(B) Inlet valves
(C) Exhaust valves g00790861
Illustration 18
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 16
G3612 Engine design
(A) Gas admission valves
(B) Inlet valves
(C) Exhaust valves
26
Product Information Section
Model Views and Specifications

Engine Front Gear Train

g00790864
Illustration 19
SAE standard engine crankshaft rotation g00891685
Illustration 20
In-line engines and vee engines SAE standard engine crankshaft rotation
(4) Water outlet In-line engines and vee engines
(5) Water inlet
(6) Oil outlet (1) Crankshaft
(7) Oil inlet (2) Idler
(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
 27
Product Information Section
Model Views and Specifications

Engine Rear Gear Train

g00891620
Illustration 21
SAE standard engine crankshaft rotation
In-line engines
(1) Crankshaft
(2) Large cluster idler
(3) Small cluster idler
(4) Camshaft

g00891688
Illustration 22
SAE standard engine crankshaft rotation
Vee engines
(1) Crankshaft
(2) Large cluster idler
(3) Small cluster idler
(4) Camshaft
(5) Idler

Table 4
Rear Gear Train
Gear Number Of Teeth
(1) Crankshaft 81
(2) Large cluster idler 90
(3) Small cluster idler 45
(4) Camshaft 81
(5) Idler 81
28
Product Information Section
Model Views and Specifications

Reference Weights
Table 5
Approximate Weights Of Package Generator Sets
Item G3606 Engine G3608 Engine G3612 Engine G3616 Engine
Engine(1) 15 680 kg (34 568 lb) 19 000 kg (41 888 lb) 25 084 kg (55 300 lb) 29 892 kg (65 900 lb)
Generator 8300 kg (18 298 lb) 9400 kg (20 723 lb) 15 855 kg (34 954 lb) 15 855 kg (34 954 lb)
(2)

8270 kg (18 232 lb)

(3)

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
Approximate Weights Of Serviceable Parts
Component G3606 Engine G3608 Engine G3612 Engine G3616 Engine
Cylinder block 4638 kg (10 225 lb) 6476 kg (14 260 lb) 6805 kg (14 971 lb) 9625 kg (21 219 lb)
Bearing cap 65 kg (144 lb) 65 kg (144 lb) 65 kg (144 lb) 65 kg (144 lb)
Crankshaft 1782 kg (3929 lb) 2288 kg (5034 lb) 2091 kg (4600 lb) 3800 kg (8378 lb)
Flywheel assembly 491 kg (1082 lb) 491 kg (1082 lb) 491 kg (1082 lb) 491 kg (1082 lb)
Crankshaft vibration damper 183 kg (403 lb) 267 kg (588 lb) 183 kg (403 lb) 183 kg (403 lb)
Cylinder head assembly 196 kg (432 lb) 196 kg (432 lb) 196 kg (432 lb) 196 kg (432 lb)
Cylinder liner 110 kg (243 lb) 110 kg (243 lb) 110 kg (243 lb) 110 kg (243 lb)
Piston assembly 48 kg (106 lb) 48 kg (106 lb) 48 kg (106 lb) 48 kg (106 lb)
Piston pin 19 kg (42 lb) 19 kg (42 lb) 19 kg (42 lb) 19 kg (42 lb)
Piston rod assembly 57 kg (126 lb) 57 kg (126 lb) 57 kg (126 lb) 57 kg (126 lb)
Turbocharger (one) 401 kg (884 lb) 401 kg (884 lb) 401 kg (884 lb) 401 kg (884 lb)
Aftercooler core(1) 52 kg (115 lb) 52 kg (115 lb) 94 kg (207 lb) 125 kg (275 lb)
Front housing 258 kg (569 lb) 258 kg (569 lb) 258 kg (569 lb) 258 kg (569 lb)
Rear housing 222 kg (489 lb) 222 kg (489 lb) 350 kg (772 lb) 350 kg (772 lb)
Used air cleaner element 29 kg (64 lb) 29 kg (64 lb) 29 kg (64 lb) 29 kg (64 lb)
(1) The weight for a single-stage type of aftercooler is listed. The two-stage aftercooler and the aftercooler with a deep core are also available.

Product Identification
Information
i01519197
Plate Locations and Film
Locations
SMCS Code: 1000; 4450
Engine Identification
Caterpillar engines are identified with serial
numbers, with performance specification numbers,
and with arrangement numbers. In some of the
cases, modification numbers are used. These
numbers are shown on the Serial Number Plate
and the Information Plate that are mounted on the
engine.
Caterpillar dealers need these numbers in order to
determine the components that were included with
the engine. This permits accurate identification of
replacement part numbers.
Serial Number Plate
g00123229
Illustration 23
The Serial Number Plate is on the side of the
cylinder block above one of the crankshaft
inspection covers. The following information is
stamped on the Serial Number Plate: engine serial
number, model, and arrangement number.
29
Product Information Section
Product Identification Information
Information Plate
Illustration 24
g00361974
The Information Plate is on the side of the cylinder
block above one of the crankshaft inspection
covers. The following information is stamped on
the Information Plate: engines maximum altitude,
horsepower, high idle, full load rpm, fuel settings,
and other information.
i01519312
Reference Information
SMCS Code: 1000; 4450
Identification of the items in Table 7 may be needed
in order to obtain parts and service. Some of the
numbers are on the engine Serial Number Plate
and/or Information Plate. Locate the information
for your engine. Record the information on the
appropriate space in Table 7. Make a copy of this
list for a record. Retain the information for future
reference.
The top level part numbers in the Parts Manual for
the engine are listed with the engine arrangement
number.
The performance specification can be used by
your Caterpillar dealer with the Technical Marketing
Information system. Before the engine leaves the
factory, the engine performance is tested. Detailed
performance data is recorded. The performance
specification number can be used for obtaining the
data.
30
Product Information Section
Product Identification Information

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
 31
Operation Section
Engine Lifting and Storage

Operation Section Engine Lifting with a Generator

NOTICE
Do not use the engine lifting eyes to remove the engine
Engine Lifting and Storage and generator together.

i01492427 A lifting plate is provided with the package

generator set. Instructions for lifting the package
Engine Lifting generator set are stamped on the lifting plate.
SMCS Code: 1000; 1122
Consult your Caterpillar dealer for information
regarding proper fixtures and lifting devices.

Lifting packaged generator sets will not be

level if you lift the unit with a single point lift. A
counterweight can be added between the package
frame rails whenever the application requires
frequent relocation of the unit. For complete
information about adding the counterweight, consult
your Caterpillar dealer.

The single point lifting eye is secured from the

Illustration 25
g00103219
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
factory before the enclosure is shipped. The correct
orientation of the single point lifting eye will allow
you to look through the eye when you stand at the
side of the enclosure. The lifting eye may stretch
when the package is lifted. This may cause the
locking nuts to loosen. This could cause the lifting
eye to swivel. Ensure that the lifting eye is correctly
oriented on the packaged generator set. Ensure
that the lifting eye is tightened to the correct torque
before you lift the packaged generator set.

When it is necessary to remove a component at an

angle, only use a link bracket that is properly rated for
the weight.

Use a hoist to remove heavy components. Use

an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should
be parallel to each other. The chains and cables
should be perpendicular to the top of the object
that is being lifted.

Some removals require lifting fixtures in order to

obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that

are on the engine.

Lifting eyes are designed and installed for the

specific engine arrangement. Alterations to the lifting
eyes and/or the engine make the lifting eyes and
the lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Caterpillar dealer for information
regarding fixtures for proper engine lifting.
32
Operation Section
Engine Lifting and Storage

i00816700

Engine Storage
SMCS Code: 1000

If the engine will not be started for several weeks,

the lubricating oil will drain from the cylinder walls
and from the piston rings. Rust can form on the
cylinder liner surface, which will increase engine
wear which can reduce engine service life.

To help prevent excessive engine wear, use the

following guidelines:

Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance
Manual, Maintenance Interval Schedule
(Maintenance Section).

If freezing temperatures are expected, check the

cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, General Coolant Information
(Maintenance Section).

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

engine is not planned, special precautions should
be made. If the engine will be stored for more than
one month, a complete protection procedure is
recommended.

Your Caterpillar dealer will have instructions for

preparing the engine for extended storage periods.

For more detailed information on engine storage,

see Special Instruction, SEHS9031, Storage
Procedure for Caterpillar Products.

Generator Storage
For information on generator storage, see the
literature that is provided by the OEM of the
generator. Consult your Caterpillar dealer for
assistance.
 33
Operation Section
Features and Controls

Features and Controls (Table 8, contd)

Configuration Parameters for G3600 Engines
i01765789 Choke Compensation

Programmable System Wastegate Gain

Parameters Wastegate Stability

Wastegate Compensation
SMCS Code: 1900
Start/Stop Control
Certain parameters are unique for each engine Driven Equipment Delay Time
application. Table 8 is a list of the parameters
that can be configured in the Electronic Control Crank Terminate Speed
Module (ECM) for G3600 Engines. The values of the Engine Purge Cycle Time
parameters can be viewed on the Configuration
screen of Caterpillar Electronic Technician (ET). Engine Cooldown Duration
Cycle Crank Time
Table 8
Engine Overcrank Time
Configuration Parameters for G3600 Engines
Engine Speed Drop Time
Information for the ECM
Engine Pre-lube Time Out Period
Engine Serial Number
Engine PostLube Time Out Period
Equipment ID
Monitoring and Protection
Customer Password #1
High Inlet Air Temp Engine Load Set Point
Customer Password #2
Total Tattletale
For detailed information on the parameters, refer
Air/Fuel Ratio Control to Systems Operation/Testing and Adjusting,
RENR5908, Electronic Control System Parameters.
Fuel Quality
Gas Specific Gravity
i01758402
Speed Control
Monitoring System
Low Idle Speed
Minimum Engine High Idle Speed SMCS Code: 1900; 7400; 7450; 7451
Maximum Engine High Idle Speed The Electronic Control Module (ECM) monitors the
Engine Accel. Rate operating parameters of the engine. The ECM can
initiate a warning or a shutdown if a specific engine
Desired Speed Input Configuration parameter exceeds an acceptable range. Some
Governor Type Setting of the responses are not available for some of the
parameters. Use Caterpillar Electronic Technician
Engine Speed Droop (ET) to perform the following activities:
Governing Select the available responses.
Governor Gain
Program the level for monitoring.
Governor Stability
Governor Compensation Program delay times for each response.
Auxiliary Proportional Governor Gain 1 The default settings for the parameters are
Auxiliary Integral Governor Gain 1 programmed at the factory. To accommodate unique
applications and sites, the parameters may be
Auxiliary Derivative Governor Gain 1 reprogrammed with ET. The screens of ET provide
Choke Gain guidance for the changing of trip points.

Choke Stability Note: Some of the parameters are protected by

(continued) factory passwords. Other parameters can be
changed with customer passwords.
34
Operation Section
Features and Controls

For more detailed information on the monitoring

system and for programming instructions, refer to
Systems Operation/Testing and Adjusting.

Examples of the default settings for the parameters

are listed in Table 9. The values may have changed.
Use the ET to determine the programming for your
engine. Many of the items can be reprogrammed
in order to accommodate the requirements of
individual sites.
Table 9
Default Settings of the Programmable Monitoring System
Security Range of
System Trip Delay in
Parameter Event Code State Level Range the Delay
Response Point Seconds
Password in Seconds

Low System E043 (1) Warning 20 volts 20

On (1) This item cannot be programmed.
Voltage E042 (3) Shutdown 18 volts 10
High Engine E017 (1) Warning On 92 C
Coolant 80 to 129 C
Temperature E016 (3) Shutdown On (1) 98 C
20 Customer 1 to 60
Low Engine
Coolant E038 (1) Warning On 5 C 5 to 80 C
Temperature
1120
rpm
Engine 800 to 1300
E004 (3) Shutdown or 0 Factory 0
Overspeed rpm
1017
rpm

High Engine Oil E020 (1) Warning 88 C Customer 85 to 102 C

20 1 to 60
Temperature E019 (3) Shutdown 90 C Factory 85 to 104 C
379
E100 (1) Warning 10
Low Engine Oil kPa
On (1) This item cannot be programmed.
Pressure 355 0
E040 (3) Shutdown
kPa
103
High Oil Filter E129 (1) Warning Customer
kPa
Differential 0 to 35 kPa
Pressure 138
E130 (3) Shutdown Factory
kPa 10
Low Oil Filter E127 (1) Warning 5 kPa Customer
Differential 0 to 150 kPa
Pressure E128 (3) Shutdown 3 kPa Factory

High Fuel 1 to 60
E223 (1) 60 C 20 0 to 60 C
Temperature
On
Low Fuel Warning 105 Customer 100 to 135
E053 (1) 10
Pressure kPa kPa
High Jacket E123 (1) 10 C(2)
Water to Engine
On (1) 20 0 to 80 C
Oil Temperature E124 (3) Shutdown 15 C(2) Factory
Differential
(continued)
 35
Operation Section
Features and Controls

(Table 9, contd)
Default Settings of the Programmable Monitoring System
Security Range of
System Trip Delay in
Parameter Event Code State Level Range the Delay
Response Point Seconds
Password in Seconds
High System Warning
E050 (1) On (1) 34 volts 20 This item cannot be programmed.
Voltage
72 C(3)
High Inlet Air E027 (1) On 77 C(4) 32 to 100 C
Temperature 82 C(5)
at Low Engine 75 C(3) 32 to 120 C
Load E026 (3) Shutdown On (1) 80 C(4)
85 C(5)
20 Customer 1 to 60
57 C(3)
High Inlet Air E027 (1) Warning On 65 C(4)
Temperature at 72 C(5)
High Engine 60 C(3)
Load E026 (3) Shutdown On (1) 68 C(4)
75 C(5)
(1) This parameter is permanently active. This parameter cannot be turned off.
(2) Above 50% load
(3) This temperature is for systems that operate at 32C.
(4) This temperature is for systems that operate at 43C.
(5) This temperature is for systems that operate at 58C.

Integrated Combustion Sensing

Module (ICSM)
The Integrated Combustion Sensing Module (ICSM)
monitors the temperatures of the cylinder exhaust
ports, the inlets of the turbocharger turbine, and the
outlets of the turbocharger turbines. The ICSM also
monitors the combustion sensors.

Table 10 lists default examples of the values for the

parameters.
36
Operation Section
Features and Controls

Table 10
Default Settings for the Integrated Combustion Sensing Module
Parameter Event Code System State Trip Delay in Security Range Range
Response Point Seconds Level of the
Password Delay in
Seconds
High Exhaust E801 (1)
Temperature through E816 Warning 600 C 5
(1) 100 to
E801 (3) 1000 C
through E816 Shutdown 650 C
(3)
Exhaust Port E821 (1)
Temperature through E836 Warning 50 C
High Deviation (1)
On
E821 (3)
through E836 Shutdown 100 C
(3) 10 to 500

Exhaust Port E841 (1) C
Temperature through E856 Warning 120 C Customer 1 to 6000
Low Deviation (1)
10
E841 (3)
through E856 Shutdown 400 C
(3)
High Turbo E245 (1)
Warning 600 C
Turbine Inlet E246 (1)
Temperature
E245 (3)
Shutdown 650 C
E246 (3) 100 to
Off
High Turbo E243 (1) 400 to 1000 C
Warning
Turbine Outlet E244 (1) 650 C
Temperature
E243 (3)
Shutdown 600 C
E244 (3)
 37
Operation Section
Features and Controls

i01765805

Control Panel
SMCS Code: 7451

g00799615
Illustration 27
Keypad

Note: At the time of this publication, these keys

have no function: X, . (period or decimal), check,
and 0 (zero).

The keypad is protected in a sealed membrane.

When you press a key, press firmly. When a key
is pressed sufficiently, a small red indicator in the
upper left corner of the keypad will flash once.
g00824832
Illustration 26
Control panel
When the control panel is powered up, the screen
becomes active. To view the options for the display,
(1) Display for the Machine Information Display System (MIDS)
(2) Keypad for the MIDS press the ? key. Table 11 lists the menu.
(3) EMERGENCY STOP button
(4) ENGINE ON indicator Table 11
(5) ACTIVE ALARM indicator
Menu
(6) ENGINE FAILURE indicator
(7) MANUAL PRELUBE switch and PRELUBE ACTIVE (1) Status Information
indicator
(8) Mode control switch (2) Detonation Levels
(9) DESIRED SPEED potentiometer
(3) Ignition Timing
The features of the control panel are described (4) Filtered Burn Times
below.
(5) Unfiltered Burn Times
Machine Information Display (6) Exhaust Temperatures
System (MIDS) (7) Turbo Temperatures
(8) Events and Diagnostics
The Machine Information Display System (MIDS)
is a device which enables the operator to monitor (9) Display Setup
engine operation. The MIDS receives information
from the Electronic Control Module (ECM). The
To select an option, press the number on the
device cannot be used for programming. A screen
keypad that corresponds to the selection. To exit
display and a keypad provide the interface for the
the option, press the ? key or any of the numbered
operator.
keys. It is not necessary to return to the menu in
order to select a different option. When you press a
different numbered key, the corresponding option is
displayed.
38
Operation Section
Features and Controls

(1) Status Information There are four status Table 14

screens. The upper left corner of the display Parameters of the MISC Status Screen
identifies the four screens with A/F, SPD, MISC,
and RLY. When you select item (1) from the menu, Oil pressure Oil filter Oil temperature
the A/F screen is automatically displayed and differential
A/F is highlighted in the upper left corner of the pressure
screen. To display a different status screen, press Crankcase BTU of the fuel Temperature of
the left arrow key or the right arrow key. The display pressure (quality) the jacket water
will change and the identifier for the screen will be
highlighted in the upper left corner of the screen. Detonation level Service hours Battery voltage
(bars)
A/F screen This screen displays the status of
parameters that pertain to the air and fuel. The RLY screen This screen displays the status of
actual data is continuously updated. Table 12 lists switches and relays that are identified in Table 15.
the information that is displayed.
Table 15
Table 12
Status of Switches and Relays on the RLY Screen
Parameters of the A/F Status Screen
Item Status
Inlet manifold air Desired inlet Inlet manifold air
pressure manifold air temperature Speed Idle Rated
pressure Mode control switch Auto Start Run Stop
Volume of air flow Volume of fuel The percent Emergency stop Run Stop
flow of the fuel
command Driven equipment Ready Not Ready
Fuel pressure The percent Fuel temperature Solenoid for the prelube Off Energized
of the fuel pump
correction factor
Pressure switch for the Ready Not Ready
prelube
SPD screen This screen displays parameters
that pertain to the engine speed and some Initiate contact Run Stop
additional parameters. Table 13 lists the information Hydraulic oil pressure Ready Not Ready
that is displayed. switch
Table 13 Starting motor solenoid Ready Not Ready
Parameters of the SPD Status Screen Normal stop Run Stop
Engine speed Desired engine Percent load
(rpm) speed (2) Detonation Levels This screen displays the
Remote input or Percent of droop Type of governor level of detonation for each cylinder in bars. The
local input for the average detonation level for all of the cylinders is
speed control also displayed.
Percent of the Percent of the Status of the (3) Ignition Timing This screen displays the current
command for command for the feedback for the degrees before top center for the timing of each
the wastegate air choke ECM (1)
(exhaust bypass)
cylinder. The values for the programmable desired
timing are listed. The current active selected timing
(1) There are four possibilities: no feedback, exhaust temperatures, is indicated.
combustion burn time, and PC calibration.
(4) Filtered Burn Times This screen displays an
MISC screen This screen displays the average of the combustion burn time for each bank
parameters that are listed in Table 14. of cylinders. The desired combustion burn time
and the time for each individual cylinder are also
displayed.

(5) Unfiltered Burn Times This screen displays

the actual instantaneous combustion burn time for
each individual cylinder. The desired combustion
burn time and the average combustion burn time
for each bank of cylinders are also displayed.
 39
Operation Section
Features and Controls

(6) Exhaust Temperatures This screen displays the

actual exhaust port temperature for each cylinder.
The average temperature for all of the exhaust
ports in each bank is also displayed. If the engine
is operating at a load that is less than 40 percent,
the desired exhaust temperature is displayed. If the
engine load is greater than 40 percent, the desired
exhaust temperature is not a factor.

(7) Turbo Temperatures This screen displays the

temperatures of the exhaust at the inlet and outlet
of each turbocharger. The average temperature for
each bank is also displayed.

(8) Events and Diagnostics This screen has two g00824884

options for displaying information on event codes
and diagnostic codes: LIST and DETAIL. When
you select item (8) from the menu, the LIST screen
is automatically displayed and LIST is highlighted
in the upper left corner of the screen. To display the
DETAIL screen, press the left arrow key or the right
arrow key. The display will change and DETAIL will
be highlighted in the upper left corner of the screen.
LIST screen This screen is a list of all of the
diagnostic codes and event codes that are logged.
The list includes this information regarding the
code: Module Identifier (MID), code, number of
occurrences, service hours at the first occurrence,
service hours at the last occurrence, and an X
for active codes. If more than one code is logged,
the code that occurred first is listed first. To view
more detail about a particular code, you can use
the down arrow or the up arrow to select the code.
Then use the left arrow or the right arrow in order to
display the DETAIL screen.
Illustration 28
The fuel and the ignition are immediately shut off
when the EMERGENCY STOP button is pressed.
No postlube cycle occurs.
The EMERGENCY STOP button and the mode
control switch must be reset before the engine will
start. To reset the EMERGENCY STOP button, turn
the button clockwise. To reset the mode control
switch, turn the switch to the OFF/RESET position.
Note: The engine mounted junction box also has an
EMERGENCY STOP button.
Indicators
The remote panel has three indicators for the status
of the engine operation.

DETAIL screen This screen displays the same

information as the LIST screen for the selected
code. Additionally, the module that generated the
code and the codes description is displayed.

(9) Display Setup This screen enables the operator

to adjust the display. The contrast and back lighting
can be adjusted. Metric units or English units can
also be selected for the display. Use the left arrow
or the right arrow to navigate the options. Use the
up arrow or the down arrow to select the preference.
g00824980
Illustration 29
EMERGENCY STOP Button
(1) ENGINE ON indicator
(2) ACTIVE ALARM indicator
NOTICE (3) ENGINE FAILURE indicator
Only use the Emergency Stop button in order to stop
the engine in an emergency situation. Do not use the Illumination of green ENGINE ON indicator (1)
Emergency Stop button for normal engine stopping. indicates normal operation.

To prevent damage to the engine, use the mode con- Yellow ACTIVE ALARM indicator (2) illuminates if
trol switch or use the remote start/stop initiate contact the control system initiates a warning for an event
for normal engine stopping. or a diagnostic condition.
40
Operation Section
Features and Controls
Red ENGINE FAILURE indicator (3) illuminates if
the control system shuts down the engine due to
an event or a diagnostic condition. The ENGINE
FAILURE indicator also illuminates if an emergency
stop is performed.
MANUAL PRELUBE Switch and
PRELUBE ACTIVE Indicator
All G3600 Engines require lubrication prior to
start-up. The ECM will not permit the engine to start
until sufficient prelube pressure has been achieved.
Lubrication of the engine is required prior to rotation
of the crankshaft. This includes crankshaft rotation in
order to service the engine. Rotating the crankshaft
before prelube may cause damage to the crankshaft
bearings if the surfaces of the bearings are dry.
g00825028
Illustration 30
MANUAL PRELUBE switch and PRELUBE ACTIVE indicator
The MANUAL PRELUBE switch enables the
operator to prelube the engine by pressing the
switch.
A lamp behind the switch illuminates when the
prelube is active. This is the PRELUBE ACTIVE
indicator. If the mode control switch is in the AUTO
position and the remote start/stop initiate contact
closes, the prelube system will operate and the
lamp will illuminate. The lamp will also illuminate
during the postlube.
Note: The ECM is programmed to provide engine
lubrication after the engine is shut off. The typical
duration of the postlube is 180 seconds.
Mode Control Switch
g00825037
Illustration 31
Mode control switch in the AUTO position
The mode control switch has four positions: AUTO,
START, STOP, and OFF/RESET
AUTO When the mode control switch is in
the AUTO position (12 oclock), the system is
configured for remote operation. When the remote
start/stop initiate contact closes, the prelube system
will operate. When the prelube pressure is sufficient,
the engine will start. When the remote start/stop
initiate contact opens, the engine will shut off. If the
cool down cycle is programmed, the engine will
operate for the cool down period before the engine
stops. The cool down cycle can be programmed for
a 0 to 30 minute period.
START When the mode control switch is turned
to the START position (3 oclock), the prelube
system will operate. When the prelube pressure
is sufficient, the engine will start. The engine will
operate until the ECM receives a shutdown signal.
The following methods cause a shutdown signal:
The remote start/stop initiate contact opens when
the mode control switch is in the AUTO position.
The mode control switch is turned to the STOP
position.
The mode control switch is turned to the
OFF/RESET position.
The EMERGENCY STOP button is pressed.
An undesirable operating condition is sensed and
an engine shutdown is initiated by the ECM.
 41
Operation Section
Features and Controls

STOP When the mode control switch is turned

to the STOP position (6 oclock), the engine will
shut off. If the cool down cycle is programmed,
the engine will operate for the cool down period
before the engine stops. When the engine is
coasting to a stop, a postlube cycle will operate.
The power to the control panel is maintained when
the mode control switch is in the STOP position.
The STOP position can be used to troubleshoot
some problems without starting the engine.

OFF/RESET When the mode control switch is

turned to the OFF/RESET position (9 oclock), the
engine is immediately shut off and the diagnostic
lights are reset. Power is removed from the control
panel and the actuators after the engine completes
the postlube cycle.

DESIRED SPEED Potentiometer

g00825039
Illustration 32
DESIRED SPEED potentiometer

The DESIRED SPEED potentiometer allows the

operator to adjust the desired engine speed. This is
achieved by providing a 0 to 5 volt input to the ECM.
42
Operation Section
Engine Starting
Engine Starting
i01519373
Before Starting Engine
SMCS Code: 1000; 1400; 1450
Perform the required daily maintenance and other
periodic maintenance before starting the engine.
This can prevent major repairs at a later date.
Refer to this Operation and Maintenance Manual,
Maintenance Interval Schedule (Maintenance
Section).
Walk-Around Inspection
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
To obtain maximum service life for your engine,
make a thorough inspection before starting the
engine. Make a walk-around inspection of the
installation. Look for items such as oil or coolant
leaks, loose bolts and trash buildup. Remove any
trash. Make repairs, if necessary.
The guards must be in the proper place. Repair
damaged guards or replace missing guards.
Ensure that the areas around the rotating parts
are clear.
Air Inlet System
Ensure that the air inlet piping and the air filters
are in place.
Ensure that all clamps and connections are
secure.
Cooling System
Inspect the cooling system for leaks or loose
connections. Inspect the condition of all the
pipes for the cooling system. Ensure that the
connections are properly clamped.
Inspect the water pumps for evidence of leaks.
Check the coolant level. Add coolant, if necessary.
For information on the proper coolant to use,
refer to this Operation and Maintenance Manual,
Cooling System Specifications (Maintenance
Section).
Driven Equipment
If necessary, check the oil levels of the driven
equipment. Perform any maintenance that is
required for the driven equipment. Refer to the
literature that is provided by the OEM of the
driven equipment.
If the engine is equipped with a clutch, ensure
that the clutch is disengaged.
For generator set engines, ensure that the main
circuit breaker is open.
Electrical System
Inspect the wiring for the following conditions:
Loose connections
Wiring that is worn or frayed
Inspect the gauge panel and the control panel
for good condition. Reset any shutoff or alarm
components.
Lubrication System
Illustration 33 g00760044
Engine oil level gauge
(1) ADD mark
(2) FULL mark
Check the engine oil level. Maintain the engine
oil level between the ADD and FULL marks
on the ENGINE STOPPED side of the engine
oil level gauge. For information on the proper
engine oil to use, refer to this Operation and
Maintenance Manual, Lubricant Specifications
(Maintenance Section).

Check for leaks at the following components:
crankshaft seals, crankcase, engine oil filters,
plugs for the engine oil gallery, sensors, and
valve covers.
Inspect the tubes, tee pieces, and clamps on the
crankcase breathers.
If the engine has an air cleaner for crankcase
ventilation, inspect the air cleaner service
indicator. Service the air cleaner filter element
when the yellow diaphragm enters the red zone,
or the red piston locks in the visible position.
Fuel System
Inspect the fuel lines for loose fittings and leaks.
Ensure that the fuel lines are properly clamped.
Ensure that the fuel is supplied to the engine at
the correct pressure for the application.
Many engines use a fuel pressure of 310 14 kPa
(45 2 psi).
Some engines use a variable fuel pressure that is
based on the engine load.
For the proper fuel pressure, refer to the report from
the engine commissioning.
Hydraulic Actuator System
Check the level of the oil in the tank for the hydraulic
actuator system. Make sure that the oil is between
the ADD and FULL marks on the oil level gauge.
For information on the proper engine oil to use,
refer to this Operation and Maintenance Manual,
Hydraulic Oil (Maintenance Section).
Starting System
Ensure that the barring device is fully disengaged.
Drain moisture and sediment from the air tank
and from any other air piping.
Check the oil level in the lubricator for the air
starting motor. Keep the lubricator at least half
full. Add oil, if necessary. Use nondetergent
10W oil for temperatures that are greater than
0 C (32 F). Use air tool oil for temperatures that
are below 0 C (32 F).
Check the air pressure before starting. Starting
motors with vanes require air pressure in a range
of 620 to 1550 kPa (90 to 225 psi). Air turbines
require air pressure in a range of 414 to 620 kPa
(60 to 90 psi) or 690 to 1034 kPa (100 to 150 psi).
43
Operation Section
Engine Starting
Open the air supply valve for the air starting
motor.
Note: If the engine is equipped with a system for
external support, prepare the system before starting
the engine. Ensure that all of the systems for engine
support are enabled. Perform all prestart checks for
the control system.
i00662769
Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
See Gas Engines Application and Installation Guide,
LEKQ7255 for more information on the following
topics:
Recommendations for the size and installation of
jacket water heaters and oil heaters
Requirements for cranking torque and air starting
motors at various temperatures
Consult your Caterpillar dealer for more information
on the starting aids that are available for cold
weather starting.
Jacket Water Heaters
Jacket water heaters are available as optional
equipment. Jacket water heaters are recommended
for improving startability in ambient temperatures
below 21 C (70 F). These heaters are
recommended for all installations that have
automatic starting.
Lubricating Oil Heaters
Note: Oil pan immersion heaters are not
recommended for heating the lube oil. To ensure
the compatibility of the components, only use
equipment that is recommended by Caterpillar.
NOTICE
Heating elements that are in direct contact with the
lubricating oil can cause coking of the oil.
To aviod coking of the oil when the oil is heated, follow
these recommendations:
The temperature of the heating surface must not ex-
ceed 150 C (300 F). The maximum heat density
of the heating surface must not exceed 1.24 w/cm2
(8W/in2).
44
Operation Section
Engine Starting

Oil viscosity affects the amount of torque that is
needed to crank the engine. Oil temperatures
below 10 C (50 F) require cranking torque that
is excessive. Oil heaters are recommended for
heating the lube oil to 10 C (50 F) when the
ambient conditions are below this temperature.
Requirements for Starting with Air
To start the engine at colder temperatures, a larger
volume of starting air and/or a higher air pressure
is necessary. Ensure a sufficient supply of air
pressure for cold weather starting. Do not exceed
the maximum air pressure for the starting motor.
Do not start the engine or move any of the controls
if there is a DO NOT OPERATE warning tag or
similar warning tag attached to the start switch or
to the controls.
Ensure that no one will be endangered before the
engine is started and when the engine is started.
Perform the procedures that are described in
this Operation and Maintenance Manual, Before
Starting Engine (Operation Section).
Automatic Starting

Water Separator
Condensation of vapor in the air supply can freeze
in cold weather. This can enable the following
problems to occur:
Ice that forms in the supply lines will restrict the
air supply.
If particles of ice enter the inlet of the starting
motor, the starting motor can be damaged.
A water separator removes vapor from compressed
air prior to the air storage tank. Dry air is required
for cold weather in order to help prevent ice from
forming in the supply lines.
i01765812
Starting the Engine
SMCS Code: 1000; 1450
When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid personal
injury, always remain clear of the the engine when
the engine is in the AUTOMATIC mode.
If the engine control switch is in the AUTO
position, the engine will automatically start when the
remote start/stop initiate contact closes. The engine
will accelerate to rated rpm when the oil pressure
is sufficient.
Manual Starting
1. Ensure that fuel is supplied to the engine. Ensure
that no gas is leaking.
2. Ensure that the driven equipment is unloaded.
a. For generator set engines, open the main
circuit breaker.

b. For industrial engines, unload the compressor

or pump. Disengage the clutch (if equipped).
Place the transmission and/or other
Engine exhaust contains products of combustion
attachments for the power take-off in
which may be harmful to your health. Always start
NEUTRAL.
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.

NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
fuel supply and/or the ignition to the engine.

Note: The EMERGENCY STOP button will shut off

both the fuel and the ignition.
g00791099
Illustration 34
(1) Engine control switch in the START position
(2) DESIRED SPEED potentiometer

3. Verify that DESIRED SPEED potentiometer (2)
is set to an rpm that is appropriate. Verify that
the IDLE/RATED display (if equipped) indicates
IDLE.
4. Observe the Configuration screen on Caterpillar
Electronic Technician (ET) and verify that the
FUEL ENERGY CONTENT and the SPECIFIC
GRAVITY are correct.
5. Turn engine control switch (1) to the START
position.
NOTICE
The engine must be prelubed before the crankshaft is
rotated. Damage can result if the crankshaft is rotated
on dry bearing surfaces.
Note: The prelube oil pump will operate for
approximately 30 seconds. The Electronic Control
Module (ECM) will initiate the engine start-up
after the prelube pressure switch detects 1 psi
of oil pressure. If the module detects a signal
for preventing the start-up, the corresponding
diagnostic code will be generated.
6. Allow the engine to idle for three to five minutes.
The engine speed should stabilize at low idle
rpm. Perform these checks during the warm-up:
Check all of the pressure gauges.
Inspect the engine for leaks.
Listen for unusual noises.
When all systems are normal, the rpm may be
increased.
Ensure that the oil pressure and the fuel pressure
are in the normal ranges. After the engine has
started and the warm-up is complete, the engine
can be operated at low rpm and low load. The
engine will reach normal operating temperature
faster if the engine is operated at low rpm and
with a low power demand. This procedure is more
effective than idling the engine with no load. The
engine should reach normal operating temperature
in a few minutes.
i01742728
After Starting Engine
SMCS Code: 1000
Note: For new installations and engines that are
recently rebuilt, carefully monitor the engine in order
to detect any unusual engine performance.
45
Operation Section
Engine Starting
Check the gauges during the warm-up. Complete
a walk-around inspection. Check for leaks and
unusual noises. Correct any problems before
proceeding.
Engaging the Driven Equipment
Avoid detonation during loading. Generally, no
load operation to full load operation can be
accomplished in one to five minutes without any
problems.
DO NOT apply a load to the engine or increase the
rpm until the engine oil pressure is a minimum of
160 kPa (23 psi) at low idle rpm.
1. Increase the engine rpm.
The minimum rpm for operating an engine with a
load is 750 rpm. The maximum rpm for operating
an engine with a load is 1000 rpm.
a. For engines with a SPEED CONTROL
potentiometer or a remote speed control, turn
the control to the engine rpm that is desired.
b. For engines with an IDLE/RATED switch,
toggle the switch to the RATED position.
Ensure that the gauges are in the normal
ranges for the engine rpm.
Note: It may be necessary to apply some load in
order to attain normal operating temperatures.
2. After verifying that the engine systems are
normal, engage the driven equipment.
Apply the load according to the requirements
for temperatures:
Before you apply a load up to 49 percent of
the rated load, the minimum temperature of the
jacket water is 38 C (100 F). The minimum
engine oil temperature is 10 C (50 F).
Before you apply a load between 50 and
100 percent of the rated load, the minimum
temperature of the jacket water is 50 C (122 F).
The minimum engine oil temperature is 50 C
(122 F).
Continue to check the gauges and the driven
equipment.
For information on partial load operation, refer to
this Operation and Maintenance Manual, Engine
Operation topic (Operation Section).
3. Adjust the load, as needed.
46
Operation Section
Engine Operation

Engine Operation Caterpillar Engines can be operated at very light

loads for limited times with no harmful effects. Table
16 lists the limits for hours of operation at various
i01765829 loads.

Engine Operation
SMCS Code: 1000
Proper operation and maintenance are key factors
in attaining the maximum service life and economy
for the engine. Follow the instructions in this
Operation and Maintenance Manual in order to
minimize operating costs and maximize the service
life of the engine.
After the time limit for reduced load operation
has expired, operate the engine for a minimum of
two hours at a load that is more than 70 percent
of the rated load.
For example, an engine is operating at 20 percent
of the rated load. The engine may be operated at
this load factor for a maximum of one-half hour. After
the one-half hour, operate this engine for at least
two hours at a load factor of more than 70 percent.

Observe the gauges or the Caterpillar Electronic To keep engine maintenance at a minimum, follow
Technician (ET) frequently while the engine is the guidelines that are listed in Table 16.
operating. Record the data from the gauges in a log.
Average the data that is recorded during operation Table 16
and record the average values for each day. Time Limits for Low Load Operation
Compare the data to the specifications for normal
engine operation. Comparing the data over time will Engine Load Time Limit
help to detect trends in engine performance. 0 to 30 percent 1/2 hour
Investigate any significant change in the gauge 31 to 50 percent 2 hours
readings. Monitor the engine operation and take 51 to 100 percent Continuous (1)
action when discrepancies are found.
(1) For continuous operation, the manifold air pressure must be
greater than the atmospheric pressure.
Operating the Engine and the
Driven Equipment
The minimum rpm for operating an engine with a
load is 750 rpm. The maximum rpm for operating
an engine with a load is 1000 rpm.

Check the gauges and the driven equipment

frequently while the engine is operating under a
load. The engine can be operated continuously at
full load.

Partial Load Operation

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

Accelerated wear of components

Loss of control of the exhaust emissions
Narrow margin for detonation
Poor performance
Power loss

Engine Stopping
i01526313
Emergency Stopping
SMCS Code: 1000; 7418
NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.
Ensure that any system that provides external
support to the engine is secured after the engine is
stopped. Turn off the auxiliary systems for engine
operation after the engine is stopped.
NOTICE
Do not start the engine until the problem necessitating
the emergency stop has been located and corrected.
Emergency Stop Button
g00792865
Illustration 35
(1) Emergency stop button
(2) Mode control switch in the OFF/RESET position
The emergency stop button is in the OUT position
for normal engine operation. For an emergency
stop, push emergency stop button (2). The engine
will not start when the button is locked. To reset
the button, turn the button clockwise or pull the
button. The spring-loaded button will return to the
OUT position.
47
Operation Section
Engine Stopping
The control panel must also be reset before the
engine will start. To reset the control panel, turn
mode control switch (1) to the OFF/RESET
position.
i01748696
Manual Stop Procedure
SMCS Code: 1000; 7418
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of engine components.
Excessive temperatures in the turbocharger center-
housing will cause oil coking problems.
Allow the engine to gradually cool before stopping the
engine
Note: Remove the load at a rate that will avoid
detonation.
1. Disengage or unload the driven equipment.
a. For generator set engines, open the main
circuit breaker.
b. For industrial engines, unload the compressor
or pump. Disengage the clutch (if equipped).
Place the transmission and/or other
attachments for the power take-off in
NEUTRAL.
Note: Extended idling can cause excessive oil
consumption and related problems. See this
Operation and Maintenance Manual, Engine
Operation topic (Operation Section).
2. Reduce the engine rpm to low idle.
Note: If the cooldown feature is not utilized, operate
the engine at low idle rpm for a cooldown period of
approximately one to two minutes before stopping
the engine.
3. Use one of the following methods in order to
stop the engine:
48
Operation Section
Engine Stopping
g00825057
Illustration 36
Engine control switch in the STOP position
a. Turn the engine control switch to the STOP
position.
b. If the engine control switch is in the AUTO
position, the engine will stop when the remote
start/stop initiate contact opens.
If the cooldown feature is utilized, the engine
will operate for a programmed period of
time before the engine stops. Otherwise,
the engine will immediately shut off. When
the engine rpm is reduced to approximately
100 rpm, the postlube cycle will operate for
approximately 180 seconds.
The engine will coast to a stop. Ensure that any
system that provides external support to the engine
is secured after the engine is stopped. Turn off
the auxiliary systems for engine operation after the
engine is stopped.
The power to the control panel will be maintained
until the engine control switch is turned to the
OFF/RESET position.
i00662051
After Stopping Engine
SMCS Code: 1000
Check the engine crankcase oil level. Maintain
the oil level between the ADD and FULL
marks on the ENGINE STOPPED side of the oil
level gauge.
If necessary, perform minor adjustments. Repair
any leaks and tighten loose bolts.
Note the service hour meter reading. Perform the
maintenance that is scheduled in this Operation
and Maintenance Manual, Maintenance Interval
Schedule (Maintenance Section).
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Coolant Specifications of this manual. Failure to do
so can cause engine damage.
Allow the engine to cool. Check the coolant level.
If freezing temperatures are expected, check
the coolant for protection against freezing. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.
Perform all required periodic maintenance on all
driven equipment. Refer to the instructions that
are provided by the OEM of the driven equipment.

Maintenance Section
Lubricant Specifications
i00708567
Lubricant Information
SMCS Code: 1000; 1300; 7581
Engine oil performs several functions:
Keeping the engine clean
Preventing rust and corrosion
Acting as a coolant
Reducing friction and wear
Engines that use gaseous fuel require oils that are
formulated with additives that are specific to these
engines.
No performance specifications are available to
define the performance levels that are required
by engines that use gaseous fuels. Field tests
must be used in order to define oils that are
acceptable. To aid in oil selection, guidelines are
provided in Supplement, SEBU6400, Caterpillar
Gaseous Fueled Spark Ignited Engines Lubrication
Specifications.
Grease is classified by the National Lubricating
Grease Institute (NLGI). The classification is
based on the ASTM D217-68 Worked Penetration
characteristics. The characteristics have a number
for consistency that is defined. For information
on grease, see this Operation and Maintenance
Manual, Lubricating Grease topic (Maintenance
Section).
i01607552
Engine Oil
SMCS Code: 1300; 1348; 7581
Caterpillar Engine Oils have been developed and
tested in order to provide the full performance and
service life that has been designed and built into
Caterpillar Engines. These engine oils are offered
by Caterpillar dealers for continued use when the
engine oil is changed. Consult your Caterpillar
dealer for more information.
49
Maintenance Section
Lubricant Specifications
Due to significant variations in the quality and in the
performance of commercially available engine oils,
Caterpillar makes the following recommendation:
Caterpillar Natural Gas Engine Oil (NGEO)
Caterpillar NGEO has been tested throughout
the world in demanding environments. Caterpillar
NGEO has been tested in engines that use all types
of gaseous fuel. The formulation of the engine oil
has been proven to be superior to many brands of
engine oil that are locally available.
For maximum service life of the engine and the
engine oil, use Caterpillar NGEO with low sulfur
gaseous fuels that contain less than 0.43 mg H2S/MJ
(0.45 g H2S/Btu).
Caterpillar NGEO may also be used with high sulfur
natural gas. The use of these fuels may require a
reduced oil change interval.
Caterpillar NGEO is formulated and blended with
special additives in order to provide protection
against oxidation and nitration. Caterpillar NGEO
also has thermal stability.
Caterpillar NGEO also provides the following
benefits:
Reduction of the formation of carbon and sludge
Resistance to foaming
Resistance to corrosion
Improved cleanliness of cylinder liners, pistons,
valves, and valve seats
Lubrication that helps to protect against scoring,
scuffing, and wear
Table 17 lists the properties of Caterpillar NGEO. The
properties are based on ASTM test specifications.
50
Maintenance Section
Lubricant Specifications

Table 17 Field Test

Caterpillar NGEO Properties
Note: For more information, refer to , SEBU6400-02,
Characteristic ASTM SAE Viscosity Operation and Maintenance Manual, Field
Test Grade Evaluation of Commercial Oil.
30W 40W
API Gravity D 0286 28.4 27.5
Lubrication for Engines that use
Flash Point D 0092 265 265
Sour Gas and Bio-Gas
Pour Point D 0097 15 15 Note: For more information, refer to the specific
engines Operation and Maintenance Manual, Fuel
Viscosity (cSt) at D 0455 95 130
40 C (104 F)
Recommendations.

Viscosity (cSt) at D 0455 11 13.5 Many gaseous fuels contain sulfur compounds.
100 C (212 F) These compounds are primarily composed of
Viscosity Index D 0567 99 99 hydrogen sulfide (H2S). If the concentration is less
than the following amount, the gaseous fuels are
Weight (Percent) of D 0874 0.48 0.48 considered to be sweet. If the concentration is
Sulfated Ash greater than the following amount, the gaseous
Total Base Number D 2896 6.2 6.2 fuels are considered to be sour.
Weight (Percent) of D 4951 0.030 0.030 0.43 mg H2S/MJ (0.45 g H2S/Btu)
Phosphorus
Sour gas can reduce the service life of an engine
and the engine oil. When the sulfur compounds
Commercial Engine Oils are combined with water, acids are produced in
the engine oil. These acids attack the metals in
Specifications for commercial engine oils do not the engine crankcase. This causes corrosive wear.
exist for Caterpillar Engines that operate on gaseous To reduce the effects of these sulfur compounds,
fuels. The performance of lubrication oil for gas Caterpillar recommends the use of devices that
engines is determined by a field test. Successful treat the fuel.
field operation has been achieved with engine oils
that meet the following guidelines: If the sour gas cannot be treated in order to reduce
the level of sulfur, additional measures must be
Caterpillar recommends the use of engine oils taken in order to protect the engine. To reduce the
that are formulated specifically for heavy-duty harmful effects of sour gas, Caterpillar recommends
gas engines. Do not use engine oils that are the following guidelines:
specially formulated for gasoline engines or for
diesel engines.
Obtain frequent oil analyses.
Caterpillar recommends the use of engine oils Reduce the intervals for changing the engine oil.
that have a sulfated ash content between 0.40 Change the engine oil according to the results
and 0.60 percent. of the oil analysis.
The oil must demonstrate adequate protection Caterpillar does not recommend the use of engine
for a minimum of 7000 hours in a field test under oils with a high concentration of sulfated ash in
controlled conditions. order to reduce the harmful effects of sour gas.
High levels of sulfated ash may produce excessive
NOTICE deposits on the valves and on the turbine wheel of
Failure to follow these oil recommendations can cause the turbocharger. These deposits will reduce the
shortened engine service life due to deposits and/or service life of the engine. These deposits will also
excessive wear. increase the cost of maintenance.

For additional information on gaseous fuels and

NOTICE
on treatment of the fuel, refer to the following
Caterpillar recommends the use of oils that are formu- publications:
lated specifically for heavy duty spark ignited gaseous
fueled engines. Oils that are formulated for gasoline
engines only or for diesel engines only should not be Application and Installation, LEKQ7256,
Fuels/Fuel Systems
used.

Application and Installation, LEKQ7260, Low
BTU Engines
Maintenance Management Schedules,
SEBU6127, Schedules for Industrial and EPG
Spark Ignited Gas Engines
For information regarding condemning limits of
the lubrication oil, refer to this Operation and
Maintenance Manual, SOS Oil Analysis topic
(Maintenance Section).
Lubricant Viscosity
Table 18
Engine Oil Viscosity
Caterpillar Ambient Temperature
NGEO
Grade of Minimum Maximum
Viscosity
SAE 40 (1) 5 C (41 F) 50 C (122 F)
(1) Multigrade oils are NOT recommended for use in Caterpillar
Gas Engines. If other grades of viscosity are selected, ensure
that the oil meets the requirements for Caterpillar Gas Engines.
Consult the supplier of the oil.
i01123104
Aftermarket Oil Additives
SMCS Code: 1348; 7581
Caterpillar does not recommend the use of
aftermarket additives in oil. It is not necessary to
use aftermarket additives in order to achieve the
engines maximum service life or rated performance.
Fully formulated, finished oils consist of base oils
and of commercial additive packages. These
additive packages are blended into the base oils
at precise percentages in order to help provide
finished oils with performance characteristics that
meet industry standards.
There are no industry standard tests that evaluate
the performance or the compatibility of aftermarket
additives in finished oil. Aftermarket additives may
not be compatible with the finished oils additive
package, which could lower the performance of the
finished oil. The aftermarket additive could fail to
mix with the finished oil. This could produce sludge
in the crankcase. Caterpillar discourages the use of
aftermarket additives in finished oils.
To achieve the best performance from a Caterpillar
engine, conform to the following guidelines:
Select the proper Caterpillar oil or a commercial
oil that meets the EMA Recommended Guideline
on Diesel Engine Oil or the recommended API
classification.
51
Maintenance Section
Lubricant Specifications
See the appropriate Lubricant Viscosities table
in order to find the correct oil viscosity grade for
your engine.
At the specified interval, service the engine
compartment. Use new oil and install a new oil
filter.
Perform maintenance at the intervals that are
specified in the Operation and Maintenance
Manual, Maintenance Interval Schedule.
i01145644
Hydraulic Oil
SMCS Code: 1264; 5095
Applications
Hydraulic Systems
Hydrostatic Transmissions
Caterpillar Hydraulic Oil (HYDO)
Caterpillar Hydraulic Oil is formulated with a
balanced additive system. The system includes
the following agents: detergents, rust inhibitors,
antiwear agents, and defoamers. Caterpillar
Hydraulic Oil offers the following benefits: protection
against mechanical wear, protection against rusting,
protection against corrosive wear in hydraulic
systems, and protection against wear in hydrostatic
transmission systems. Caterpillar Hydraulic Oil
should be used to achieve maximum life and
maximum performance from hydraulic system
components and from hydrostatic transmissions.
Caterpillar Hydraulic Oil is recommended in most
hydraulic systems and in most hydrostatic systems.
Caterpillar Hydraulic Oil
If a different viscosity is required due to ambient
temperatures, the following Caterpillar oils can be
used:
Caterpillar Multigrade Diesel Engine Oil (DEO)
Caterpillar Single Grade Diesel Engine Oil (DEO)
Caterpillar Transmission/Drive Train Oil (TDTO)
Caterpillar Transmission Multi-Season Oil (TMS)
Caterpillar Multipurpose Tractor Oil (MTO)
52
Maintenance Section
Lubricant Specifications
Commercial Oils
If Caterpillar oils cannot be used, the following
commercial classifications can be used in hydraulic
systems and in hydrostatic transmission systems:
CH-4 engine oils that have a minimum zinc
additive of 0.09 percent (900 ppm)
CG-4 engine oils that have a minimum zinc
additive of 0.09 percent (900 ppm)
CF-4 engine oils that have a minimum zinc
additive of 0.09 percent (900 ppm)
CF engine oils that have a minimum zinc additive
of 0.09 percent (900 ppm)
Caterpillar Biodegradable
Hydraulic Oil (HEES)
Caterpillar has a biodegradable hydraulic oil that
is available for use in machine hydraulic systems.
This fluid is recommended for the hydraulic systems
when environmental compliance is required or
desired.
g00103844
Illustration 37
Machines with this symbol are filled with
biodegradable hydraulic oil. This symbol is located
on the hydraulic tank.
This fluid is formulated with the following
components: a saturated HEES (Hydraulic
Environmental Ester Synthetic), synthetic base
stock, and selected additives. Use this oil only in
hydraulic systems.
Caterpillar Biodegradable Hydraulic Oil (HEES)
may become darker in color throughout the service
life of the oil. Analysis is required to determine the
quality of the oil.
The maximum recommended water content for
hydraulic systems that are filled with Caterpillar
Biodegradable Hydraulic Oil (HEES) is 0.10 percent.
If the water levels exceed 0.10 percent, the water
should be removed or the oil should be replaced.
Consult your Caterpillar dealer for additional
information on this product and on the potential use.
Commercial Biodegradable Hydraulic Oil
(HEES)
If Caterpillar Biodegradable Hydraulic Oil (HEES) is
not used, commercial oils which meet the Caterpillar
BF-1 specifications should be used.
i01489947
SOS Oil Analysis
SMCS Code: 1348; 7542-008
Caterpillar recommends the SOS oil analysis
program in order to monitor the condition of the
oil and the maintenance requirements of the
engine. The SOS program is part of the preventive
maintenance program.
The SOS oil analysis includes these tests:
The Wear Rate Analysis monitors wear by
detecting, identifying and assessing the amount
and the type of wear metal that is in the oil. The
increase in the rate of engine wear metal in the
oil is as important as the quantity of engine wear
metal in the oil. For this reason, regular sampling
at specified intervals is necessary in order to
establish wear rates. Intermittent sampling does
not allow wear rate trend lines to be established.
Engine wear metals in the oil sample are
compared to established Caterpillar norms in
order to determine acceptability. Potential failures
can be identified when the wear rate and/or the
contaminants exceed the established trend.
Tests are conducted in order to detect
contamination of the oil by water and/or glycol.
The Oil Condition Analysis determines the loss
of the oils lubricating properties. An infrared
analysis is used to compare the properties of
new oil to the properties of the used oil sample.
This analysis allows technicians to determine the
amount of deterioration of the oil during use.
The test results of the oil samples will then be used
as a basis for determining the oil change interval
for the engine. The results of the SOS oil analysis
may enable the engine to operate longer between
oil changes without the risk of damage.
 53
Maintenance Section
Lubricant Specifications

Obtain each oil sample when the oil is warm and

well mixed in order to ensure that the sample is
representative of the oil in the engine crankcase.

Oil analysis is essential in order to determine

satisfactory performance of the oil.

Refer to Special Publication, PEDP7036, SOS

Fluid Analysis for more information.

Consult your Caterpillar dealer for complete

information and assistance about the program.

Condemning Limits of the Oil

Oil analysis is the only method of determining if
an oil is protecting the engine. The oil analysis
is compared to limits that have been established
through experience.

The condemning limits for lubrication oil were

developed from experience with engine operation
and from the analysis of used oil. The limits provide
guidelines for determining the useful service life of
the engine oil. Table 19 lists the limits for the service
life of the oil.
Table 19
SOS Oil Analysis
Condemning Limits
Parameter Limit
Oxidation 100% defined by the
SOS Oil Analysis
Nitration 100% defined by the
SOS Oil Analysis
Water 0.5% maximum
Glycol 0%
Silicon (Bio-gas) 25 ppm
Wear Metals Based on Caterpillar
norms and on the trend of
the Wear Rate Analysis(1)
Additional Oil Analysis
Viscosity at 100 C (212 F)

Increase of 3 cSt from
by ASTM D445 new oil
Total acid number (TAN) by 3.0 maximum TAN or
ASTM D664 2.0 greater TAN than
the new oil
Total base number by 50% of new oil TBN
ASTM D2896
(1) A trend can be established from the results of three oil analyses.
54
Maintenance Section
Fuel Specifications
Fuel Specifications
i00880165
Fuel Recommendations
SMCS Code: 1280
General Fuel Information
Gaseous fuels consist primarily of hydrocarbons
(combinations of hydrogen and carbon) and some
inert gases. Pipeline natural gas has been used
for many years. Other types of fuels such as
wellhead, bio-gas, and manufactured gas need to
be reviewed for acceptability.
Each commercial fuel gas is a mixture of gases.
Some of the gases are combustible and some of
the gases are inert. The compositions of these gas
mixtures have extreme variations.
Caterpillar Gas Engines will operate successfully
on a broad range of gaseous fuels. Adjustments
must be made to the fuel system when the fuel is
changed. Consult your Caterpillar dealer about the
proper adjustments.
Permissible fuels must be analyzed in order to
determine the following characteristics:
Composition
Specific gravity
Heat value
Methane number
A fuels potential for detonation is indicated by a
methane number. The methane number of any gas
(fuel) can be determined with the following method:
1. Obtain a fuel analysis of the gas.
2. Enter the data from the fuel analysis into the
Caterpillar Software Program, LEKQ6378,
Methane Number Program.
This software program calculates the fuels methane
number.
The methane number is used for determining the
following parameters:
Compression ratio
Fuel system components
Ignition timing
Rated load
For a detailed explanation of methane numbers,
see Application and Installation Guide, LEKQ7256,
Fuels/Fuel Systems.
Dry Natural Gas
Dry natural gas is a mixture of methane, ethane,
propane, and butane. Dry natural gas may also
have traces of heavier hydrocarbons.
The Low Heat Value (LHV) of a gas is the high
heat value (HHV) minus the heat that is required to
vaporize the water that is formed by combustion.
For more information on heat values, see Application
and Installation Guide, LEKQ7256, Fuels/Fuel
Systems.
The heat value of dry natural gases may vary.
This depends on the composition of the gas. Dry
natural gas usually has an LHV that is between
33.53 to 34.65 kJ/L (900 to 930 Btu/ft3). Caterpillar
Gas Engines are adjusted at the factory with a dry
natural gas that is within this range.
For dry natural gas, the acceptable limit of hydrogen
sulfide is 0.43 mg H2S/MJ (.450 g H2S/Btu).
Sour Gas
Note: For sour gas, Caterpillar recommends engine
arrangements that are similar to arrangements for
landfill gas.
Sour gas refers to fuels that contain more than
0.43 mg H2S/MJ (.450 g H2S/Btu). The following
gases are within this category:
Some wellhead gases
Landfill gas
Digester gas
Sweet gas pertains to fuels that have less than
0.43 mg H2S/MJ (.450 g H2S/Btu).
The use of gases that have hydrogen sulfide can
damage the engine. Products of combustion (water
vapor and sulfur oxides) form sulfurous acid and
sulfuric acid. Sulfur reacts easily with bright metals
such as copper. Therefore, oil coolers are usually
the first components that are affected by the acids.
Other engine parts that are attacked by the acids
include the following components:
Valves
Valve guides

Piston pin bushings
Piston rings
Cylinder liners
Exhaust manifolds
Aftercoolers
Analyze the gas before use. If the gas has more
than 0.43 mg H2S/MJ (.450 g H2S/Btu), treat the
gas in order to reduce the content of hydrogen
sulfide.
Various devices can reduce the content of hydrogen
sulfide. Examples are chemically active filters,
reactive beds, and solutions. The performance of
the devices deteriorates as the reactive chemicals
are depleted. The devices must be serviced or
replaced in order to maintain effectiveness.
Take the following precautions even if the gas is
treated in order to reduce the level of hydrogen
sulfide. This will help to protect the engine against
intervals when the devices for treating the fuel
deteriorate. Even brief intervals of operation with
high sulfur fuels can damage the engine, unless
precautions are taken.
Maintain the temperature

of the coolant outlet to

a minimum of 110 C (230 F). Do not allow the
rise in temperature across the engine to exceed
8.3 C (15 F). A rise in temperature of 5.6 C
(10 F) is preferable.
Lower jacket water temperatures permit water
vapor and hydrogen sulfide to condense on the
cylinder liners. Higher temperatures will reduce this
condensation.
Establish an oil analysis program in order to
ensure that the oil change intervals are not
extended beyond the condemning limits of the
oil. The oil analysis will also be able to detect
other problems that may occur.
Wellhead Gas (Field Gas)
Wellhead gas is natural gas that has not been
processed. The composition of gases from the
wellheads in different gas fields varies. The
composition of the gas from different wellheads
within the same gas field can vary. As a result, the
gas from one source may be acceptable for use
but the gas from a different source may not be
acceptable. For this reason, a fuel analysis from
each source is required to determine if the fuel is
acceptable for a particular Caterpillar Engine.
55
Maintenance Section
Fuel Specifications
Note: The composition of the gas from a field can
change over time. Allow some adaptability for this
change during the life of the project.
Wellhead gas has minimal processing before
entering the fuel manifold. This fuel is commonly
used in engines that power gas compressors. The
engines burn the same gas that is compressed in
order to be transferred through pipelines.
Some gas fields contain significant amounts
of hydrogen sulfide. In these cases, follow the
precautions that are recommended for using sour
gas. Obtain a fuel analysis and determine the
methane number.
Many wellhead gases have some heavier
hydrocarbons such as pentane, isobutane and
other gasolines. These heavier hydrocarbons
cause detonation and other problems.
For more information on hydrocarbons, see
Application and Installation Guide, LEKQ7256,
Fuels/Fuel Systems.
Consult your Caterpillar dealer before operating the
engine with fuel that has more than one percent of
hydrocarbons that are heavier than butane.
Bio-Gas
Bio-gas is generally classified as either gas that
is produced from landfills or gas that is produced
from digester gas facilities. Although these gases
are both the result of organic decomposition, the
compositions are different.
Landfill Gas
The decomposition of organic material produces
landfill gas. The composition of landfill gas depends
on the materials that are in the landfill. The gas is
collected through a grid of pipes that are laid out
within the landfill.
The collection of landfill gas was prompted by
ecological concerns. Landfill gas contains methane
and other pollutants. These harmful pollutants are
consumed in order to produce useful energy.
Caterpillar offers a variety of engines that can be
operated successfully with landfill gas.
Fuel analysis is required in order to provide
guidelines for treatment of the fuel. When
an application that uses landfill gas initiates
operation, the operation and maintenance that is
recommended by Caterpillar must be followed.
Landfill gas may contain the following contaminants
that can cause harmful effects on engines:
56
Maintenance Section
Fuel Specifications
Chlorine
Fluorine
Siloxanes
Sulfur
Water vapor
The sulfur compounds in landfill gas cause the
same engine problems as sulfur in sour gas. When
landfill gas is used, follow the precautions that are
recommended for using sour gas.
Landfills can contain chlorine and fluorine
compounds in the form of form volatile organic
compounds and chlorofluorocarbons. When these
substances are burned in engines, corrosive
hydrochloric acid and hydrofluoric acid can be
produced.
Landfill gas can corrode both the equipment that
handles the gas and the engine. Vapor is produced
by combustion. If that vapor condenses in the
crankcase, a solution that is potentially corrosive
to the engine can form.
Landfill gas and digester gas can contain siloxanes.
Siloxanes are formed when silica ions attach to
the methane hydrocarbon chain. These gaseous
compounds enter the combustion chamber with the
fuel. This enables silica type deposits to form in
the cylinders.
Because the engine oil contains some calcium,
deposits in the combustion chamber are generally a
combination of silicon and calcium with some other
trace elements. These substances can coagulate in
the combustion process and form larger particles.
The larger particles can be abrasive to exhaust
valve faces and valve seats. This causes the valves
to become pitted and indented. The particles can
also build up on the valve seat. The buildup can
cause guttering of the valves.
Deposits also form on the pistons and on the bottom
deck of the cylinder heads. Detonation can loosen
the deposits. The deposits that are loosened can
be trapped between the valve and the valve seat.
The valve will be held open. Guttering of the valve
will result.
The formation of deposits depends on the following
factors:
Composition of the fuel
Operating conditions
Type of lubrication oil
Most landfill applications will generate some
deposits in the combustion chamber and the
turbocharger. Siloxanes are a major contributor
to these deposits. The fuel requires treatment in
order to remove the siloxanes. For information
on equipment for processing landfill gas, see
Application and Installation Guide, LEKQ7260, Low
Energy Fuels.
Note: The amount of silicon in the fuel can be
measured with a test that was developed by
Caterpillar and Bio-Engineering Services. The test
kit enables a sample of the fuel to be analyzed.
The fuel can also be analyzed for other harmful
contaminants such as chlorines, fluorines, sulfur,
and halides. Details can be obtained from the
following address:
Bio-Engineering Services
36 Virginia Street
Southport, Merseyside PR8 6RU England
Telephone: 44 (0) 1704-539094
Fax: 44 (0) 1704-501660
During normal combustion, some exhaust gas and
unburned fuel is forced past the piston rings and
into the crankcase. The contaminants in this blowby
are vented away from the crankcase by positive
crankcase ventilation. The contaminants are diluted
and purged.
The formation of water in the crankcase can result
in an acid solution which allows corrosion to occur.
A high jacket water temperature helps to prevent
the condensation of water in the crankcase. For
landfill gas, the engines have a high temperature
jacket water cooling system as standard equipment.
The standard water temperature regulators (outlet)
begin to open at 110 C (230 F).
Because of the higher jacket water temperatures,
the oil must be cooled by other means. In engines
that use landfill gas, the oil is cooled by the water in
the separate circuit aftercooling system.
To protect the service life of the engine, it is
necessary to follow the guidelines for operation and
maintenance that are recommended by Caterpillar.
For engines that use landfill gas, practice the
following recommendations in addition to the
precautions for using sour gas:
Exhaust gases are likely to contain acids. If the
engine installation has a device that uses the heat
from the exhaust, maintain a minimum exhaust
gas temperature of 204 C (400 F). This will
prevent condensation in the device.
 57
Maintenance Section
Fuel Specifications

Landfill gas requires regular, careful maintenance Gaseous Fuel Filters

of the spark plugs. Misfire causes the engine
to run rough. The cylinder temperatures are
reduced. Cooler cylinders allow deposits to build
up faster in the combustion chamber, the exhaust
manifold, and the turbocharger. Exhaust port
temperatures can indicate the performance of the
spark plugs. An exhaust port temperature that
decreases more than 66 C (150 F) below the
average operating temperature may indicate the
misfire of a spark plug. Clean the spark plug.
Inspect the spark plug and set the electrode gap.
Replace the spark plug if the performance is in
question.
The customer is responsible for supplying clean,
dry fuel to the engine.
Fuel filters are no less important than air filters to
protect gas engines from dirt and debris. A proper
fuel filter removes impurities that can damage the
internal components of the engine.
The gas must be supplied to the engine at a
pressure that is acceptable. For optimum operation,
use a fuel filter that is properly sized for the gas
pressure.

Caterpillar Natural Gas Engine Oil (NGEO)
is recommended for engines that use landfill
gas. NGEO has 0.45 percent sulfated ash. The
use of an oil that has a high concentration of
sulfated ash will result in excessive deposits
in the combustion chamber. Because of the
inconsistent composition of landfill gas, oil may
react differently to a particular landfill gas. Use
the SOS oil analysis program to determine
proper oil change intervals.
For many gas engines, fuel filters are a provision of
the design for the application. These devices are
included in the normal maintenance of the plant.
Therefore, Caterpillar does not include a standard
fuel filter as a part of each gas engine. However,
fuel filters are available from your Caterpillar dealer.
Consult your Caterpillar dealer about the
requirements for filtering your engines fuel.

For new installations, sample the oil frequently

in order to establish a consistent program for oil
changes. Initially, sample the oil on a daily basis.
The properties of landfill gas can change rapidly.
Therefore, it is necessary to continue to monitor the
oil on a weekly basis or two times per month in
order to ensure adequate protection.

Note: For more information on landfill gas and

digester gas, see Application and Installation Guide,
LEKQ7260, Low Energy Fuels.

Digester Gas
A variety of materials can produce digester gas:

Sewage
Animal waste
Liquid effluent from vegetable oil mills and alcohol
mills

Digester gas has properties that are similar to the

properties of landfill gas. Digester gas usually has
some sulfur and siloxanes. However, digester gas
does not usually contain the chloroflorocarbons that
are found in landfill gas. The same precautions for
treatment of the fuel and protecting the engine are
required. Until experience proves otherwise, the
same maintenance recommendations are used.
58
Maintenance Section
Cooling System Specifications

Cooling System Many engine failures are related to the cooling

system. The following problems are related to
Specifications cooling system failures: overheating, leakage of the
water pump, plugged radiators or heat exchangers,
and pitting of the cylinder liners.
i01640527
These failures can be avoided with proper cooling
General Coolant Information system maintenance. Cooling system maintenance
is as important as maintenance of the fuel system
SMCS Code: 1350; 1395 and the lubrication system. Quality of the coolant
is as important as the quality of the fuel and the
NOTICE lubricating oil.
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first. Coolant is normally composed of three elements:
water, additives, and glycol.

NOTICE
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temper-
ature or drained completely to prevent damage.
NOTICE
Frequently check the specific gravity of the coolant for
proper freeze protection or for anti-boil protection.
Clean the cooling system for the following reasons:
Water
NOTICE
Never use water alone without Supplemental Coolant
Additives (SCA) or without inhibited coolant. Water
alone is corrosive at engine operating temperatures.
Water alone does not provide adequate protection
against boiling or freezing.
Water is used in the cooling system in order to
transfer heat.

Contamination of the cooling system Distilled water or deionized water is

recommended for use in engine cooling systems.
Overheating of the engine
DO NOT use the following types of water in cooling
Foaming of the coolant systems: hard water, softened water that has been
conditioned with salt, and sea water.
Note: Air pockets can form in the cooling system if
the cooling system is filled at a rate that is greater If distilled water or deionized water is not available,
than 20 L (5 US gal) per minute. use water with the properties that are listed in Table
20.
After you drain the cooling system and after you
refill the cooling system, operate the engine.
Operate the engine without the filler cap until the
coolant reaches normal operating temperature and
the coolant level stabilizes. Ensure that the coolant
is maintained to the proper level.

NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.

Refer to Special Instruction, SEBD0518, Know

Your Cooling System and Special Instruction,
SEBD0970, Coolant and Your Engine for more
detailed information.
 59
Maintenance Section
Cooling System Specifications

Table 20 Reduction of heat transfer

Caterpillar Minimum Acceptable Water Requirements
Leakage of the water pump seal
Property Maximum Limit ASTM Test
40 mg/L D512, Plugging of radiators, coolers, and small
Chloride (Cl) passages
(2.4 grains/US gal) D4327
100 mg/L
Sulfate (SO4)
(5.9 grains/US gal)
D516 Glycol
170 mg/L Glycol in the coolant helps to provide protection
Total Hardness D1126
(10 grains/US gal) against the following conditions:
340 mg/L
Total Solids D1888 Boiling
(20 grain/US gal)
Acidity pH of 5.5 to 9.0 D1293 Freezing
For a water analysis, consult one of the following Cavitation of the water pump and the cylinder liner
sources:
For optimum performance, Caterpillar recommends
Caterpillar dealer a 1:1 mixture of a water/glycol solution.

Local water utility company Note: Use a mixture that will provide protection
against the lowest ambient temperature.
Agricultural agent
Note: 100 percent pure glycol will freeze at a
Independent laboratory temperature of 23 C (9 F).

Most conventional heavy-duty coolant/antifreezes

Additives use ethylene glycol. Propylene glycol may also be
used. In a 1:1 mixture with water, ethylene and
Additives help to protect the metal surfaces of propylene glycol provide similar protection against
the cooling system. A lack of coolant additives freezing and boiling. See Tables 21 and 22.
or insufficient amounts of additives enable the
following conditions to occur: Table 21
Ethylene Glycol
Corrosion
Freeze Boil
Concentration
Formation of mineral deposits Protection Protection
50 Percent 36 C (33 F) 106 C (223 F)
Rust
60 Percent 51 C (60 F) 111 C (232 F)
Scale
Pitting and erosion from cavitation of the cylinder NOTICE
liner Do not use propylene glycol in concentrations that ex-
ceed 50 percent glycol because of propylene glycols
Foaming of the coolant reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against
Many additives are depleted during engine boiling or freezing.
operation. These additives must be replaced
periodically. This can be done by adding
Supplemental Coolant Additives (SCA) to Diesel
Engine Antifreeze/Coolant (DEAC).

Additives must be added at the proper

concentration. Overconcentration of additives can
cause the inhibitors to drop out-of-solution. The
deposits can enable the following problems to
occur:

Formation of gel compounds

60
Maintenance Section
Cooling System Specifications
Table 22
Propylene Glycol
Freeze Anti-Boil
Concentration
Protection Protection
50 Percent 29 C (20 F) 106 C (223 F)
To check the concentration of glycol, use the
1U-7298 Coolant/Battery Tester (Degree Celsius)
or use the 1U-7297 Coolant/Battery Tester (Degree
Fahrenheit). The testers give readings that are
immediate and accurate. The testers can be used
with ethylene or propylene glycol.
i01452829
Coolant Recommendations
SMCS Code: 1350; 1352; 1395
NOTICE
Do not use a commercial coolant/antifreeze that only
meets the ASTM D3306 or D4656 specification. This
type of coolant/antifreeze is made for light duty auto-
motive applications.
The following coolants are the primary types of
coolants that are used in Caterpillar Gas Engines:
Preferred Caterpillar Diesel Engine
Antifreeze/Coolant (DEAC) or a commercial
heavy-duty coolant/antifreeze that meets ASTM
D4985 or ASTM D5345 specifications
Acceptable A mixture of Caterpillar Supplemental
Coolant Additive and water that has the acceptable
characteristics
Caterpillar recommends a 1:1 mixture of water and
glycol. This mixture will provide optimum heavy-duty
performance as a coolant/antifreeze.
Note: Caterpillar DEAC DOES NOT require a
treatment with an SCA at the initial fill. Commercial
heavy-duty coolant/antifreeze that meets ASTM
D4985 or ASTM D5345 specifications MAY
require a treatment with an SCA at the initial fill.
Read the label or the instructions that are provided
by the OEM of the product.
In those engine applications that do not require
protection from boiling or freezing, a mixture
of SCA and water is acceptable. Caterpillar
recommends a minimum of six percent to a
maximum of eight percent SCA concentration in
those cooling systems. Distilled water or deionized
water is preferred. Water which has the acceptable
characteristics may be used. For the acceptable
characteristics, see this publication, General
Coolant Information topic (Maintenance Section).
Note: Table 23 is a list of the coolants that are
recommended and the service life (calendar) of
the coolants. The service life of coolant is also
limited by use (service hours). Refer to the specific
engines Operation and Maintenance Manual,
Maintenance Interval Schedule (Maintenance
Section). To achieve this service life, the coolants
must be properly maintained. The maintenance
program includes SOS coolant analysis.
Table 23
Coolant Service Life
Coolant Type Service Life (1)
Caterpillar DEAC Three Years
Commercial Heavy-Duty
Coolant/Antifreeze that Two Years
meets ASTM D5345
Commercial Heavy-Duty
Coolant/Antifreeze that One Year
meets ASTM D4985
Caterpillar SCA and
Two Years
Water
Commercial SCA and
One Year
Water
(1) The service life of coolant is also limited by use (service hours).
Refer to the specific engines Operation and Maintenance
Manual, Maintenance Interval Schedule (Maintenance
Section).
i01111753
Diesel Engine Antifreeze/
Coolant (DEAC)
SMCS Code: 1350; 1352; 1395
Caterpillar recommends using Caterpillar
Diesel Engine Antifreeze/Coolant (DEAC) for
cooling systems that require a heavy-duty
coolant/antifreeze. Caterpillar DEAC is an alkaline
single-phase ethylene glycol type antifreeze that
contains corrosion inhibitors and antifoam agents.
Caterpillar DEAC is formulated with the correct
amount of Caterpillar Supplemental Coolant Additive
(SCA). Do no use SCA at the initial fill when DEAC
is used.

Containers of several sizes are available. Consult
your Caterpillar dealer for the part numbers.
If concentrated DEAC is used, Caterpillar
recommends mixing the concentrate with distilled
water or with deionized water. If distilled water is
not available or deionized water is not available,
use water which has the required properties. For
the water properties, see this publication, General
Coolant Information topic (Maintenance Section).
i01164588
Commercial Heavy-Duty
Coolant/Antifreeze and SCA
SMCS Code: 1350; 1352; 1395
If Caterpillar DEAC is not used, select a
coolant/antifreeze with low silicate content for
heavy-duty applications that meets ASTM D5345
or ASTM D4985 specifications.
Note: When you are not using Caterpillar DEAC the
cooling system must be drained one time during
every year. The cooling system must be flushed at
this time as well.
When a heavy-duty coolant/antifreeze is used,
treat the cooling system with three to six
percent Caterpillar SCA by volume. For more
information, see this publication, Conventional
Coolant/Antifreeze Cooling System Maintenance
topic (Maintenance Section).
If Caterpillar SCA is not used, select a commercial
SCA. The commercial SCA must provide a minimum
of 1200 mg/L or 1200 ppm (70 grains/US gal) of
nitrites in the final coolant mixture.
Coolant/antifreeze that meets ASTM D5345 or
ASTM D4985 specifications MAY require treatment
with SCA at the initial fill. These coolants WILL
require treatment with SCA on a maintenance basis.
When concentrated coolant/antifreeze is mixed,
Caterpillar recommends mixing the concentrate with
distilled water or with deionized water. If distilled
water or deionized water is not available, water
which has the required properties may be used. For
the water properties, see this publication, General
Coolant Information topic (Maintenance Section).
61
Maintenance Section
Cooling System Specifications
i01069295
Supplemental Coolant Additive
(SCA)
SMCS Code: 1350; 1352; 1395
The use of SCA helps to prevent the following
conditions from occurring:
Corrosion
Formation of mineral deposits
Cavitation erosion of the cylinder liners
Foaming of the coolant
Caterpillar Diesel Engine Antifreeze/Coolant (DEAC)
is formulated with the correct level of Caterpillar
SCA. When the cooling system is initially filled with
DEAC, adding more SCA is not necessary until the
concentration of SCA has been depleted. To ensure
that the correct amount of SCA is in the cooling
system, the concentration of SCA must be tested
on a scheduled basis. Refer to the specific engines
Operation and Maintenance Manual, Maintenance
Interval Schedule.
Containers of SCA are available in several sizes.
Consult your Caterpillar dealer for the part numbers.
i01166959
Conventional Coolant/
Antifreeze Cooling System
Maintenance
SMCS Code: 1350; 1352; 1395
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.
Check the coolant/antifreeze (glycol concentration)
in order to ensure adequate protection against
boiling or freezing. Caterpillar recommends the
use of a refractometer for checking the glycol
concentration. Use the 1U-7298 Coolant/Battery
Tester (Celsius) or use the 1U-7297 Coolant/Battery
Tester (Fahrenheit). The testers give readings that
are immediate and accurate. The testers can be
used with ethylene or with propylene glycol.
62
Maintenance Section
Cooling System Specifications

Adding the SCA to Conventional
Coolant/Antifreeze at the Initial Fill
Note: Caterpillar DEAC DOES NOT require an
addition of SCA when the cooling system is initially
filled.
Commercial heavy-duty coolant/antifreeze
that meets ASTM D4985 or ASTM D5345
specifications MAY require an addition of SCA when
the cooling system is initially filled. Read the label
or the instructions that are provided by the OEM
of the product.
The size of the cooling system determines the
amount of SCA that is required. Use the equation
that is in Table 24 to determine the amount of
Caterpillar SCA that may be required when the
cooling system is initially filled with heavy-duty
coolant/antifreeze that meets ASTM D4985 or
ASTM D5345 specifications.
Table 24
Equation For Adding The SCA At The Initial Fill
Coolant/Antifreeze That Meets ASTM D4985
or ASTM D5345 Specifications (1)
V 0.045 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.
(1)
Read the label or the instructions that are provided by the OEM
of the product.
Table 25 is an example for using the equation that
is in Table 24.
Table 25
Example of the Equation For Adding The
SCA At The Initial Fill
Coolant/Antifreeze That Meets ASTM D4985
or ASTM D5345 Specifications
Total Volume Factor for Amount of SCA
of the Cooling Multiplication that is Required
System (V)
946 L 0.045
(250 US gal)
Test the coolant/antifreeze periodically for the
concentration of SCA. For the interval, see the
specific engines Operation and Maintenance
Manual, Maintenance Interval Schedule
(Maintenance Section). SCA test kits are available
from your Caterpillar dealer. Test the concentration of
SCA or submit a coolant sample to your Caterpillar
dealer. For more information on coolant analysis,
see the Operation and Maintenance Manual, SOS
Coolant Analysis topic (Maintenance Section).
Additions of SCA are based on the results of the
test or based on the results of the coolant analysis.
The size of the cooling system determines the
amount of SCA that is needed.
Use the equation that is in Table 26 to determine
the amount of Caterpillar SCA that is required.
Table 26
Equation For Adding The SCA To Conventional
Coolant/Antifreeze For Maintenance
V 0.014 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.
Table 27 is an example for using the equation that
is in Table 26.
Table 27
Example Of The Equation For Adding The SCA To
Conventional Coolant/Antifreeze For Maintenance
Total Volume Factor for Amount of SCA
of the Cooling Multiplication that is Required
System (V) (X)
946 L 0.014 13 L
(250 US gal) (3.5 US gal)
Note: Specific engine applications may require
maintenance practices to be periodically evaluated
in order to properly maintain the engines cooling
(X) system.
43 L
Table 28 lists part numbers and quantities of SCA
(11 US gal)
that is available from your Caterpillar dealer.

Table 28
Adding the SCA to Conventional
Caterpillar Liquid SCA
Coolant/Antifreeze For
Part Number Quantity
Maintenance
8C-3680 19 L (5 US gal)
Heavy-duty coolant/antifreeze of all types REQUIRE
5P-2907 208 L (55 US gal)
periodic additions of an SCA.

Cleaning the Cooling System of
Heavy-Duty Coolant/Antifreeze
Caterpillar Cooling System Cleaner dissolves
mineral scale, corrosion products, light oil
contamination and sludge.
Clean the cooling system after used coolant is
drained or before the cooling system is filled with
new coolant.
Clean the cooling system whenever the coolant is
contaminated or whenever the coolant is foaming.
i01314838
Water/Supplemental Coolant
Additive (SCA)
SMCS Code: 1350; 1352; 1395
NOTICE
To help prevent water pump cavitation, Caterpillar rec-
ommends a minimum of 30 percent of glycol in the
coolant/antifreeze mixture.
Use a mixture that will provide protection against the
lowest ambient temperature.
100 percent pure glycol will freeze at a temperature of
13 C (9 F).
NOTICE
Never use water alone without Supplemental Coolant
Additives (SCA) or without inhibited coolant. Water
alone is corrosive at engine operating temperatures.
Water alone does not provide adequate protection
against boiling or freezing.
Do not use water alone as an engine coolant.
Supplemental Coolant Additive (SCA) helps to
prevent the following conditions from occurring:
Corrosion
Formation of mineral deposits
Cavitation of the cylinder liner
Foaming of the coolant
If Caterpillar SCA is not used, select a commercial
SCA. The commercial SCA must provide a minimum
of 2400 mg/L or 2400 ppm (140 grains/US gal) of
nitrites in the final coolant mixture.
63
Maintenance Section
Cooling System Specifications
The quality of the water is a very important factor
in this type of cooling system. Distilled water or
deionized water is recommended for use in cooling
systems. If distilled water or deionized water is not
available, water that has the required properties
may be used. For the water properties, see this
Operation and Maintenance Manual, General
Coolant Information topic (Maintenance Section).
A cooling system that uses a mixture of only SCA
and water requires more SCA than a cooling system
that uses a mixture of glycol and water. The SCA
and water requires six to eight percent of SCA.
Adding the SCA to Water at the
Initial Fill
The capacity of the cooling system determines the
amount of SCA that is required. Use the equation
that is in Table 29 to determine the amount of
Caterpillar SCA that is required at the initial fill. This
equation is for a mixture of only SCA and water.
Table 29
Equation For Adding The SCA To Water
At The Initial Fill
V 0.07 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.
Table 30 is an example for using the equation that
is in Table 29.
Table 30
Example Of The Equation For Adding The SCA
To Water At The Initial Fill
Total Volume Factor for Amount of SCA
of the Cooling Multiplication that is Required
System (V) (X)
946 L 0.07 66 L
(250 US gal) (18 US gal)
Adding the SCA to Water for
Maintenance
Test the mixture of SCA and water periodically for
the concentration of SCA. For the interval, see
the specific engines Operation and Maintenance
Manual, Maintenance Interval Schedule
(Maintenance Section).
Test the concentration of SCA with the 8T-5296
Coolant Conditioner Test Kit or with SOS coolant
analysis. For more information on coolant analysis,
see this Operation and Maintenance Manual, SOS
Coolant Analysis topic (Maintenance Section).
64
Maintenance Section
Cooling System Specifications
Instructions are provided with the 8T-5296
Coolant Conditioner Test Kit. Make the following
modifications to Steps 3 and 5 of the instructions.
These modifications are needed for mixtures of SCA
and water:
STEP 3 Add tap water to the vial up to the 20
ml mark.
STEP 5 When the defined procedure is used,
a concentration of six to eight percent will yield
between 20 drops and 27 drops. If the number of
drops is below 20 drops, the concentration of SCA
is low. If the number of drops is above 27 drops, the
concentration of SCA is high. Make the appropriate
adjustments to the concentration of SCA.
Additions of SCA are based on the results of the
test or based on the results of the coolant analysis.
The capacity of the cooling system determines the
amount of SCA that is required.
Use the equation that is in Table 31 to determine
the amount of Caterpillar SCA that is required.
Table 31
Equation For Adding the SCA To Water
For Maintenance
V 0.023 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.
Table 32 is an example for using the equation that
is in Table 31.
Table 32
Example Of The Equation For Adding the SCA
To Water For Maintenance
Total Volume Factor for Amount of SCA
of the Cooling Multiplication that is Required
System (V) (X)
946 L 0.023 22 L
(250 US gal) (6 US gal)
Note: Specific engine applications may require
maintenance practices to be periodically evaluated
in order to properly maintain the engines cooling
system.
Table 33 lists part numbers and quantities of SCA
that is available from your Caterpillar dealer.
Table 33
Caterpillar Liquid SCA
Part Number Quantity
8C-3680 19 L (5 US gal)
5P-2907 208 L (55 US gal)
i01069690
SOS Coolant Analysis
SMCS Code: 1350; 1352; 1395
Testing the engine coolant is important to ensure
that the engine is protected from internal cavitation
and from corrosion. The analysis also tests the
ability of the coolant to protect the engine from
boiling and from freezing.
Coolant analysis can be performed at your
Caterpillar dealership. Caterpillars SOS coolant
analysis is an excellent way to monitor the condition
of your coolant and your cooling system.
The most critical aspect of coolant analysis is
the interpretation of the results. The analyst must
be properly trained in order to provide a correct
diagnosis. The analyst must understand several
variables.
Different coolants have different formulations and
different condemning limits. Different commercial
labs may use different methods to test for the
same variable. These other considerations are also
important for interpreting the results of a coolant
analysis:
The number of hours on the sample
The equipment that uses the coolant
The application of the equipment
Analysts at Caterpillars SOS fluid labs are trained
to determine the acceptability of coolants. These
analysts have knowledge of the equipment and
applications. These qualifications enable the
analysts to detect problems before damage occurs.
 65
Maintenance Section
Cooling System Specifications

Identification of buildup of the impurities that

NOTICE cause scaling
Do not use the same vacuum sampling pump for ex-
tracting oil samples that is used for extracting coolant Determination of possible electrolysis within the
samples. engines cooling system

A small residue of either type sample may remain in
the pump and may cause a false positive analysis for
the sample being taken.
Always use a designated pump for oil sampling and a
designated pump for coolant sampling.
The results are reported, and appropriate
recommendations are made.
For more information on SOS coolant analysis,
consult your Caterpillar dealer.

Failure to do so may cause a false analysis which

could lead to customer and dealer concerns.

Caterpillars SOS coolant analysis is a program

with two levels. The program is based on periodic
samples. The samples are analyzed. The results
are reported, and appropriate recommendations are
made according to the results.

SOS Coolant Analysis (Level I)

A coolant analysis (Level I) is a test of the properties
of the coolant that includes the following items:

Glycol concentration for protection from boiling

and freezing

Ability to protect from erosion and corrosion

pH
Conductivity
Water hardness
Visual analysis
Analysis of the odor
The results are reported, and appropriate
recommendations are made.

SOS Coolant Analysis (Level II)

A coolant analysis (Level II) is a comprehensive
chemical evaluation of the coolant. This analysis is
also a check of the overall condition of the inside
of the cooling system. The following services are
provided:

Full Level I analysis

Identification of the source of metal corrosion and
of contaminants

Identification of buildup of the impurities that

cause corrosion
66
Maintenance Section
Refill Capacities

Refill Capacities For the recommended coolant, refer to this

Operation and Maintenance Manual, Coolant
Recommendations (Maintenance Section).
i01742801
Table 36
Refill Capacities G3606 Engine Cooling System
Approximate Refill Capacities
SMCS Code: 1000; 1348; 1395; 7560
Compartment or System Liters US Gallons
Lubrication System Jacket Water 340 90
Aftercooler 61 16
The capacity of the Engine Crankcase includes the
capacity of the oil filters that are installed at the Accessory Module 345 91
factory.
External System
For the recommended oil, refer to this Operation Total Cooling System
and Maintenance Manual, Engine Oil topic
(Maintenance Section). Table 37

Table 34 G3608 Engine Cooling System

Approximate Refill Capacities
Approximate Refill Capacity of Crankcase
Compartment or System Liters US Gallons
Sales Model Liters US Gallons
Jacket Water 469 124
G3606 708 187
Aftercooler 61 16
G3608 912 241
Accessory Module 345 91
G3612 1030 272
External System
G3616 1325 351
Total Cooling System

Hydraulic Actuator System Table 38

For the recommended hydraulic oil, see this G3612 Engine Cooling System
Approximate Refill Capacity
Operation and Maintenance Manual, Hydraulic Oil
topic (Maintenance Section). Compartment or System Liters US Gallons

Table 35 Jacket Water 669 177

Electrohydraulic Actuators System Aftercooler 64 17

Approximate Refill Capacity
Accessory Module 345 91
Compartment or System Liters US Gallons
External System
Hydraulic Oil Tank 19 5
Total Cooling System

Cooling System
To properly maintain the cooling system, the total
cooling system capacity must be determined. The
total cooling system capacity will vary between
individual installations.

The external system capacity includes the following

components: engine, expansion tank, heat
exchanger, and piping. Refer to the specifications
that are provided by Caterpillar or by the OEM of
the equipment. Record the total cooling system
capacity in the appropriate Table.
 67
Maintenance Section
Refill Capacities

Table 39
G3616 Engine Cooling System
Approximate Refill Capacity
Compartment or System Liters US Gallons
Jacket Water 900 238
Aftercooler 72 19
Accessory Module 345 91
External System
Total Cooling System
68
Maintenance Section
Maintenance Interval Schedule
i01742877
Maintenance Interval Schedule
(Engines with a 9:1
Compression Ratio that
use Wellhead Gas or Natural
Gas)
SMCS Code: 1000; 4450; 7500
When Required
Actuator Control Linkage - Replace ...................... 73
Barring Device - Lubricate .................................... 77
Engine Air Cleaner Element - Replace ................. 92
Overhaul Considerations .................................... 115
Valve Stem Projection - Measure/Record ........... 120
Daily
Air Starting Motor Lubricator Oil Level - Check .... 75
Air Tank Moisture and Sediment - Drain ............... 75
Control Panel - Inspect ......................................... 80
Cooling System Coolant Level - Check ................ 82
Driven Equipment - Inspect/Replace/Lubricate ... 88
Electrohydraulic System - Inspect ......................... 91
Engine Oil Level - Check .................................... 100
Fuel System Fuel Filter Differential Pressure -
Check ................................................................ 104
Walk-Around Inspection ...................................... 121
Every 250 Service Hours
Battery Electrolyte Level - Check .......................... 78
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 84
Engine Oil Sample - Obtain ................................ 101
Initial 1000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 74
Air Starting Motor Lubricator Bowl - Clean ........... 74
Crankcase Blowby - Measure/Record .................. 85
Cylinder Pressure - Measure/Record ................... 86
Electrohydraulic System Oil Filter - Change ......... 92
Engine Crankcase Breather - Clean ..................... 94
Engine Speed/Timing Sensor - Clean/Inspect .... 102
Engine Valve Lash - Inspect/Adjust .................... 102
Engine Valve Rotators - Inspect .......................... 103
Valve Stem Projection - Measure/Record ........... 120
Every 1000 Service Hours
Alternator Belt - Inspect/Adjust/Replace ............... 76
Ignition System Spark Plugs - Check/Adjust ...... 107
Every 2000 Service Hours
Aftercooler Condensation - Drain ......................... 73
Cooling System Coolant Analysis (Level II) -
Obtain ................................................................. 82
Crankshaft Vibration Damper - Inspect ................. 85
Engine Crankcase Breather - Clean ..................... 94
Engine Mounts - Check ........................................ 95
Engine Valve Lash - Inspect/Adjust .................... 102
Engine Valve Rotators - Inspect .......................... 103
Valve Stem Projection - Measure/Record ........... 120
Every 5000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 74
Air Starting Motor Lubricator Bowl - Clean ........... 74
Combustion Sensor - Clean/Inspect/Replace ....... 78
Cooling System Level Switch - Inspect ................. 83
Crankcase Blowby - Measure/Record .................. 85
Cylinder Pressure - Measure/Record ................... 86
Driven Equipment - Check .................................... 87
Electrohydraulic System - Check/Adjust ............... 90
Electrohydraulic System Oil - Change .................. 91
Electrohydraulic System Oil Filter - Change ......... 92
Engine Oil - Change ............................................. 95
Engine Oil Filter - Change .................................... 97
Engine Protective Devices - Check ..................... 101
Exhaust Bypass - Recondition ............................ 104
Gas Shutoff Valve - Inspect ................................ 106
Ignition System Spark Plugs - Replace .............. 110
Inlet Air System - Inspect .................................... 110
Inlet Gas Manifold and Piping - Inspect/Replace .. 110
Prechamber Check Valves - Clean ..................... 117
Starting Motor - Inspect ...................................... 118
Every 10 000 Service Hours
Actuator Control Linkage - Replace ...................... 73
Alternator - Inspect ............................................... 76
Driven Equipment - Check .................................... 87
Electrohydraulic Actuator - Inspect ....................... 88
Engine Oil Temperature Regulator - Replace ..... 101
Engine Speed/Timing Sensor - Clean/Inspect .... 102
Exhaust Shields - Inspect ................................... 104
Gas Pressure Regulator - Inspect/Replace ........ 106
Prechamber Check Valves - Replace ................. 117
Prelube Pump - Inspect ...................................... 118
Water Pump - Inspect ......................................... 121
Water Temperature Regulator - Replace ............ 121
Every 20 000 Service Hours or 3 Years
Cooling System Coolant (DEAC) - Change .......... 80
Every 25 000 Service Hours
Gas Admission Valve Seals - Inspect/Replace ... 105
Overhaul (Top End) ............................................. 114
Every 50 000 Service Hours
Electrohydraulic Actuator - Recondition ................ 89
Gas Admission Valve - Recondition .................... 105
Overhaul (In-Frame) ........................................... 111
Every 100 000 Service Hours
Overhaul (Major) ................................................. 112

i01742871
Maintenance Interval Schedule
(Engines that use Bio-Gas)
SMCS Code: 1000; 4450; 7500
When Required
Actuator Control Linkage - Replace ...................... 73
Barring Device - Lubricate .................................... 77
Engine Air Cleaner Element - Replace ................. 92
Engine Oil - Change ............................................. 95
Engine Oil Filter - Change .................................... 97
Overhaul Considerations .................................... 115
Valve Stem Projection - Measure/Record ........... 120
Daily
Air Starting Motor Lubricator Oil Level - Check .... 75
Air Tank Moisture and Sediment - Drain ............... 75
Control Panel - Inspect ......................................... 80
Cooling System Coolant Level - Check ................ 82
Driven Equipment - Inspect/Replace/Lubricate ... 88
Electrohydraulic System - Inspect ......................... 91
Engine Air Cleaner Service Indicator - Inspect ..... 93
Engine Oil Level - Check .................................... 100
Fuel System Fuel Filter Differential Pressure -
Check ................................................................ 104
Turbocharger - Clean .......................................... 119
Walk-Around Inspection ...................................... 121
Every 125 Service Hours
Engine Oil Sample - Obtain ................................ 101
Every 250 Service Hours
Battery Electrolyte Level - Check .......................... 78
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 84
Initial 1000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 74
Air Starting Motor Lubricator Bowl - Clean ........... 74
Crankcase Blowby - Measure/Record .................. 85
Cylinder Pressure - Measure/Record ................... 86
Electrohydraulic System Oil Filter - Change ......... 92
Engine Crankcase Breather - Clean ..................... 94
Engine Speed/Timing Sensor - Clean/Inspect .... 102
Engine Valve Lash - Inspect/Adjust .................... 102
Engine Valve Rotators - Inspect .......................... 103
Valve Stem Projection - Measure/Record ........... 120
Every 1000 Service Hours
Alternator Belt - Inspect/Adjust/Replace ............... 76
Combustion Sensor - Clean/Inspect/Replace ....... 78
Ignition System Spark Plugs - Replace .............. 110
Prechamber Check Valves - Clean ..................... 117
69
Maintenance Section
Maintenance Interval Schedule
Every 2000 Service Hours
Aftercooler Condensation - Drain ......................... 73
Cooling System Coolant Analysis (Level II) -
Obtain ................................................................. 82
Crankshaft Vibration Damper - Inspect ................. 85
Cylinders - Inspect ................................................ 87
Engine Crankcase Breather - Clean ..................... 94
Engine Mounts - Check ........................................ 95
Engine Valve Lash - Inspect/Adjust .................... 102
Engine Valve Rotators - Inspect .......................... 103
Valve Stem Projection - Measure/Record ........... 120
Every 5000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 74
Air Starting Motor Lubricator Bowl - Clean ........... 74
Cooling System Level Switch - Inspect ................. 83
Crankcase Blowby - Measure/Record .................. 85
Cylinder Pressure - Measure/Record ................... 86
Driven Equipment - Check .................................... 87
Electrohydraulic System - Check/Adjust ............... 90
Electrohydraulic System Oil - Change .................. 91
Electrohydraulic System Oil Filter - Change ......... 92
Engine Protective Devices - Check ..................... 101
Exhaust Bypass - Recondition ............................ 104
Gas Shutoff Valve - Inspect ................................ 106
Inlet Air System - Inspect .................................... 110
Inlet Gas Manifold and Piping - Inspect/Replace .. 110
Prechamber Check Valves - Replace ................. 117
Starting Motor - Inspect ...................................... 118
Turbocharger Cleaner Tube - Replace ................ 120
Every 10 000 Service Hours
Actuator Control Linkage - Replace ...................... 73
Alternator - Inspect ............................................... 76
Driven Equipment - Check .................................... 87
Electrohydraulic Actuator - Inspect ....................... 88
Engine Oil Temperature Regulator - Replace ..... 101
Engine Speed/Timing Sensor - Clean/Inspect .... 102
Exhaust Shields - Inspect ................................... 104
Gas Pressure Regulator - Inspect/Replace ........ 106
Prelube Pump - Inspect ...................................... 118
Water Pump - Inspect ......................................... 121
Water Temperature Regulator - Replace ............ 121
Between 13 000 and 13 500 Service Hours
Gas Admission Valve Seals - Inspect/Replace ... 105
Overhaul (Top End) ............................................. 114
Every 20 000 Service Hours or 3 Years
Cooling System Coolant (DEAC) - Change .......... 80
Between 26 000 and 27 000 Service Hours
Electrohydraulic Actuator - Recondition ................ 89
Gas Admission Valve - Recondition .................... 105
Overhaul (In-Frame) ........................................... 111
70
Maintenance Section
Maintenance Interval Schedule

Between 39 000 and 39 500 Service Hours

Gas Admission Valve Seals - Inspect/Replace ... 105
Overhaul (Top End) ............................................. 114

Between 52 000 and 54 000 Service Hours

Overhaul (Major) ................................................. 112

i01742883
Maintenance Interval Schedule
(Engines with a 10.5:1
Compression Ratio that
use Wellhead Gas or Natural
Gas)
SMCS Code: 1000; 4450; 7500
When Required
Actuator Control Linkage - Replace ...................... 73
Barring Device - Lubricate .................................... 77
Engine Air Cleaner Element - Replace ................. 92
Overhaul Considerations .................................... 115
Valve Stem Projection - Measure/Record ........... 120
Daily
Air Starting Motor Lubricator Oil Level - Check .... 75
Air Tank Moisture and Sediment - Drain ............... 75
Control Panel - Inspect ......................................... 80
Cooling System Coolant Level - Check ................ 82
Driven Equipment - Inspect/Replace/Lubricate ... 88
Electrohydraulic System - Inspect ......................... 91
Engine Oil Level - Check .................................... 100
Fuel System Fuel Filter Differential Pressure -
Check ................................................................ 104
Walk-Around Inspection ...................................... 121
Every 250 Service Hours
Battery Electrolyte Level - Check .......................... 78
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 84
Engine Oil Sample - Obtain ................................ 101
Initial 1000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 74
Air Starting Motor Lubricator Bowl - Clean ........... 74
Crankcase Blowby - Measure/Record .................. 85
Cylinder Pressure - Measure/Record ................... 86
Electrohydraulic System Oil Filter - Change ......... 92
Engine Crankcase Breather - Clean ..................... 94
Engine Speed/Timing Sensor - Clean/Inspect .... 102
Engine Valve Lash - Inspect/Adjust .................... 102
Engine Valve Rotators - Inspect .......................... 103
Valve Stem Projection - Measure/Record ........... 120
Every 1000 Service Hours
Alternator Belt - Inspect/Adjust/Replace ............... 76
Ignition System Spark Plugs - Replace .............. 110
Every 2000 Service Hours
Aftercooler Condensation - Drain ......................... 73
Cooling System Coolant Analysis (Level II) -
Obtain ................................................................. 82
71
Maintenance Section
Maintenance Interval Schedule
Crankshaft Vibration Damper - Inspect ................. 85
Engine Crankcase Breather - Clean ..................... 94
Engine Mounts - Check ........................................ 95
Engine Valve Lash - Inspect/Adjust .................... 102
Engine Valve Rotators - Inspect .......................... 103
Valve Stem Projection - Measure/Record ........... 120
Every 5000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 74
Air Starting Motor Lubricator Bowl - Clean ........... 74
Combustion Sensor - Clean/Inspect/Replace ....... 78
Cooling System Level Switch - Inspect ................. 83
Crankcase Blowby - Measure/Record .................. 85
Cylinder Pressure - Measure/Record ................... 86
Driven Equipment - Check .................................... 87
Electrohydraulic System - Check/Adjust ............... 90
Electrohydraulic System Oil - Change .................. 91
Electrohydraulic System Oil Filter - Change ......... 92
Engine Oil - Change ............................................. 95
Engine Oil Filter - Change .................................... 97
Engine Protective Devices - Check ..................... 101
Exhaust Bypass - Recondition ............................ 104
Gas Shutoff Valve - Inspect ................................ 106
Inlet Air System - Inspect .................................... 110
Inlet Gas Manifold and Piping - Inspect/Replace .. 110
Prechamber Check Valves - Clean ..................... 117
Starting Motor - Inspect ...................................... 118
Every 10 000 Service Hours
Actuator Control Linkage - Replace ...................... 73
Alternator - Inspect ............................................... 76
Driven Equipment - Check .................................... 87
Electrohydraulic Actuator - Inspect ....................... 88
Engine Oil Temperature Regulator - Replace ..... 101
Engine Speed/Timing Sensor - Clean/Inspect .... 102
Exhaust Shields - Inspect ................................... 104
Gas Pressure Regulator - Inspect/Replace ........ 106
Prechamber Check Valves - Replace ................. 117
Prelube Pump - Inspect ...................................... 118
Water Pump - Inspect ......................................... 121
Water Temperature Regulator - Replace ............ 121
Between 15 000 and 16 000 Service Hours
Gas Admission Valve Seals - Inspect/Replace ... 105
Overhaul (Top End) ............................................. 114
Every 20 000 Service Hours or 3 Years
Cooling System Coolant (DEAC) - Change .......... 80
Between 30 000 and 32 000 Service Hours
Gas Admission Valve Seals - Inspect/Replace ... 105
Overhaul (Top End) ............................................. 114
Between 45 000 and 48 000 Service Hours
Electrohydraulic Actuator - Recondition ................ 89
Gas Admission Valve - Recondition .................... 105
Overhaul (In-Frame) ........................................... 111
72
Maintenance Section
Maintenance Interval Schedule

Between 60 000 and 64 000 Service Hours

Gas Admission Valve Seals - Inspect/Replace ... 105
Overhaul (Top End) ............................................. 114

Between 75 000 and 80 000 Service Hours

Overhaul (Major) ................................................. 112
 73
Maintenance Section
Actuator Control Linkage - Replace

i01765614

Actuator Control Linkage -

Replace
(Replace the Rod Ends)
SMCS Code: 1265-510

g00788934
Illustration 39
A drain plug is located on the right side near the rear of the engine.
(1) Plug

g00799207
Illustration 38
Typical example of rod ends on an actuator and on the linkage
for an actuator

Note: Use of a platform may be necessary to reach

the linkages.

Inspect the rod ends of the following components

for wear:

Air choke actuator Illustration 40

g00788946

A drain plug is located on the left side near the front of the engine.
Exhaust bypass actuator
(2) Plug
Fuel control actuator
1. Ensure that the engine is not running.
Linkages
2. Remove plugs (1) and (2).
If necessary, replace the rod ends. Assemble the
linkage according to the instructions in the engines 3. Drain the moisture into suitable containers.
Specifications.
4. Install the plugs.

i01762572

Aftercooler Condensation -
Drain
SMCS Code: 1063

The aftercooler is similar to a radiator. Coolant

passes through the tubes in the aftercooler core.
Inlet air that is warmed by the turbocharger
compressor is directed through the aftercooler core.
The air is cooled in the aftercooler.

Condensation can form in the passages of the

aftercooler system. Drain plugs are provided for
draining the condensation.
74
Maintenance Section
Air Starting Motor Lines Screen - Clean

i01762654

Air Starting Motor Lines

Personal injury can result from removing hoses or
Screen - Clean fittings in a pressure system.
SMCS Code: 1451-070-LI Failure to relieve pressure can cause personal in-
jury.

Do not disconnect or remove hoses or fittings un-

til all pressure in the system has been relieved.

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

g00789123
Illustration 41
(1) Plug
(2) Screen

If the engine is equipped with an air starting motor,

use the following procedure:
g00745554
1. Ensure that the air supply to the air lines is OFF. Illustration 42
(1) Filler plug
2. Remove plug (1). (2) Bowl
(3) Drain valve
3. Carefully remove screen (2). Clean the screen
with nonflammable solvent. Inspect the screen 2. Slowly loosen filler plug (1) in order to release
for damage. If the screen is damaged, replace the pressure from the lubricator.
the damaged screen with a new screen.
NOTICE
4. Install clean, dry screen (2). Clean plug (1). Care must be taken to ensure that fluids are contained
Install the plug. during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
i01762681
ing any compartment or disassembling any compo-
Air Starting Motor Lubricator nent containing fluids.
Bowl - Clean Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
SMCS Code: 1451-070 suitable to collect and contain fluids on Caterpillar
products.
If the engine is equipped with an air starting motor,
use the following procedure: Dispose of all fluids according to local regulations and
mandates.

3. Place a suitable container under bowl (2) and

open drain valve (3) in order to drain the oil from
the bowl.

4. Remove bowl (2). Clean the bowl with warm

water.

5. Dry the bowl. Inspect the bowl for cracks. If the
bowl is cracked, replace the damaged bowl with
a new bowl.
6. Install the bowl.
7. Make sure that drain valve (3) is closed. Fill bowl
(2) through the hole for filler plug (1).
Use nondetergent 10W oil for temperatures that
are greater than 0 C (32 F). Use air tool oil for
temperatures that are below 0 C (32 F).
8. Install filler plug (1).
9. If necessary, adjust the lubricator in order to
release two drops of oil per 30 seconds. For
instructions, see this Operation and Maintenance
Manual, Air Starting Motor Lubricator Oil Level -
Check topic (Maintenance Section).
i01762698
Air Starting Motor Lubricator
Oil Level - Check
SMCS Code: 1451-535
If the engine is equipped with an air starting motor,
use the following procedure:
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.
g00745561
Illustration 43
1. Observe the oil level in sight gauge (3). If the oil
level is less than 1/2, add oil to the lubricator
bowl.
75
Maintenance Section
Air Starting Motor Lubricator Oil Level - Check
Personal injury can result from removing hoses or
fittings in a pressure system.
Failure to relieve pressure can cause personal in-
jury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
2. Ensure that the air supply to the lubricator is OFF.
Slowly loosen filler plug (4) in order to release
pressure from the lubricator bowl.
3. Remove filler plug (4). Pour oil into the
lubricator bowl. Use nondetergent 10W oil for
temperatures that are greater than 0 C (32 F).
Use air tool oil for temperatures that are below
0 C (32 F).
4. Install filler plug (4).
Adjust the Lubricator
Note: Adjust the lubricator with a constant rate of air
flow. After the adjustment, the lubricator will release
oil in proportion to variations of the air flow.
1. Ensure that the fuel supply to the engine is OFF.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
2. Operate the air starting motor. Observe the drops
of oil that are released in dome (1).
Note: Some lubricators have an adjustment screw
rather than a knob.
3. If necessary, adjust the lubricator in order to
release two drops of oil per 30 seconds. To
increase the rate, turn knob (2) counterclockwise.
To decrease the rate, turn the knob clockwise.
i00351324
Air Tank Moisture and
Sediment - Drain
SMCS Code: 1466-543-M&S
Moisture and sediment in the air starting system
can cause the following conditions:
Freezing
76
Maintenance Section
Alternator - Inspect

Corrosion of internal parts Belts

Malfunction of the air starting system Pulleys
Bearings
If the belts are too tight, unnecessary stress is
When opening the drain valve, wear protective placed on the components. This reduces the
gloves, a protective face shield, protective cloth- service life of the components.
ing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal
injury. Adjustment

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

the air tank. Allow the moisture and sediment
to drain.

2. Close the drain valve.

i00839754

Alternator - Inspect
SMCS Code: 1405-040

Inspect the alternator for the following conditions:

g00789191
Illustration 44
Loose connections (1) Adjusting nuts
(2) Mounting bolt
Proper charging of the battery
1. Remove the belt guard.
Observe the ammeter during engine operation in
order to ensure proper battery performance and/or 2. Loosen mounting bolt (2).
proper performance of the electrical system.
3. Turn adjusting nuts (1) in order to increase or
Make repairs, if necessary. See the Service Manual decrease the belt tension.
for service procedures. Consult your Caterpillar
dealer for assistance. 4. Tighten adjusting nuts (1). Tighten mounting
bolt (2). For the proper torque, see the Service
Manual, Specifications module.
i01519792

Alternator Belt - 5. Install the belt guard.

Inspect/Adjust/Replace If new belts are installed, check the belt tension

again after 30 minutes of engine operation at rated
SMCS Code: 1357-025; 1357-040; 1357-510; 1405 rpm.

Inspection
Inspect the alternator belts for wear and for
cracking. Replace belts that are not in good
condition.
Check the belt tension according to the information
in the Service Manual, Specifications module.
Replacement
For applications that require multiple drive belts,
replace the belts in matched sets. Used belts are
stretched. Replacing only one belt of a matched set
will cause the new belt to carry an excessive load.
The additional load on the new belt could cause the
new belt to break.

Slippage of loose belts can reduce the efficiency

of the driven components. Vibration of loose belts
can cause unnecessary wear on the following
components:
 77
Maintenance Section
Barring Device - Lubricate

i01519824 Note: Illustration 46 and Illustration 47 show the

locations of the grease fittings for two typical barring
Barring Device - Lubricate devices. Some engines may be equipped with
different barring devices.
SMCS Code: 1235-086

NOTICE
Do not use an impact wrench to operate the barring
device. The use of an impact wrench will cause gear
tooth failure.

Guards must be in place prior to operating barring

device motor.

Remove all hand tools prior to operating barring

device motor.
g00789211
Illustration 46
Right side section view of a barring device without an electric motor
(1) Grease fitting
(2) Vent

1. Ensure that the barring device is locked in the

disengaged position.

2. Lubricate grease fitting (1) with MPGM until the

grease is visible at vent (2).

g00334420
Illustration 45
Rear view of a barring device with an electric motor

Note: Prelube of the engine is required before the

crankshaft is rotated for normal maintenance.

The barring device provides a means for slowly

turning the flywheel in order to service the engine.
The barring device can also be used to prevent
rotation of the crankshaft. When the barring device g00789218
is in the engaged position, the engine starting Illustration 47
system is disabled. (1) Grease fitting
(2) Gear end
When the barring device is not used, the barring
device must be fully disengaged from the flywheel 1. Ensure that the barring device is locked in the
and secured in the disengaged position. Refer to disengaged position.
the Service Manual for information on operation of
the barring device. 2. Lubricate grease fitting (1) with MPGM until the
grease is visible at gear end (2).
NOTICE
Do not operate the engine starting motor until the bar-
ring group pinion gear is fully disengaged from the fly-
wheel ring gear. Serious damage to the engine could
result.
78
Maintenance Section
Battery Electrolyte Level - Check

i01639002 i01765627

Battery Electrolyte Level - Combustion Sensor -

Check Clean/Inspect/Replace
SMCS Code: 1401-535-FLV SMCS Code: 1900; 1905

When the engine is not run for long periods of To provide a signal without interference to the
time or when the engine is run for short periods, engine control module, the sensor must be in good
the batteries may not fully recharge. Ensure a full condition. The connections must be clean.
charge in order to help prevent the battery from
freezing. If batteries are properly charged, ammeter
reading should be very near zero.

All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.

1. Remove the filler caps. Maintain the electrolyte

level to the FULL mark on the battery.

If the addition of water is necessary, use distilled

water. If distilled water is not available use
clean water that is low in minerals. Do not use
artificially softened water.

2. Check the condition of the electrolyte with the

1U-7298 Coolant/Battery Tester (C) or the
1U-7297 Coolant/Battery Tester (F).

3. Keep the batteries clean.

Clean the battery case with one of the following

cleaning solutions: g00789241
Illustration 48
A mixture of 0.1 kg (0.2 lb) of baking soda and Section view of a cylinder head with a combustion sensor
1 L (1 qt) of clean water (1) Harness connector
(2) Connector
(3) Extension
A mixture of 0.1 L (0.11 qt) of ammonia and (4) Sensor
1 L (1 qt) of clean water (5) Gasket
(6) Discs
Thoroughly rinse the battery case with clean
water. Note: Use of a platform may be necessary to reach
the combustion sensor.
Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items Note: Clean the connections and polish the
until the surfaces are bright or shiny. DO NOT connections with a clean, dry cloth. Always install
remove material excessively. Excessive removal a new O-ring seal in connector (1) when the
of material can cause the clamps to not fit combustion sensor is serviced.
properly. Coat the clamps and the terminals with
5N-5561 Silicone Lubricant, petroleum jelly or 1. Disconnect harness connector (1) from
MPGM grease. connector (2). Remove the O-ring seal from the
harness connector. Clean the end of the harness
connector. Install a new O-ring seal.

2. Remove connector (2). Clean the inside of the

connectors adapters.

3. Remove extension (3). Clean both ends of the
extension.
Pressurized air can cause personal injury. When
pressurized air is used for cleaning, wear a protec-
tive face shield, protective clothing, and protective
shoes.
Note: The maximum air pressure for cleaning
purposes must be below 207 kPa (30 psi).
4. The area around sensor (4) may have debris.
Thoroughly remove any debris. Use compressed
air. Ensure that the area around the sensor is
clean and free of debris.
5. Loosen sensor (4) with a 15.9 mm (5/8 inch)
spark plug socket and an extension. After the
sensor has been loosened, remove the sensor
by hand in order to detect problems with the
threads.
If the sensor resists removal by hand, apply
penetrating oil to the threads. Use the wrench
and apply steady pressure to the sensor until
the sensor is loose.
g00789274
Illustration 49
Combustion sensor
(6) Terminal post
(7) Insulator
(8) Shell
(9) Gasket
(10) Electrode
6. After the sensor is removed, discard gasket (9).
7. Inspect the sensor closely for damage.
Terminal post (6) must not move. If the terminal
post can be moved by hand, discard the sensor.
Inspect insulator (7) for cracks. If a crack is
found, discard the sensor.
Inspect shell (8) for damage. Cracks can
be caused by overtightening the sensor.
Overtightening can also loosen the shell. Discard
any sensor that has a shell that is cracked or
loose.
Inspect electrode (10) for excessive wear.
79
Maintenance Section
Combustion Sensor - Clean/Inspect/Replace
Light brown deposits or beige deposits around
the electrode is produced by normal operation.
White deposits or gray deposits may be caused
by the following substances:
Excessive oil
Use of the wrong oil
A substance that is introduced through the fuel
system or the air system
A buildup of ash on the electrode reduces the
efficiency of the sensor.
8. Measure the resistance between terminal post
(6) and electrode (10).
The sensor must pass a low voltage check for
continuity between the terminal post and the
electrode (15 volts DC). The resistance must not
exceed five ohms.
9. Thoroughly clean the sensor.
Clean the shell and the electrode that is inside of
the shell. Do not use a wire brush. Glass beads
are the preferred method for cleaning. Follow
these guidelines for the use of glass beads:
Always use clean glass beads.
Use care in order to clean only the electrode
and the insulator near the electrode.
Do not use glass beads on the outside of the
shell or on the upper part of the insulator.
Ensure that the sensor is clean and free of dirt
and oil.
Note: Do not use anti-seize compound on the
sensor. Most of the heat is transferred through
the threads and the seat area of the sensor. The
surfaces must be in contact in order to provide the
heat transfer that is required.
10. Place a new 108-3515 Plug Gasket on the
sensor. Install the sensor by hand until the sensor
bottoms out. Tighten the sensor to 38 2 Nm
(28 2 lb ft).
11. Install extension (3). Make sure that discs (5)
are positioned in order to align the extensions
connectors with sensor (4) and connector (2).
12. Make sure that the O-ring seal on connector (2)
is in good condition. Install the connector.
13. Attach harness connector (1) to connector (2).
80
Maintenance Section
Control Panel - Inspect

i01762721

Control Panel - Inspect

SMCS Code: 4490-040; 7451-040

Inspect the condition of the panel. If a component is

damaged, ensure that the component is repaired or
that the component is replaced. If equipped, ensure
that the electronic displays are operating properly.

Inspect the wiring for good condition. Ensure that

the wiring connections are secure.

Record the Data and Review the Illustration 50

g00792409

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. (2) Aftercooler and oil cooler pump
Record the data in a log. Compare the new data to
the data that was previously recorded. Comparing
the new data to the recorded data will establish the
normal gauge readings for the engine. A gauge
reading that is abnormal may indicate a problem
with operation or with the gauge.

i01762726

Cooling System Coolant

(DEAC) - Change
SMCS Code: 1350-044
g00901833
Clean the cooling system before the recommended Illustration 51
maintenance interval if the following conditions exist: Location of drain plug for the jacket water system

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
coolant is contaminated.
NOTICE
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
Drain the Cooling System
1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the
cooling system is drained.
2. Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology
Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

Clean the Cooling System
1. Flush the cooling system with clean water in
order to remove any debris.
2. Close the cooling system drain valves (if
equipped). Clean the cooling system drain plugs
and install the cooling system drain plugs.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
4. Start the engine. Operate the engine for
a minimum of 30 minutes with a coolant
temperature of at least 82 C (180 F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valves (if equipped). Remove the cooling system
drain plugs. Allow the water to drain.
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
6. Flush the cooling system with clean water until
the water that drains is clean. Close the cooling
system drain valves (if equipped). Clean the
cooling system drain plugs and install the cooling
system drain plugs.
Cleaning a Cooling System that
has Heavy Deposits or Plugging
Note: For the following procedure to be effective,
there must be an active flow through the cooling
system components.
1. Flush the cooling system with clean water in
order to remove any debris.
2. Close the cooling system drain valves (if
equipped). Clean the cooling system drain plugs
and install the cooling system drain plugs.
81
Maintenance Section
Cooling System Coolant (DEAC) - Change
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling
System Cleaner. Add .5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the cooling system filler cap.
4. Start the engine. Operate the engine for
a minimum of 90 minutes with a coolant
temperature of at least 82 C (180 F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valves (if equipped). Remove the cooling system
drain plugs. Allow the water to drain.
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
6. Flush the cooling system with clean water until
the water that drains is clean. Close the cooling
system drain valves (if equipped). Clean the
cooling system drain plugs and install the cooling
system drain plugs.
Fill the Cooling System
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute in order to avoid air locks.
Note: For information about the proper coolant
to use, see this Operation and Maintenance
Manual, Coolant Recommendations (Maintenance
Section). For the capacity of the cooling system,
see the Operation and Maintenance Manual, Refill
Capacities (Maintenance Section).
1. Fill the cooling system with coolant/antifreeze. Do
not install the cooling system filler cap.
2. Start the engine. Operate the engine in order
to purge the air from the cavities of the engine
block. Allow the coolant to warm and allow the
coolant level to stabilize. Stop the engine.
3. Check the coolant level. Maintain the coolant to
the proper level on the sight gauge (if equipped).
If a sight gauge is not equipped, maintain the
coolant to the level that is specified by the OEM
of the cooling system.
82
Maintenance Section
Cooling System Coolant Analysis (Level II) - Obtain

4. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
gaskets of the cooling system filler cap are
damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gaskets of the cooling system filler cap are
not damaged, use a 9S-8140 Pressurizing Pump
in order to pressure test the cooling system filler
cap. The correct pressure is stamped on the face
of the cooling system filler cap. If the cooling
system filler cap does not retain the correct
pressure, install a new cooling system filler cap.
Identification of buildup of the impurities that
cause corrosion
Identification of buildup of the impurities that
cause scaling
Determination of possible electrolysis within the
engines cooling system
A report of the results of the analysis is provided.
Maintenance recommendations are based on the
results.

5. Start the engine. Inspect the cooling system for For more information about SOS coolant analysis,
leaks and for proper operating temperature. consult your Caterpillar dealer.

i01065859 i01762768

Cooling System Coolant Cooling System Coolant Level

Analysis (Level II) - Obtain - Check
SMCS Code: 1350 SMCS Code: 1350-535-FLV

For conventional heavy-duty coolant/antifreeze,

check the concentration of supplemental coolant
additive (SCA) regularly. The concentration of SCA Climbing equipment may be required to access
can be checked with an SOS coolant analysis this service point. Refer to the Operation and
(Level I). A more detailed coolant analysis is Maintenance Manual, Mounting and Dismount-
recommended periodically. ing topic for safety information.
For example, considerable deposits are found in the
water jacket areas on the external cooling system, Engines That Are Equipped With a
but the concentrations of coolant additives were
carefully maintained. The coolant water probably Sight Gauge
contained minerals which were deposited on the
engine over time.

A coolant analysis can be conducted in order to

verify the condition of the water that is being used
in the cooling system. A full water analysis may be
obtained from the following sources:

Caterpillar dealer
Local water utility company
Agricultural agent
Independent laboratory
Caterpillar recommends an SOS coolant analysis
(Level II). This is a comprehensive chemical
evaluation of the coolant. This analysis is also a
check of the overall condition of the inside of the
cooling system. The following services are provided:
Full Level I analysis
Identification of the source of metal corrosion and
of contaminants
g00750429
Illustration 52
(1) Filler cap
(2) Sight gauge
If the engine is equipped with a sight gauge,
observe the position of the coolant in the sight
gauge. At normal operating temperature, the proper
coolant level is in the upper half of the sight gauge.
If the coolant level is low, add the proper coolant
mixture.
 83
Maintenance Section
Cooling System Level Switch - Inspect

Engines That Are Not Equipped i01519993

With a Sight Gauge Cooling System Level Switch

- Inspect
SMCS Code: 7422-040
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, The low coolant level switch actuates an alarm or
stop the engine and wait until the cooling system a shutoff if the coolant level is low. A low coolant
components are cool. Loosen the cooling system level could cause the engine to overheat. This could
pressure cap slowly in order to relieve the pres- result in damage to the engine.
sure.
If the coolant level is low, coolant must be added to
Check the coolant level when the engine is stopped the expansion tank or the heat exchanger.
and cool. Check the coolant level only after the
engine has been stopped and the cooling system
filler cap is cool enough to touch with your bare
hand.

Remove the cooling system filler cap slowly in order

to relieve any pressure. Maintain the coolant within
13 mm (0.5 inch) below the bottom of the filler pipe.

Add Coolant
Note: For the proper coolant mixture to use, see
this Operation and Maintenance Manual, Coolant
Recommendations (Maintenance Section).
g00789360
Illustration 54
1. Stop the engine. Allow the engine to cool. (1) Switch
(2) Lines
2. Remove the cooling system filler cap slowly in
order to relieve any pressure. Pour the proper For proper operation of the switch, the lines and
coolant mixture into the filler pipe. the switch must be clean.

1. Drain the coolant to a level below lower line (2).

Drain the coolant into a clean container so that
the coolant can be reused.

2. Remove switch (1). Inspect the openings of the

inlet and the outlet for plugging. If an opening is
plugged, clean the switch.

3. Inspect lines (2) for plugging. Clean the lines, if

necessary. Pressure air or a flexible wire can be
used to clean the lines.

4. Install switch (1).

g00103639
Illustration 53 5. Pour the coolant into the cooling system. Verify
Gaskets that the low coolant level switch is operating
properly. A switch that is operating properly will
3. Clean the cooling system filler cap. Inspect the activate an alarm until a sufficient amount of
gaskets of the cooling system filler cap. If the coolant is added.
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.

4. Start the engine. Inspect the cooling system for

leaks.
84
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
i01613281
Cooling System Supplemental
Coolant Additive (SCA) -
Test/Add
SMCS Code: 1352-045; 1395-081
This maintenance procedure is required for
conventional coolants such as DEAC and for
mixtures of water and SCA.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with
the skin and eyes. Do not drink cooling system
coolant additive.
Note: Test the concentration of the SCA or obtain an
SOS coolant analysis (Level I).
Test the Concentration of the SCA
Coolant/Antifreeze and SCA
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit or the 4C-9301 Coolant
Conditioner Test Kit. Follow the instructions that are
on the label of the test kit.
Water and SCA
NOTICE
Do not exceed the recommended eight percent sup-
plemental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Follow the instructions
that are in this Operation and Maintenance Manual,
Water/Supplemental Coolant Additive (SCA) topic
(Maintenance Section).
SOS Coolant Analysis (Level I)
Level I is a basic analysis of the coolant. The
following items are tested: SCA concentration,
glycol concentration, pH, and conductivity.
The results are reported, and recommendations
are made according to the results. Consult your
Caterpillar dealer for information on the benefits of
managing your equipment with an SOS analysis.
Add the SCA, If Necessary
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Remove the cooling system filler cap slowly.
Note: Always dispose of fluids according to local
regulations.
2. If necessary, drain some coolant in order to allow
space for the addition of the SCA.
NOTICE
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engines
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat exchang-
er, overheating, and/or accelerated wear of the water
pump seal.
Do not exceed the recommended amount of supple-
mental coolant additive concentration.
3. Add the proper amount of SCA. The
concentration of the SCA depends on the type
of coolant that is used.
a. For cooling systems that use conventional
coolant/antifreeze, refer to this Operation
and Maintenance Manual, Conventional
Coolant/Antifreeze Cooling System
Maintenance topic (Maintenance Section).
b. For cooling systems that use only a mixture
of water and SCA, refer to this Operation and
Maintenance Manual, Water/Supplemental
Coolant Additive (SCA) topic (Maintenance
Section).
4. Clean the cooling system filler cap. Install the
cooling system filler cap.

i00708678
Crankcase Blowby -
Measure/Record
SMCS Code: 1317
Note: The typical crankcase blowby on a new engine
is approximately 0.02 m3/bkW h (.50 ft3/bhp h).
Measure the crankcase blowby of new engines.
Record the data. Continue to periodically measure
the crankcase blowby. Comparing the recorded
data to the new data provides information about the
condition of the engine.
Note: Crankcase blowby is one of the three factors
that help to determine the in-frame overhaul interval.
For more information, see the Operation and
Maintenance manual, Overhaul (In-Frame) topic in
the Maintenance Section.
After a new engine is used for a short time, the
crankcase blowby can decrease as the piston rings
are seated. The crankcase blowby will gradually
increase as the following components show wear:
piston rings
cylinder liners
Note: A problem with the piston rings causes the
oil to deteriorate rapidly. Information regarding the
condition of the piston rings can be obtained from
the measurement of the crankcase blowby and the
results of oil analysis.
The crankcase blowby of a worn engine may
exceed the crankcase blowby of a new engine by
two times or more.
A sudden increase in crankcase blowby could
indicate a broken piston ring. The following
conditions are other potential sources of crankcase
blowby:
Worn valve guides
A turbocharger seal that leaks
A rebuilt engine can have a high crankcase blowby
due to the following factors:
The piston rings are not seated properly.
Worn parts such as valve guides were not
replaced.
85
Maintenance Section
Crankcase Blowby - Measure/Record
Excessive crankcase blowby may indicate the need
for an overhaul. By keeping a record of the results,
a gradual increase in the amount of the crankcase
blowby will be noted until the amount of crankcase
blowby has become excessive.
Use the following tools to measure the blowby:
8T-2700 Blowby/Air Flow Indicator
1U-8860 Large Engine Blowby Pickup Group
Refer to these Special Instructions that are provided
with the tools:
Special Instruction, SEHS8712, Using the
8T-2700 Blowby/Airflow Indicator Group
Special Instruction, SEHS8984, Using the
1U-8860 Large Engine Blowby Pickup Group
Record the crankcase blowby for the engine. Keep
a record of the results.
For more information, see the Service Manual,
Systems Operation/Testing and Adjusting. For
assistance, consult your Caterpillar dealer.
i01664687
Crankshaft Vibration Damper
- Inspect
SMCS Code: 1205-040
The crankshaft vibration damper limits the torsional
vibration of the crankshaft. The visconic damper
has a weight that is located inside a fluid filled case.
Damage to the crankshaft vibration damper or failure
of the damper can increase torsional vibrations.
This can result in damage to the crankshaft and to
other engine components. A deteriorating damper
can cause excessive gear train noise at variable
points in the speed range.
A damper that is hot is due to excessive torsional
vibration. Monitor the temperature of the damper
during operation.
The 8T-2821 Temperature Indicator or the
8T-2822 Temperature Indicator are recommended
for monitoring the temperature of the damper.
Evenly space four of the adhesive indicators around
the outer diameter of the damper.
86
Maintenance Section
Cylinder Pressure - Measure/Record
Note: If you use an infrared thermometer to monitor
the temperature of the damper, use the thermometer
during operation with similar loads and speeds.
Keep a record of the data. If the temperature
begins to rise, reduce the interval for inspecting the
damper.
If the temperature of the damper reaches 110 C
(230 F), consult your Caterpillar dealer.
Inspect the damper for evidence of dents, cracks,
and leaks of the fluid.
If a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has
the following characteristics: transparent, viscous,
smooth, and sticky. If leaking silicone is found,
repair the damper or replace the damper.
If the fluid leak is oil, inspect the crankshaft seal for
leaks. If a leak is observed, replace the seal.
Inspect the damper and repair or replace the
damper for any of the following reasons.
The damper is dented, cracked, or leaking.
The paint on the damper is discolored from heat.
The engine has had a failure because of a broken
crankshaft.
An analysis of the oil has revealed that the front
bearing of the crankshaft is badly worn.
There is a large amount of gear train wear that is
not caused by a lack of oil.
Removal and Installation
Refer to the Service Manual, Disassembly and
Assembly or consult your Caterpillar dealer for
information about damper replacement.
i01520103
Cylinder Pressure -
Measure/Record
SMCS Code: 1223-082-CC; 1223; 7450-082
Measure the cylinder pressure of new engines.
Record the data. Continue to periodically measure
the cylinder pressure. Comparing the recorded data
to the new data provides information about the
condition of the engine.
Note: Cylinder pressure is one of the three factors
that help to determine the in-frame overhaul
interval. For more information, refer to this Operation
and Maintenance manual, Overhaul (In-Frame)
(Maintenance Section).
Cylinder pressure can be measured during
inspection of the spark plugs. Use the following
guidelines for checking the cylinder pressure:
Remove all of the spark plugs.
Minimize the cranking time. This will enable a
maximum consistent cranking speed for the
check. Also, the starting air or battery power will
be conserved.
A loss of cylinder pressure or a change of pressure
in one or more cylinders may indicate the following
conditions. These conditions may indicate a
problem with lubrication:
Excessive deposits
Guttering of valves
A broken valve
A piston ring that sticks
A broken piston ring
Worn piston rings
Worn cylinder liners
If the cylinder pressure has risen by one or more
compression ratios, the engine needs a top end
overhaul in order to remove deposits. Failure to
remove the deposits will increase the chance for
detonation. Severe guttering of the valves will occur.
To measure the cylinder pressure, refer to Special
Instruction, GMG00694, Analyzing Cylinder
Condition By Measuring Air Flow. Also, use the
146-2739 Cylinder Pressure Adapter.
Illustration 55 is a graph of typical cylinder pressures
for engines with different compression ratios.

Illustration 55
g00789376
(Y) Cylinder pressure in kPa (psi)
(X) Compression ratio
(1) Normal range for cylinder pressure
Record the pressure for each cylinder. Use
Operation and Maintenance Manual, Valve Data
Sheet (Reference Materials Section).
i01765658
Cylinders - Inspect
(Inspect the Combustion
Chamber)
SMCS Code: 1223-040; 1223
Excessive deposits can accumulate in the
combustion chambers of engines that use gas
with a low BTU such as bio-gas fuel, landfill gas,
etc. The deposits can affect the characteristics of
combustion. Erratic operation can result. The rate of
recession of the exhaust valves can increase. The
risk of guttering of the exhaust valves can increase.
Note: Use of a platform may be necessary to
inspect the combustion chamber.
Use a borescope to inspect the combustion
chamber. The inspection will provide information
about the internal condition of the engine.
A borescope with a lens that can be rotated is
recommended. This type of borescope provides a
clear view of the combustion chamber and of the
bottom deck of the cylinder head. Photographic
documentation or video documentation is also
recommended. Consult your Caterpillar dealer for
information on available borescopes.
87
Maintenance Section
Cylinders - Inspect
When possible, insert the borescope through the
opening in the cylinder head for the prechamber
assembly and the ignition body. This location
will provide the best possible view of the entire
combustion chamber. This requires draining the
coolant to a level below the cylinder head. If this
is not possible, insert the borescope through the
opening for the combustion sensor. Look for the
following conditions:
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
upper limit of the piston stroke
Deposits that are on the valve face and the valve
seat can cause guttering of the valve. Inspect
the valve seat and the valve face for excessive
deposits. If excessive deposits are found, replace
the valve and the valve seat.
Determine whether the exhaust valve face has
erosion from pitting. This requires the exhaust valve
to be in the open position. To obtain as much detail
as possible, obtain a close up view of the valve
face. Erosion of the exhaust valve face can lead
to guttering of the valve. If erosion is found on the
exhaust valve face, recondition the cylinder head as
soon as possible.
Note: Operation at loads that are less than 50
percent of the rated load can result in an excessive
buildup of carbon deposits in the combustion
chamber. The deposits can lead to detonation and
premature ignition. This condition is more obvious
at certain engine speeds and loads.
i00693905
Driven Equipment - Check
SMCS Code: 3279-535
Every 5000 Service Hours
Engines That Are Not Attached To the
Base with a Dowel
If some engines are too rigidly mounted, excessive
stress may affect the internal support of the cylinder
block. This could cause the following problems:
88
Maintenance Section
Driven Equipment - Inspect/Replace/Lubricate

Distortion of the bores of the main bearing Damaged parts

Distortion of the alignment of the bore Perform any maintenance that is recommended
by the OEM of the driven equipment. Refer to the
Severe damage to the engine could result. The literature of the OEM of the driven equipment for the
service life of the engine could be severely reduced. following service instructions.

For engines that are not attached to the base with Inspection
a dowel, check the alignment after every 5000
service hours. Lubricating grease and lubricating oil
requirements
Every 10,000 Service Hours
Specifications for adjustment
Engines That Are Attached To the Base Replacement of components
with a Dowel
Requirements for ventilation
Some engines must be more rigidly mounted. Due
to thermal expansion, a cold engine will expand
i01610487
after the engine achieves operating temperature.

Some engines are attached to the base with a dowel

Electrohydraulic Actuator -
in the rear mounting support. This installation forces Inspect
the thermal growth forward. The driven equipment
is also attached with a dowel in order to maintain SMCS Code: 1716-040
alignment with the engine.
Inspect the actuators for the fuel control, the
For this type of installation, check the alignment wastegate, and the air choke.
after every 10,000 service hours.

Check the Alignment

The alignment between the engine and the driven
equipment must be maintained properly. Improper
alignment will cause damage to the engine, the
coupling, and the driven equipment.
During operation, the linkage of the electrohy-
draulic actuators can form pinch points which
can cause personal injury. Shut down the engine
before you service the electrohydraulic actuators.

Check the alignment according to the instructions

that are provided by the following manufacturers:

Caterpillar
OEM of the coupling
OEM of the driven equipment

i00935098

Driven Equipment -
Inspect/Replace/Lubricate Illustration 56
g00833473

(1) Receptacle for the wiring harness

SMCS Code: 3279-040 (2) Solenoid
(3) Bolt
Observe the driven equipment during operation. (4) Guards
Look for the following items:
1. Disconnect the wiring harness from receptacle
Unusual noise and vibration (1). Inspect the connectors for damage and
corrosion. Make repairs, if necessary.
Loose connections
 89
Maintenance Section
Electrohydraulic Actuator - Recondition

2. Inspect the joint between solenoid (2) and the
housing for leaks.
If a leak is found between the solenoid and the
housing, replace the O-ring seal for the solenoid.
For instructions, refer to this Operation and
Maintenance Manual, Electrohydraulic Actuator
- Recondition.
3. Check the solenoids mounting bolts (3) for
tightness.
4. Remove guards (4).
11. Connect the wiring harness to receptacle (1).
i01610640
Electrohydraulic Actuator -
Recondition
SMCS Code: 1716-020
Recondition the actuators for the fuel control, the
wastegate, and the air choke. The main components
of each actuator include the housing, a piston
assembly, and a solenoid which actuates the piston.
The piston assembly and the solenoid can be
serviced separately.

Note: New parts or remanufactured parts may be

used for reconditioning the actuators.

During operation, the linkage of the electrohy-

draulic actuators can form pinch points which
can cause personal injury. Shut down the engine
before you service the electrohydraulic actuators.

g00833477
Illustration 57
(5) Rod end
(6) Clevis
(7) Boot

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

6. Remove clevis (6).

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

damage. If the boot is damaged, obtain a new
boot for assembly.

There may be a small amount of hydraulic fluid

inside of the boot. Wipe off the boot and reinstall
the boot.
If an excessive amount of hydraulic fluid is found
inside the boot, the seal for the actuators shaft
is probably worn. If this is the case, replace
the piston assembly. For instructions, refer
to this Operation and Maintenance Manual,
Electrohydraulic Actuator - Recondition.
g00833592
Illustration 58
(1) Receptacle for the wiring harness
(2) Guards
1. Disconnect the wiring harness from receptacle
(1). Inspect the connectors for damage and
corrosion. Make repairs, if necessary.
2. Remove guards (2).

8. Install boot (7). Make sure that the outer end of 3. Disconnect the supply line (not shown) and the
the boot folds inward when the actuators shaft return line (not shown) for the hydraulic oil.
moves from the fully open position to the fully
closed position.

9. Install clevis (6). Connect rod end (5) to the

clevis.

10. Install guards (4).

90
Maintenance Section
Electrohydraulic System - Check/Adjust

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

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

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

assembly.

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

(8). Make sure that the spring in the housing
is properly aligned in the bore of the piston.
Tighten the piston assembly according to the
engines Specifications.

g00833594 9. Remove bolts (10) in order to remove solenoid

Illustration 59 (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 engines Specifications.

5. Remove clevis (4) and rubber boot (5). Inspect
the boot for damage. If the boot is damaged,
obtain a new boot for assembly.
Note: Handle the actuator carefully. Use care not to
damage the actuators shaft. Damage to the shaft
can result in premature failure of the O-ring seal.
This will cause hydraulic fluid to leak.
6. Remove nut (6) in order to remove the actuator
from the bracket.
11. Install the actuator in the bracket with nut (6).
12. Install boot (5). Make sure that the outer end of
the boot folds inward when the actuators shaft
moves from the fully open position to the fully
closed position.
13. Install clevis (4). Connect rod end (3) to the
clevis.
14. Install guards (2).

Note: Do not allow debris to enter the actuator. Seal 15. Connect the supply line and the return line for
the openings with clean covers immediately after the hydraulic oil.
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

Check the Pressure Relief Valve

Check the pressure relief valve for the hydraulic
system according to the procedure that is in
Systems Operation/Testing and Adjusting. Adjust
g00833595
Illustration 60 the pressure according to the instructions.
(7) Housing
(8) Piston assembly
(9) O-ring seal
(10) Bolt
(11) Solenoid
(12) O-ring seal

Note: The spring in the housing will be loose after

the piston assembly is removed.
 91
Maintenance Section
Electrohydraulic System - Inspect

i01525272 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

Oil level Pressure relief valve

Hoses, lines, connections, and components Pump

Make repairs, if necessary.

i01525302

Electrohydraulic System Oil -

Change
SMCS Code: 1716-510-OC

Ensure that the engine cannot start during this

procedure.

g00792283
Illustration 61
(1) Sight gauge
(2) Hose
(3) Line

Check the Oil Level

1. Check the oil level in sight gauge (1).

The oil should be between the ADD and FULL

marks on the tank.

Note: For the proper oil to use, refer to this Illustration 62

g00792335
Operation and Maintenance Manual, Hydraulic Oil
(1) Oil filler cap
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.

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

The linkage can move and form a pinch point
which can cause personal injury. Keep hands
away from the linkage.
Operation and Maintenance Manual, Hydraulic Oil
topic (Maintenance Section).
3. Pour the proper oil into the oil filler. Clean the oil
filler cap. Install the oil filler cap.

4. Clean up any oil that may have spilled.

92
Maintenance Section
Electrohydraulic System Oil Filter - Change

i01525282 5. Start the engine. Check the oil level in sight

gauge (2). The oil should be between the ADD
Electrohydraulic System Oil and FULL marks on the tank. If necessary,
Filter - Change remove oil filler cap (4). Pour the correct oil into
the oil filler. Clean the oil filler cap. Install the
SMCS Code: 1716-510-FI oil filler cap.

i01765689

Engine Air Cleaner Element -

Replace
SMCS Code: 1051-510; 1054-510

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
g00792302
engine causes premature wear and damage to engine
Illustration 63 components. Air cleaner elements help to prevent air-
(1) Filter borne debris from entering the air inlet.
(2) Sight gauge
(3) Filler cap
NOTICE
1. Remove filter (1) with a 1U-8760 Chain Wrench. Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
2. Clean the sealing surface of the filter mounting
base. Ensure that all of the old filter gasket is
removed. Note: Use of a platform may be necessary to reach
the air cleaner element.

Clean the air cleaner elements or replace the air

cleaner elements when the following conditions
occur:

Inspect the air cleaner elements before the air filter

restriction reaches 2.5 kPa (10 inches of H2O). A
loss of engine performance may occur when the
air filter restriction exceeds this limit.

The air cleaner elements must be cleaned or

replaced before the air filter restriction exceeds
3.75 kPa (15 inches of H2O).
g00103713
Illustration 64 Note: The air filter restriction is measured at the air
Typical filter mounting base and gasket inlet to the turbocharger compressor.

Note: For the proper oil to use, refer to this Servicing the Air Cleaner Elements
Operation and Maintenance Manual, Hydraulic Oil
topic (Maintenance Section). Note: If the air cleaner is not manufactured by
Caterpillar, follow the instructions that are provided
3. Apply clean hydraulic oil to the new filter gasket. by the OEM of the air cleaner.
4. Install the filter by hand. Tighten the filter until the
gasket contacts the mounting base. Tighten the
filter according to the instructions that are shown
on the filter. Do not overtighten the filter.
 93
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

If the air cleaner element becomes plugged, the
air can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
engine wear. Your Caterpillar dealer has the proper
air cleaner elements for your application. Consult
your Caterpillar dealer for the correct air cleaner
element.
Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt
and debris, as needed.
Do not use an element that has any tears and/or
holes in the filter material. Do not use an element
with damaged pleats, gaskets or seals. Discard
damaged elements.
Storing Air Cleaner Elements
If an element that passes inspection will not be
used, the element can be stored for future use.

Replace the dirty paper air cleaner elements with

clean air cleaner elements. Before installation,
thoroughly inspect the air cleaner elements for tears
and/or holes in the filter material. Inspect the gasket
or the seal of the air cleaner element for damage.
Maintain a supply of suitable air cleaner elements
for replacement purposes.

1. Remove the air cleaner cover. Remove the air

cleaner element.

2. Cover the turbocharger air inlet with tape in

order to keep dirt out. g00281694
Illustration 66

3. Clean the inside of the air cleaner cover and
body with a clean, dry cloth.
4. Remove the tape for the turbocharger air inlet.
Install an air cleaner element that is new or
cleaned.
5. Install the air cleaner cover.
Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. Restricted air flow
may result. To protect against dirt and damage,
wrap the elements in Volatile Corrosion Inhibited
(VCI) paper.
Place the element into a box for storage. For
identification, mark the outside of the box.

Inspecting Air Cleaner Elements Store the box in a dry location.

i01520297

Engine Air Cleaner Service

Indicator - Inspect
SMCS Code: 7452-040

Some engines are equipped with an air cleaner for

crankcase ventilation.

This air cleaner filters air that is drawn into the

crankcase. The air dilutes the harmful fumes that
may accumulate in the crankcase. The air and the
Illustration 65 g00281693 fumes are drawn away from the crankcase.

Inspect the clean, dry air cleaner element. Use a

60 watt blue light in a dark room or in a similar
facility. Place the blue light in the element. Rotate
the element. Inspect the element for tears and/or
holes. Inspect the element for light that may show
through the filter material. If it is necessary in order
to confirm the result, compare the element to a new
element that has the same part number.
94
Maintenance Section
Engine Crankcase Breather - Clean
g00789538
Illustration 67
Service indicator
Observe the service indicator. Clean the air cleaner
element or replace the air cleaner element when
one of the following conditions occur:
The yellow diaphragm enters the red zone.
The red piston locks in the visible position.
The air filter restriction reaches .25 kPa
(1 inch of H2O).
Inspect the service indicator daily for cracks, holes,
or loose fittings. If any of these conditions are
present, repair the service indicator or replace the
service indicator.
Test the Service Indicator
Service indicators are important instruments.
Check for ease of resetting. The service indicator
should reset in less than three pushes.
Check the movement of the yellow core when the
engine is accelerated to the engine rated rpm.
The yellow core should latch approximately at the
greatest vacuum that is attained.
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
replace the service indicator. If the new service
indicator will not reset, the fitting for the service
indicator may be plugged.
g00351792
Illustration 68
Porous filter
A porous filter is part of a fitting that is used for
mounting of the service indicator. Inspect the filter
for cleanliness. Clean the filter, if necessary. Use
compressed air or a clean, nonflammable solvent.
The service indicator may need to be replaced
frequently in environments that are severely dusty.
Replace the service indicator annually regardless
of the operating conditions. Replace the service
indicator when the engine is overhauled, and
whenever major engine components are replaced.
Note: When a new service indicator is installed,
excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque
of 2 Nm (18 lb in).
i01765695
Engine Crankcase Breather -
Clean
SMCS Code: 1317-070
If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that can shut down
the engine. Leakage of the crankshaft seal can
occur.
Note: Use of a platform may be necessary to reach
the engine crankcase breather.
Perform this maintenance when the engine is
stopped.

g00789623
Illustration 69
(1) Breather assembly
(2) Tee
(3) Hose clamp
(4) O-ring seal
(5) Retaining clamp
1. Loosen retaining clamps (5). Loosen hose
clamps (3). Remove breather assemblies (1) and
O-ring seals (4).
2. Wash the breather elements in clean
nonflammable solvent. Inspect tee (2) for cracks
that can be caused by vibration. Replace the old
tee with a new tee if cracking is found.
3. Install new O-ring seals (4).
4. Allow the breather elements to dry before
installation. Install the breather assemblies in the
original position. Coat the rubber parts with clean
engine oil or petroleum jelly in order to make
installation easier. Tighten the retaining clamps
and the hose clamps according to the engines
Specifications manual.
i01612978
Engine Mounts - Check
SMCS Code: 1152-535
Check the torque of the bolts for the mounting
plates. For the proper torque, refer to Gas Engines
Application and Installation Guide, LEKQ7252,
G3600 Mounting, Alignment.
Engine vibration can be caused by the following
conditions:
Improper mounting of the engine
Deterioration of the isolators
95
Maintenance Section
Engine Mounts - Check
Settling of the isolators will result in misalignment
between the engine and the driven equipment.
Inspect the condition of isolators, if necessary.
Keep the isolators clean and dry. Ensure that the
isolators are free of oil and contamination. Inspect
the isolators for deterioration.
Replace any isolator that shows deterioration.
For more information, refer to the literature that is
provided by the OEM of the isolators. Also refer to
the following publications:
Gas Engines Application and Installation Guide,
LEKQ7252, G3600 Mounting, Alignment
Special Instruction, SEHS9162, Spring Isolator
Group Installation and Adjustment Procedure
Consult your Caterpillar dealer for assistance.
i01520399
Engine Oil - Change
SMCS Code: 1348-044; 1348
Oil Change Interval
Considerations for the oil change interval include
the type of fuel and the engine application. An
established SOS oil analysis program enables
used oil to be evaluated. The evaluation can be
used to determine if this oil change interval is
suitable for your specific engine.
Engines That Use Bio-Gas
The oil change interval is determined by the results
of oil analysis. Change the lubrication oil when oil
analysis determines that the oil has reached the
condemning limit. Also, change the engine oil filters.
Change the Engine Oil
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact skin.
NOTICE
Ensure that the engine is stopped before performing
this procedure. Attach a DO NOT OPERATE tag to the
starting controls.
96
Maintenance Section
Engine Oil - Change

Do not drain the oil when the engine is cold. As

the oil cools, suspended waste particles settle on
the bottom of the oil pan. The waste particles are
not removed when the cold oil is drained. Drain the
crankcase with the oil warm. This draining method
allows the waste particles that are suspended in the
oil to be drained properly.

Failure to follow this recommended procedure will

allow the waste particles to be recirculated through
the engine lubrication system with the new oil.

1. After the engine has been operated at normal

operating temperature, STOP the engine.
g00789729
Note: Drain the oil into a suitable container. Dispose Illustration 71
of fluids according to local regulations. (2) Screen assembly

a. Loosen the bolts of the cover for the oil

suction screen. Remove the cover and the
gasket. Discard the old gasket. Slide screen
assembly (2) from the tube.

b. Wash the screen assembly in clean

nonflammable solvent. Allow the screen
assembly to dry before installation.

c. Install the screen assembly. Install a new

gasket. Install the cover.

4. Change the engine oil filters. Refer to this

Operation and Maintenance Manual, Engine Oil
g00789667
Illustration 70 Filter - Change topic (Maintenance Section).
(1) Drain valve
NOTICE
2. Open drain valve (1) in order to drain used oil. Only use oils that are recommended by Caterpillar.
After the oil has drained, close drain valve (1). For the proper oil to use, refer to this Operation and
Maintenance Manual, Engine Oil topic (Maintenance
Note: If a suction device is used in order to remove Section).
the oil from the oil pan, ensure that the suction
device is clean. This will prevent dirt from entering
the oil pan. Be careful not to strike the engine oil
suction tubes or the piston cooling jets.

3. Clean the oil suction screen.

Note: Approximately 1 L (1 qt) of oil will remain in

the housing after the sump has been completely
drained. This oil will pour out of the housing when
the cover for the oil suction screen is removed.
Prepare to catch the oil in a suitable container.
Clean up any spilled oil with rags. DO NOT use
absorbent particles to clean up the oil.
 97
Maintenance Section
Engine Oil Filter - Change

Service tools are available to aid in the service of

NOTICE oil filters. Consult your Caterpillar dealer for the part
Engine damage can occur if the crankcase is filled names and the part numbers. Follow the instructions
above the FULL mark on the oil level gauge (dip- that are supplied with the service tools. If the
stick). service tools are not used, perform the following
appropriate procedure.
An overfull crankcase can enable the crankshaft to dip
into the oil. This will reduce the power that is devel- Replacing the Engine Oil Filters
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re- With the Engine Stopped
duction of the oils ability to lubricate, reduction of oil
pressure, inadequate cooling of the pistons, oil blow-
ing out of the crankcase breathers, and excessive oil
consumption. Hot oil and components can cause personal in-
jury.
Excessive oil consumption will enable deposits to form
on the pistons and in the combustion chamber. De- Do not allow hot oil or components to contact skin.
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. Perform the following procedure after the oil has
been drained.
If the oil level is above the FULL mark on the oil level
gauge, drain some of the oil immediately. Note: Use this procedure if the engine oil filters do
not have a control valve.
Note: For the amount of oil to use, refer to
this Operation and Maintenance Manual, Refill
Capacities (Maintenance Section).

5. Remove the oil filler cap. Fill the crankcase

through the oil filler tube only. Clean the oil filler
cap. Install the oil filler cap.

6. Follow this Operation and Maintenance Manual,

Starting The Engine procedure (Operation
Section). Operate the engine at low idle for two
minutes. Inspect the engine for oil leaks. Ensure
that the oil level is at the FULL mark on the
LOW IDLE side of the oil level gauge.
g00789754
Illustration 72
7. Stop the engine and allow the oil to drain back (1) Pressure gauge
into the sump for a minimum of ten minutes. (2) Drain
(3) Cover
8. Remove the oil level gauge and check the oil (4) Control valve
level. Maintain the oil level to the FULL mark
on the ENGINE STOPPED side of the oil level 1. Connect a hose from each drain valve (2) to a
gauge. suitable container in order to catch the oil.

2. Open both drain valves (2). Allow the oil to drain.

i01520518
Note: Some oil will remain in the housing after
Engine Oil Filter - Change the oil has been drained. This oil will pour out of
the housing when cover (3) is removed. Prepare
SMCS Code: 1308-510; 1308 to catch the oil in a suitable container. Clean up
any spilled oil with rags. DO NOT use absorbent
Replace the engine oil filters when the following particles to clean up the oil.
conditions are met:

Every oil change

The engine oil filter differential pressure reaches
100 kPa (15 psi).
98
Maintenance Section
Engine Oil Filter - Change

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

Personal injury can result from parts and/or cov-
ers under spring pressure.
Spring force will be released when covers are re-
moved.
Be prepared to hold spring loaded covers as the
bolts are loosened.
3. Be alert to the spring force. The cover has a
spring force up to 240 N (54 lb). Gradually loosen
but do not remove the last two bolts or nuts
that are located at opposite ends of covers (3).
Before removing the last two bolts or nuts, pry
the covers loose or tap the covers with a rubber
mallet in order to relieve any spring pressure.
clean. Inspect the O-ring seals. If the old O-ring
seals are damaged or deteriorated, replace the
old O-ring seals with new O-ring seals. Install
the O-ring seals.
7. Install covers (3). Ensure that the spring is seated
properly between elements (7) and covers (3).
Close drain valves (2).
8. Ensure that the crankcase is filled with oil.
Operate the prelube pump and rotate the control
valve (if equipped) to the FILL position for each
housing. After both of the housings are full of oil,
turn the control valve (if equipped) to the RUN
position.
9. Start the engine. Check for oil leaks.
Replacing the Engine Oil Filters
During Engine Operation

Filter contains hot pressurized fluid when engine

is running.

Follow instructions on control valve to avoid per-

sonal injury.

If rapid air movement exists to blow fluid, Stop the

engine to avoid fire.
g00789772
Illustration 73
(5) Wire rack If it is necessary to replace the oil filters during
(6) O-ring seal engine operation, perform the following procedure.
(7) Element

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

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

NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
g00789754
recommended by Caterpillar. Illustration 74
(1) Pressure gauge
(2) Drain
5. Ensure that the new oil filter elements are in good (3) Cover
condition. Place the elements on wire rack (5). (4) Control valve
Install the wire rack and the elements.
1. Connect a hose from drain valve (2) to a suitable
container in order to catch the oil.

2. Rotate control valve (4) to the LOWER SERVICE
position.
3. Open drain valve (2) and drain the lower oil filter
housing. Observe pressure gauge (1) until the
pressure is 0.
Note: Some oil will remain in the housing after
the oil has been drained. This oil will pour out of
the housing when cover (3) is removed. Prepare
to catch the oil in a suitable container. Clean up
any spilled oil with rags. DO NOT use absorbent
particles to clean up the oil.
Personal injury can result from parts and/or cov-
ers under spring pressure.
Spring force will be released when covers are re-
moved.
Be prepared to hold spring loaded covers as the
bolts are loosened.
4. After zero pressure has been reached, remove
cover (3). Be alert to the spring force. The cover
has a spring force up to 240 N (54 lb). Gradually
loosen but do not remove the last two bolts or
nuts that are located at opposite ends of cover
(3). Before removing the last two bolts or nuts,
pry the cover loose or tap the cover with a rubber
mallet in order to relieve any spring pressure.
g00789772
Illustration 75
(5) Wire rack
(6) O-ring seal
(7) Element
5. Elements (7) are mounted on wire rack (5) inside
the housing. Use a pan to catch the oil that drips
when wire rack (5) is removed. Remove wire
rack (5). Remove used elements (7). Clean up
any oil that is spilled.
99
Maintenance Section
Engine Oil Filter - Change
NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
6. Ensure that the new oil filter elements are in good
condition. Place the elements on wire rack (5).
Install the wire rack and the elements.
7. Ensure that the surfaces for O-ring seal (6) are
clean. Inspect the O-ring seal. If the old O-ring
seal is damaged or deteriorated, replace the old
O-ring seal with a new O-ring seal. Install the
O-ring seal.
8. Install cover (3). Ensure that the spring is seated
properly between element (8) and cover (3).
Close drain valve (2).
9. Rotate control valve (4) to the LOWER FILL
position. Observe pressure gauge (1). Check
cover (3) for leaks.
Note: A hydraulic stop will limit the rotation of the
control valve until the oil filter housing is full of oil.
10. After the pressure of the lower oil filter and the
upper oil filter is equal, rotate control valve (4) to
the UPPER SERVICE position. Repeat Step 1
through Step 9 for the upper oil filter.
11. After the oil filters have been serviced and after
the pressure of the lower oil filter and the upper
oil filter is equal, rotate control valve (4) to the
RUN position.
Inspect the Used Oil Filter Elements
Cut the used oil filter element open with a utility
knife. Remove the metal wrap. Cut the filter element
free from the end caps. Spread apart the pleats and
inspect the element for metal debris. An excessive
amount of debris in the element may indicate early
wear or a pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found
in the element. Ferrous metals may indicate wear
on the steel and the cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, the brass parts, or the bronze parts
of the engine. Parts that may be affected include the
following components: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
100
Maintenance Section
Engine Oil Level - Check

Aluminum debris may indicate problems with the Note: For engines with powered crankcase
bearings of the front gears. If aluminum is found in ventilation, remove the oil filler cap. Allow the
the filter, inspect the crankshaft vibration damper crankcase pressure to stabilize before checking the
and the front idler gear bearing. engine oil level.

Due to normal wear and friction, it is not uncommon
to find small amounts of debris in the oil filter
element. If an excessive amount of debris is found
in the oil filter element, consult your Caterpillar
dealer in order to arrange for further oil analysis.
1. Ensure that oil level gauge (1) is seated.
a. If the engine is stopped, remove oil level
gauge (1). Observe the oil level on ENGINE
STOPPED WITH OIL COLD side (3).

b. If the engine is operating, reduce the engine

i01520762
speed to low idle. Remove oil level gauge (1)
Engine Oil Level - Check and observe the oil level on ENGINE AT LOW
IDLE WITH WARM OIL side (4).
SMCS Code: 1348-535-FLV
The oil level should be between ADD mark
The most accurate check of the oil level is (5) and FULL mark (6).
performed when the engine is stopped. Perform
this maintenance on a surface that is as level as NOTICE
possible. Engine damage can occur if the crankcase is filled
above the FULL mark on the oil level gauge (dip-
stick).

An overfull crankcase can enable the crankshaft to dip

into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oils ability to lubricate, reduction of oil
pressure, inadequate cooling of the pistons, oil blow-
ing out of the crankcase breathers, and excessive oil
consumption.

Excessive oil consumption will enable deposits to form

on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
g00789822
Illustration 76 problems: guttering of the valves, packing of carbon
(1) Oil level gauge under the piston rings, and wear of the cylinder liner.
(2) Oil filler
If the oil level is above the FULL mark on the oil level
gauge, drain some of the oil immediately.

2. If necessary, remove oil filler cap (2) and add

oil. For the correct oil to use, see this Operation
and Maintenance Manual, Engine Oil topic
(Maintenance Section). Do not fill the crankcase
above FULL mark (6). Clean the oil filler cap.
Install the oil filler cap.

3. Record the amount of oil that is added. For the

next oil sample and analysis, include the total
amount of oil that has been added since the
previous sample. This will help to provide the
g00789825 most accurate oil analysis.
Illustration 77
(3) ENGINE STOPPED WITH OIL COLD side
(4) ENGINE AT LOW IDLE WITH WARM OIL side
(5) ADD mark
(6) FULL mark

i01534451
Engine Oil Sample - Obtain
SMCS Code: 1348-554-SM
In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine.
Obtain the Sample and the Analysis
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
Engine model
Service hours on the engine
The number of hours that have accumulated
since the last oil change
The amount of oil that has been added since the
last oil change
To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
101
Maintenance Section
Engine Oil Sample - Obtain
NOTICE
Do not use the same vacuum sampling pump for ex-
tracting oil samples that is used for extracting coolant
samples.
A small residue of either type sample may remain in
the pump and may cause a false positive analysis for
the sample being taken.
Always use a designated pump for oil sampling and a
designated pump for coolant sampling.
Failure to do so may cause a false analysis which
could lead to customer and dealer concerns.
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
For instructions, see Special Publication, PEHP6001,
How To Take A Good Oil Sample. Consult your
Caterpillar dealer for complete information and
assistance in establishing an SOS program for
your engine.
i00839584
Engine Oil Temperature
Regulator - Replace
SMCS Code: 1330-510
The oil temperature regulators divert the engine
oil to the oil cooler in order to maintain engine oil
temperature.
For instructions on replacing the oil temperature
regulators, see the Service Manual, Disassembly
and Assembly module.
i00626013
Engine Protective Devices -
Check
SMCS Code: 7400-535
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.
102
Maintenance Section
Engine Speed/Timing Sensor - Clean/Inspect

A calibration check of the engine protective devices 3. Inspect the sensor for damage.
will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective If the sensor is damaged, obtain a new sensor
devices are functioning properly. for installation.

NOTICE 4. Inspect the O-ring seal for the sensor.

During testing, abnormal operating conditions must be
simulated.
The tests must be performed correctly in order to pre-
vent possible damage to the engine.
If the O-ring seal is damaged, obtain a new
O-ring seal for installation.
5. Clean the tip of the sensor.

Note: The engine speed/timing sensor does not

To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
perform the tests.
Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
immediately.
require any special adjustments.
6. Install the sensor. Make sure that the sensor is
properly seated. Tighten bolt (2).
7. Inspect the wiring harness. Make sure that the
connector is in good condition. Attach the wiring
harness to the sensor. Make sure that the mating
of the connectors is proper.
i01765700

Engine Valve Lash -

i01762818
Inspect/Adjust
Engine Speed/Timing Sensor -
SMCS Code: 1102-025
Clean/Inspect
For instructions on the following procedures, refer to
SMCS Code: 1905-040; 1905-070; 1907-040;
Systems Operation/Testing and Adjusting. Consult
1907-070
your Caterpillar dealer for assistance.
The engine speed/timing sensor is located at the
Note: Use of a platform may be necessary for these
right rear side of the engine.
procedures.

Check the Timing of the Crankshaft

and Camshaft
The timing of the crankshaft and camshaft must be
checked, and the valve bridge must be adjusted
before the valve lash is adjusted.

NOTICE
If the camshaft is rotated with the timing pin installed,
the timing pin will break. This can result in further dam-
age. Make sure to remove the timing pin before the
camshaft is rotated.
g00901865
Illustration 78
(1) Engine speed/timing sensor
(2) Bolt

1. Disconnect the wiring harness from engine

speed/timing sensor (1).

2. Remove bolt (2) in order to remove engine

speed/timing sensor (1).

NOTICE
DO NOT use the starting motor to rotate the crank-
shaft. The lubrication oil can drain out from between
the crankshaft and the engine bearings if the engine
has not been operated for a period of time. Damage
can result if the crankshaft is rotated on dry bearing
surfaces.
To prevent damage to the crankshaft bearings, DO
NOT crank the engine before prelube, especially after
this maintenance procedure.
NOTICE
The prelube pump should not be operated continu-
ously for extended periods of time. If, during repairs,
the prelube pump has run continuously for a period
of three hours or more, it will be necessary to remove
any oil that may have collected in the cylinders and/or
above the valves.
Prelube of the engine is required before the
crankshaft is rotated for normal maintenance.
Activate the prelube pump for rotating the engine
crankshaft.
NOTICE
Do not use an impact wrench to operate the barring
device. The use of an impact wrench will cause gear
tooth failure.
The barring device provides a means for slowly
turning the flywheel in order to service the engine.
The barring device can also be used to prevent
rotation of the crankshaft.
Valve Bridge
NOTICE
Do NOT attempt to adjust the valves if the crankshaft
and camshaft are not synchronized. Disregard for this
can result in engine damage such as bent valves.
Check the valve bridges. Perform the procedure for
both valve bridges for each cylinder.
After the valve bridge is checked for each cylinder,
check the valve lash for the exhaust valves, the inlet
valves, and the gas admission valves.
Engine Valve Lash
If the valve lash is within the tolerance, an
adjustment of the valve lash is NOT necessary.
103
Maintenance Section
Engine Valve Rotators - Inspect
The crankshaft and camshaft timing must be
checked, and valve bridge adjustment must be
performed before making a valve lash adjustment.
Perform the valve lash setting when the engine is
cold. After the engine has been shut down and the
valve covers are removed, the engine is considered
cold.
Before performing maintenance, prevent the entry
of foreign matter into the top of the cylinder head
and the valve mechanism. Thoroughly clean the
area around the valve mechanism covers.
Gas Admission Valve
Check the valve lash for the gas admission valve
when the valve lash for the inlet valves and exhaust
valves are checked. Adjust the valve lash for the
gas admission valves, if necessary.
i01765711
Engine Valve Rotators - Inspect
SMCS Code: 1109-040
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
Note: Use of a platform may be necessary to reach
the engine valve rotators.
Perform this procedure after the valve lash has
been set.
1. Mark the tops of the valve rotators with a
permanent marker. Note the position of the
marks.
2. Install the valve covers. See the Service Manual
for the procedure.
3. Start the engine. Operate the engine for 5
minutes. Stop the engine.
4. Remove the valve covers. Observe the position
of the marks that are on the valve rotators.
If a valve fails to rotate, consult your Caterpillar
dealer.
104
Maintenance Section
Exhaust Bypass - Recondition

i01765718
NOTICE
Exhaust Bypass - Recondition The exhaust shields can be damaged if work is per-
formed on the exhaust shields or around the exhaust
SMCS Code: 1057-020 shields.

Remove the exhaust shields or protect the exhaust

shields before performing work on the exhaust shields
or around the exhaust shields. Handle the exhaust
shields carefully.

Do not tear the foil that is inside of the exhaust shields.

Torn foil will allow the insulation to absorb flammable
liquids and a fire can result from engine heat.

Ensure that the exhaust manifold is cool. Inspect

the exhaust shields. Replace any exhaust shield
that is damaged. Refer to the Service Manual for
g00799396
the procedure to remove the exhaust shields and
Illustration 79 install the exhaust shields.
Typical example
(1) Rod ends
(2) Cover and seal i01763022
(3) Shaft
Fuel System Fuel Filter
Note: Use of a platform may be necessary in order Differential Pressure - Check
to reach the components of the exhaust bypass.
SMCS Code: 1261-535
Replace the following parts:
If the engine is equipped with a fuel filter, a fuel
Rod ends (1) filter differential pressure gauge must be installed.
The fuel filter differential pressure gauge is installed
Cover and seal (2) in order to determine when the fuel filter requires
service. This gauge and the fuel filter are supplied
Shaft (3) by the customer.
For instructions on assembling the exhaust bypass, A fuel filter differential pressure gauge indicates the
refer to the Specifications. difference in fuel pressure between the inlet side
and the outlet side of the fuel filter. The differential
i00457458
pressure increases as the fuel filter becomes
plugged.
Exhaust Shields - Inspect
Operate the engine at the rated rpm and at the
SMCS Code: 1067-040 normal operating temperature. Check the fuel filter
differential pressure.

Service the fuel filter when the fuel filter differential

Hot engine components can cause injury from
burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
pressure reaches 1.7 kPa (0.25 psi).
For instructions, refer to Special Instruction,
SEHS9298, Installation and Maintenance of
Gaseous Fuel Filters. Consult your Caterpillar
dealer for assistance.
 105
Maintenance Section
Gas Admission Valve - Recondition

i01765725 Valve guide (5) will probably have very little wear.
However, measure the inner diameter of the valve
Gas Admission Valve - guide at both ends and the middle. The maximum
Recondition allowable inner diameter of the valve guide at both
ends and the middle is 9.538 mm (0.3755 inch).
SMCS Code: 1105-020-GS If any measurement exceeds this specification,
replace the valve guide. If this is not possible,
Note: Use of a platform may be necessary to reach replace support assembly (6) and the valve guide.
the gas admission valves.
It is unlikely for support assembly (6) to require
For the procedure to remove the gas admission replacement. However, inspect the valve seat in the
valve, refer to the engines Disassembly and support assembly.
Assembly.

When you disassemble the gas admission valve,

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

g00833994
Illustration 81
Angle and dimensions for the valve seat in the support assembly

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

slightly ground according to these specifications:

The angle for the valve seat is 44.75 0.5

degrees.

The gauge diameter of the valve seat within a

maximum depth of 2.0 mm (0.079 inch) from
the end of the support assembly is 39.75 mm
(1.565 inch).

Use some Prussian blue to verify complete contact

of the valve in the valve seat.

i01765734

Illustration 80
g00833978
Gas Admission Valve Seals -
Exploded view and section view of the parts for the gas admission
valve Inspect/Replace
(1) Retainer locks
(2) Valve rotator SMCS Code: 1105-040-GS; 1105-510-GS
(3) Outer valve spring
(4) Inner valve spring The camshaft operates the mechanism for the gas
(5) Valve guide admission valve in order to allow fuel to enter the
(6) Support assembly
(7) Valve
inlet port of the cylinder.

To recondition the gas admission valve, replace Note: Use of a platform may be necessary to reach
retainer locks (1), valve rotator (2), outer valve the gas admission valves.
spring (3), inner valve spring (4), and valve (7).
106
Maintenance Section
Gas Pressure Regulator - Inspect/Replace

For the procedure to remove the gas admission Pin holes

valve, refer to the engines Disassembly and
Assembly. Improper operation
If any of those conditions are found, the gas
pressure regulator must be repaired or replaced.

For information on replacing the gas pressure

regulator, see the Service Manual. Consult your
Caterpillar dealer for assistance.

i01611465

Gas Shutoff Valve - Inspect

SMCS Code: 1329-040

The gas shutoff valve (GSOV) has a solenoid that

is operated with 24 VDC. When power is supplied
to the solenoid, fuel flows through the GSOV to the
engine. When the power is interrupted, the gas is
shut off.

1. Shut off the engine.

2. Shut off the fuel supply to the GSOV.

g00833829
Illustration 82
Exploded view and section view of the parts for the gas admission
valve
(1) Upper valve stem seal
(2) Lower valve stem seal
(3, 4, and 5) O-ring seals for the support assembly

Note: The portion of the valve stem in lower valve

stem seal (2) may be slightly worn. This shallow
wear does not affect the performance of the gas
admission valve. Illustration 83 g00834076

(1) Receptacle
Inspect valve stem seals (1) and (2). Inspect (2) Gasket
O-ring seals (3), (4), and (5). Replace the seals, if (3) Cap
necessary. (4) Bolt
(5) Cover

i00679524 3. Disconnect the wiring harness from receptacle

(1). Inspect the connectors for damage and
Gas Pressure Regulator - corrosion. Make repairs, as needed.
Inspect/Replace
4. Inspect gasket (2) for damage and wear.
SMCS Code: 1550-040; 1550-510 Replace the gasket, if necessary.

Inspect the gas pressure regulator for the following 5. Remove cap (3). Remove the washer under the
conditions: cap in order to inspect the solenoid.

Wear 6. Inspect the solenoid for damage. If the epoxy

coating is cracked or damaged, obtain a new
Cracks solenoid for assembly.
 107
Maintenance Section
Ignition System Spark Plugs - Check/Adjust

7. Inspect the cavity for the solenoid. Look for Removing the Spark Plug
moisture, debris, and abrasion of the wiring.
Make repairs, if necessary. Thoroughly clean
the cavity.

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

inspect the internal parts of the GSOV.

9. Clean the internal parts. Inspect the diaphragm,

the center pin for the diaphragm, and the shaft
for the solenoid. If any of the parts are damaged,
replace the entire GSOV.

10. Inspect the internal passages. Remove any

debris.

11. Reassemble the diaphragm, the center pin for g00823378

Illustration 84
the diaphragm, and the shaft for the solenoid. (1) Harness connector
Install cover (5) with bolts (4). (2) Bolt
(3) Transformer
12. Install cap (3). Connect the wiring harness to (4) O-ring seal
(5) Extension
receptacle (1). (6) Spark plug

13. Turn on the fuel supply to the GSOV. Use a gas 1. Ensure that the mode control switch is in the
detector to check for gas leaks. STOP or OFF/RESET position.

i01763042
Ignition System Spark Plugs -
Check/Adjust
SMCS Code: 1555-535
Maintenance of the spark plugs is required in order
to obtain the following benefits:
Normal fuel consumption
Normal levels of emissions
Maximum service life of the spark plugs
The service life of the spark plugs is affected by
fouling due to deposits from the oil and by peak
voltage. Maintenance of the ignition system is also
affected by voltage. Higher voltage is required
by higher inlet manifold air pressure and a higher
compression ratio. Higher voltage reduces the
service life of components such as spark plug wires
and transformers.
NOTICE
Pulling on the wiring harness may break the wires. Do
not pull on the wiring harness.
2. Remove the lockwire. Disconnect harness
connector (1). Use pliers to turn the connector
counterclockwise.
3. Remove bolts (2).
4. Remove transformer (3). Inspect O-ring seal (4).
If the O-ring seal is worn or damaged, discard
the O-ring seal and use a new O-ring seal for
assembly.
5. Remove extension (5).
Pressurized air can cause personal injury. When
pressurized air is used for cleaning, wear a protec-
tive face shield, protective clothing, and protective
shoes.

6. Debris may have collected near the spark plug.

Thoroughly remove any debris. Use compressed
air. The maximum air pressure for cleaning
purposes must be below 207 kPa (30 psi).
Ensure that the area around the spark plug is
clean and free of dirt and debris.
108
Maintenance Section
Ignition System Spark Plugs - Check/Adjust
7. Use a 4C-4601 Spark Plug Socket and an
extension to loosen spark plug (6). After the
spark plug has been loosened, remove the
spark plug by hand in order to detect problems
with the threads. After the spark plug has been
removed, discard the used gasket.
NOTICE
The use of a thread tap will remove metal unnecessar-
ily. This will also reduce the heat transfer for the spark
plug. This can result in a reduction of the spark plug
service life and a reduction of the detonation margin.
If the spark plug resists removal by hand, apply
penetrating oil to the threads. Use the wrench and
apply steady pressure to the spark plug until the
spark plug is loose.
If the spark plug cannot be removed by hand, clean
the threads with 9U-7511 Spark Plug Seat Cleaner.
This tool scrapes debris from the seat and from the
threads.
Inspecting the Spark Plug
g00838300
Illustration 85
(1) Terminal post
(2) Insulator
(3) Shell
(4) Gasket
(5) Electrode
Inspect the spark plug closely for damage. The
condition of the spark plug can indicate the
operating condition of the engine.
Terminal post (1) must not move. If the terminal post
can be moved by hand, discard the spark plug.
Inspect insulator (2) for cracks. If a crack is found,
discard the spark plug.
Faint marks may extend from shell (3) onto the
insulator. The marks may be a result of corona that
forms at the top of the shell. The corona develops
when a very high voltage potential ionizes the
air that surrounds a conductor. This is a normal
condition. This is not an indication of leakage
between the shell and the insulator.
Inspect shell (3) for damage. Cracks can be caused
by overtightening the spark plug. Overtightening
can also loosen the shell. Discard any spark plug
that has a shell that is cracked or loose.
Inspect electrode (5) for excessive wear. Flat
surfaces with sharp edges provide the best
conditions for creating a spark. An electrode will
become worn from use. The surfaces erode. A
higher voltage is required in order to produce a
spark.
g00760569
Illustration 86
(6) Precious metal pads on the electrode and the ground strap
Caterpillar spark plugs have precious metal pads
(6) on the tips of the electrode and the ground
strap. This material will gradually erode.
Replace the spark plug if the precious metal is
worn off.
Light brown deposits or beige deposits around the
electrode are produced by normal operation. White
deposits or gray deposits may be caused by the
following substances:
Excessive oil
Use of the wrong oil
A substance that is introduced through the fuel
system or the air system
A spark plug can operate despite a buildup of ash.
However, a buildup of ash can cover the electrode
gap. This will cause misfire. Large deposits may
retain heat which can cause premature fuel ignition.
This can lead to uncontrollable detonation.

A standard ohmmeter (nine volt) can be used
for measuring the resistance of the spark plug.
The ohmmeter can be used only for spark plugs
with wire-wound resistors. It is not possible to use
a standard ohmmeter (nine volt) for measuring
the resistance of other types of spark plugs.
Measure the resistance between terminal post (1)
and electrode (5). Discard any spark plug if the
resistance is outside the range of 1000 to 1500
Ohms.
Cleaning the Spark Plug
Thoroughly clean the spark plug. Do not use a wire
brush. Glass beads are the preferred method for
cleaning.
Follow these guidelines for using glass beads:
Always use clean glass beads.
Use care in order to clean only the electrode and
the insulator near the electrode.
Do not use glass beads on the outside of the
shell or on the upper part of the insulator.
Installing the Spark Plug
Note: Use the 9U-7516 Spark Plug Gauge to
measure the electrode gap. Do not use a flat feeler
gauge for measuring the electrode gap of used
spark plugs. A feeler gauge will produce a false
measurement because the used precious metal
surfaces will be curved.
1. Before installing the spark plug, set the electrode
gap to 0.29 0.03 mm (.011 0.001 inch).
Adjust the electrode gap by bending the ground
electrode at the existing bend. Then bend the
strap near the weld in order to achieve proper
alignment and even spacing between the two
precious metal surfaces. Measure the electrode
gap after the alignment. Correct the electrode
gap, if necessary.
Note: Do not use anti-seize compound on spark
plugs. Most of the heat is transferred through the
threads and the seat area of the spark plug. The
surfaces must be in contact in order to provide the
heat transfer that is required.
2. Ensure that the spark plug is clean and free of
dirt and oil.
109
Maintenance Section
Ignition System Spark Plugs - Check/Adjust
3. Always use a new gasket when a spark plug is
installed. If a used spark plug is installed, place
a new 9Y-6792 Gasket on the spark plug. Orient
the tabs of the gasket toward the electrode.
Otherwise, the gasket may not seat properly. If
a gasket for a spark plug is installed incorrectly,
do not increase the torque on the spark plug
in order to improve the seal. Do not reuse the
gasket. Install a new gasket.
NOTICE
Do not overtighten the spark plug. The shell can be
cracked and the gasket can be deformed. The metal
can deform and the gasket can be damaged. The shell
can be stretched. This will loosen the seal that is be-
tween the shell and the insulator, allowing combustion
pressure to blow past the seal. Serious damage to the
engine can occur.
Use the proper torque.
4. Install the spark plug by hand until the spark
plug bottoms out. Tighten the spark plug to
68 4 Nm (50 3 lb ft).
5. Inspect the extension and clean the extension.
g00823413
Illustration 87
(1) O-ring seal
(2) Connection of the extension and the transformer
(3) Connection of the extension and the spark plug
a. Inspect O-ring seal (1). If the O-ring seal is
hard, cracked, or melted, use a new O-ring
seal for assembly.
b. Use a mild abrasive cleaner to clean deposits
and/or corrosion from the extension at
connection points (2) and (3).
c. Apply one of the following lubricants to O-ring
seal (1) and to the extension at connection
points (2) and (3):
4C-9504 Dielectric Grease
8T-9020 Dielectric Grease
110
Maintenance Section
Ignition System Spark Plugs - Replace

This will help to protect the connection points Leaks

of the extension from corrosion.
6. Ensure that the internal spring exerts force on
the connection points. Install the extension onto
the spark plug.
Loose connections
Ensure that all of the connections are secure.
Ensure that the components are in good condition.

7. Ensure that the transformer assembly is clean Make repairs, if necessary. For information regarding
and free of dirt and oil. Center 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
i00683392
connector cannot be loosened by hand. Replace
the lockwire. Inlet Gas Manifold and Piping -
i01612988
Inspect/Replace
SMCS Code: 1550-040; 1550-510
Ignition System Spark Plugs -
Replace Inspect the components of the fuel inlet system for
the following conditions:
SMCS Code: 1555-510
Cracks
Remove the used spark plugs. Install new spark
plugs. Deterioration
For instructions on removing and installing Leaks
spark plugs, refer to this Operation and
Maintenance Manual, Ignition System Spark Plugs Loose connections
- Check/Adjust topic (Maintenance Section).
Wear
i01765745
Inspect the following components:
Inlet Air System - Inspect
Fuel lines from the source to the gas regulator
SMCS Code: 1058-040; 1071-040; 1087-040
Fuel lines from the gas regulator to the fuel inlet
Use of a platform may be necessary to inspect the
following components of the air inlet system: Fuel inlet

Piping between the air cleaner and the Control valve

turbocharger
Fuel manifold
Rubber hoses in the air lines
Connections of the fuel manifold and the fuel lines
Turbocharger
Connections of the fuel lines to the orifice
Piping between the turbocharger and the
aftercooler Connections of the fuel lines to the cylinder head

Aftercooler Connections of the fuel lines to the precombustion

chamber
Connection of the aftercooler to the air plenum
Fuel pressure sensor
Connection of the air plenum to the cylinder head
Fuel temperature sensor
Inspect the components for the following conditions:
Ensure that all of the connections are secure.
Ensure that the components of the fuel system are
Cracks in good condition.
 111
Maintenance Section
Overhaul (In-Frame)

Make repairs, if necessary. For information regarding Scheduling an in-frame overhaul normally depends
removal and installation of the components, see the on the following three conditions:
Service Manual. Consult your Caterpillar dealer for
assistance. An increase of oil consumption

i01539111
An increase of crankcase blowby

Overhaul (In-Frame) A decrease and a variation of cylinder

compression
SMCS Code: 1000-020
Each individual condition may not indicate a need
for an overhaul. However, evaluating the three
Scheduling an In-Frame Overhaul conditions together is the most accurate method of
determining when an overhaul is necessary.
Table 40 lists the approximate number of service
hours before an in-frame overhaul for different The engine does not require an overhaul if the
G3600 Engine applications. engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder
Table 40 compression.
Estimated Service Hours Before an In-Frame
Overhaul Periodically measure each of the three conditions.
The first measurement should occur during the
Rated Fuel Compression Service
rpm Ratio Hours
first scheduled maintenance. This establishes
a baseline for future measurements. Additional
1000 Wellhead 9.2:1 50,000 measurements are scheduled at regular intervals.
gas or These measurements are performed in order to
natural gas determine a schedule for the next in-frame overhaul.
900 Natural gas 10.5:1 48,000
The following changes in the three conditions
1000 Natural gas 10.5:1 45,000 normally require a scheduled overhaul:
N/A Bio-gas 9.2:1 26,000 to
27,000 A 300 percent increase in oil consumption
A 200 percent increase in crankcase blowby
For engines with a 9.2:1 compression ratio, the
in-frame overhauls are performed for every two top
end overhauls.
A 20 percent loss of cylinder compression
Note: These indications do not require an engine
For engines with a 10.5:1 compression ratio, the to be shut down for service. These indications
in-frame overhauls are performed for every three only mean that an engine should be scheduled for
top end overhauls. service in the near future. If the engine operation
is satisfactory, an immediate overhaul is not a
For the combinations of the overhauls, refer to Table requirement.
41.
An in-frame overhaul does not typically require
Table 41
the engine to be removed. Instead, the service is
Combinations of Overhauls for Different performed with the engine in place.
Engine Applications
9.2:1 Compression Ratio 10.5:1 Compression Note: The generator or the driven equipment may
Ratio also require service when the engine overhaul is
performed.
First top end overhaul First top end overhaul
Second top end overhaul Second top end overhaul In-Frame Overhaul Information
and first in-frame overhaul
Third top end overhaul Third top end overhaul and An in-frame overhaul includes all of the work
first in-frame overhaul that is done for a top end overhaul. Additionally,
some other components that wear are replaced.
The condition of components is inspected. Those
For information on estimating operating hours before components are replaced, if necessary.
an overhaul, refer to Maintenance Management
Schedules, SEBU6127.
112
Maintenance Section
Overhaul (Major)

Inspect the following components according to Table 42

the instructions that are in Caterpillar reusability In-Frame Overhaul (1)
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, Index Procedure Component
of Publications on Reusability or Salvage of Used
Inspect Aftercooler
Parts. Replace
Cylinder liners
Your Caterpillar dealer can provide these services
Oil cooler
and components. Your Caterpillar dealer can ensure
that the components are operating within the Pistons
appropriate specifications.
Rebuild Gas admission valve
If you elect to perform an overhaul without the Electrohydraulic actuators
services of a Caterpillar dealer, be aware of the
Vibration damper
following recommendations.
Replace Camshaft bearings
The following definitions explain the terminology for
Camshaft followers
the services that are performed during an overhaul:
Connecting rod bearings
Inspect Inspect the components according to
the instructions that are in Caterpillar reusability Crankshaft seals
publications. Refer to Guidelines for Reusable Engine oil pump
Parts and Salvage Operations, SEBF8029, Index
of Publications on Reusability or Salvage of Used Exhaust shields
Parts. The guidelines were developed in order to Gaskets and seals
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not Electrohydraulic systems
required if the existing parts can still be used, oil pump
reconditioned, or repaired. If the components are Main bearings
not in the reusability guidelines, refer to the Service
Manual, Specifications module. Oil temperature regulators
Piston rings
Rebuild The component can be reconditioned in
order to comply with reusability guidelines. Prechamber assemblies
Water pumps
Replace The service life of the part is exhausted.
The part may fail before the next maintenance Water temperature
interval. The part must be replaced with a part that regulators
meets functional specifications. The replacement (1) In addition to these procedures, perform the procedures for
part may be a new part, a CAT remanufactured the top end overhaul.
part, a rebuilt part, or a used part. Various
worn components may be exchanged with your i01539146
Caterpillar dealer. Consult your Caterpillar dealer
about repair options for your engine. Overhaul (Major)
SMCS Code: 7595-020-MJ

Scheduling a Major Overhaul

Table 43 lists the approximate number of service
hours before a major overhaul for different G3600
Engine applications.
 113
Maintenance Section
Overhaul (Major)

Table 43 The following changes in the three conditions

Estimated Service Hours Before a Major Overhaul
normally require a scheduled overhaul:

Rated Fuel Compression Service A 300 percent increase in oil consumption

rpm Ratio Hours
1000 Wellhead 9.2:1 100,000 A 200 percent increase in crankcase blowby
gas or
natural gas A 20 percent loss of cylinder compression
900 Natural gas 10.5:1 80,000 Note: These indications do not require an engine
1000 Natural gas 10.5:1 75,000 to be shut down for service. These indications
only mean that an engine should be scheduled for
N/A Bio-gas 9.2:1 52,000 to service in the near future. If the engine operation
54,000 is satisfactory, an immediate overhaul is not a
requirement.
For engines with a 9.2:1 compression ratio, the
in-frame overhauls are performed for every two The engine does not require an overhaul if the
top end overhauls and the major overhauls are engine is operating within acceptable limits for
performed for every four top end overhauls. oil consumption, crankcase blowby, and cylinder
compression.
For engines with a 10.5:1 compression ratio, the
in-frame overhauls are performed for every three Other factors must also be considered for
top end overhauls and the major overhauls are determining a major overhaul:
performed for every five top end overhauls.
The service hours of the engine
Periodically, the procedures for the overhauls are
combined. For the combinations of the overhauls, The wear metal analysis of the lube oil
refer to Table 44.
An increase in the levels of noise and vibration
Table 44
Combinations of Overhauls for Different An increase of wear metals in the lube oil indicates
Engine Applications that the bearings and the surfaces that wear may
need to be serviced. An increase in the levels of
9.2:1 Compression Ratio 10.5:1 Compression noise and vibration indicates that rotating parts
Ratio require service.
First top end overhaul First top end overhaul
Note: It is possible for oil analysis to indicate a
Second top end overhaul Second top end overhaul decrease of wear metals in the lube oil. The cylinder
and first in-frame overhaul liners may be worn so that polishing of the bore
Third top end overhaul Third top end overhaul and occurs. Also, the increased use of lube oil will dilute
first in-frame overhaul the wear metals.
Fourth top end overhaul, Fourth top end overhaul
Monitor the engine as the engine accumulates
second in-frame overhaul,
and first major overhaul service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
Fifth top end overhaul Fifth top end overhaul and
first major overhaul Note: The driven equipment may also require
service when the engine is overhauled. Refer to the
For information on estimating operating hours before literature that is provided by the OEM of the driven
an overhaul, refer to Maintenance Management equipment.
Schedules, SEBU6127.
Major Overhaul Information
The need for a major overhaul is determined by
several factors. A major overhaul includes all of the work that is
done for a top end overhaul. A major overhaul
An increase of oil consumption can also include all of the work that is done for
an in-frame overhaul. A major overhaul includes
An increase of crankcase blowby additional parts and labor. Additional parts and
labor may be required in order to completely rebuild
A decrease and variation of cylinder compression the engine. In some cases, the engine is relocated
for disassembly.
114
Maintenance Section
Overhaul (Top End)

For the major overhaul, bearings, seals, gaskets, Table 45

and components that wear are disassembled. The Major Overhaul
parts are cleaned and inspected. If necessary, the
parts are replaced. The crankshaft is measured Procedure Component
for wear. The crankshaft may require regrinding.
Inspect Camshafts
Alternatively, the crankshaft may be replaced with a Replace
Caterpillar replacement part. Connecting rods
Crankshaft
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure Rebuild Inlet air piping
that the components are operating within the
Replace Aftercooler
appropriate specifications.
Camshaft lifters
If you elect to perform an overhaul without the
Exhaust manifolds
services of a Caterpillar dealer, be aware of the
following recommendations. Gear train bearings
Oil cooler
The following definitions explain the terminology for
the services that are performed during an overhaul:

Inspect Inspect the components according to i01539096

the instructions that are in Caterpillar reusability Overhaul (Top End)

publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, Index SMCS Code: 7595-020-TE
of Publications on Reusability or Salvage of Used
Parts. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid Top End Overhaul Information
unnecessary expenditures. New parts are not
required if the existing parts can still be used, Table 46 lists the approximate number of service
reconditioned, or repaired. If the components are hours before a top end overhaul for different G3600
not in the reusability guidelines, refer to the Service Engine applications.
Manual, Specifications module.
Table 46
Rebuild The component can be reconditioned in Estimated Service Hours Before a Top End Overhaul
order to comply with reusability guidelines.
Rated Fuel Compression Service
rpm Ratio Hours
Replace The service life of the part is exhausted.
The part may fail before the next maintenance 1000 Wellhead 9.2:1 25,000
interval. The part must be replaced with a part that gas or
meets functional specifications. The replacement natural gas
part may be a new part, a CAT remanufactured 900 Natural gas 10.5:1 16,000
part, a rebuilt part, or a used part. Some worn
components may be exchanged with your 1000 Natural gas 10.5:1 15,000
Caterpillar dealer. Consult your Caterpillar dealer N/A Bio-gas 9.2:1 13,000 to
about repair options for your engine. 13,500

For information on estimating operating hours before

an overhaul, refer to Maintenance Management
Schedules, SEBU6127.

A top end overhaul involves servicing the cylinder

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

Top end overhauls require more tools than

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

Torque wrenches
 115
Maintenance Section
Overhaul Considerations

Dial indicators Replace The service life of the part is exhausted.

The part may fail before the next maintenance
Accurate measurement tools interval. The part must be replaced with a part that
meets functional specifications. The replacement
Cleaning equipment part may be a new part, a CAT remanufactured
part, a rebuilt part, or a used part. Some worn
Rebuilding equipment components may be exchanged with your
Caterpillar dealer. Consult your Caterpillar dealer
Caterpillar dealers are equipped with these tools. about repair options for your engine.
Caterpillar dealers can provide a flat rate price for a
top end overhaul. Table 47
Top End Overhaul
Unexpected problems may be found during a top
end overhaul. Plan to correct these problems, if Procedure Component
necessary. Inspect Seals for the gas admission
Replace valve
Buildup in the cylinders from excessive oil
consumption Rebuild Gas pressure regulator
Starting motor
Plugging of the aftercooler from coolant that is
poorly maintained Turbochargers
Replace Cylinder heads and
Degradation of the oil cooler from hydrogen gaskets
sulfide in the fuel
Oil temperature regulators
Inspect the following components according to Spark plug extenders
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Water temperature
Parts and Salvage Operations, SEBF8029, Index regulators
of Publications on Reusability or Salvage of Used
Parts.
i01604264

Your Caterpillar dealer can provide these services Overhaul Considerations

and components. Your Caterpillar dealer can ensure
that the components are operating within the
SMCS Code: 7595-043
appropriate specifications.

If you elect to perform an overhaul without the Overhaul Information

services of a Caterpillar dealer, be aware of the
following recommendations.
The following definitions explain the terminology for
the services that are performed during an overhaul:
Inspect Inspect the components according to
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, Index
of Publications on Reusability or Salvage of Used
Parts. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
required if the existing parts can still be used,
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
Manual, Specifications module.
An overhaul is replacing the major worn components
of the engine. An overhaul is a maintenance interval
that is planned. The engine is rebuilt with certain
rebuilt parts or new parts that replace the worn
parts.
An overhaul also includes the following maintenance:
Inspection of all the parts that are visible during
the disassembly
Replacement of the seals and gaskets that are
removed
Cleaning of the internal passages of the engine
and the engine block

Rebuild The component can be reconditioned in

order to comply with reusability guidelines.
116
Maintenance Section
Overhaul Considerations
Most owners will save money by overhauling the
engine at the intervals that are recommended in
the Operation and Maintenance Manual. It is not
practical to wait until the engine exhibits symptoms
of excessive wear or failure. It is not less costly to
wait. A planned overhaul before failure may be the
best value for the following reasons:
Costly unplanned downtime can be avoided.
Many original parts can be reused according to
the guidelines for reusable parts.
The service life of the engine can be extended
without the risk of a major catastrophe due to
engine failure.
Achieve the best cost/value relationship per hour
of extended service life.
Overhaul Intervals
Note: For information on estimating operating
hours before an overhaul, refer to Maintenance
Management Schedules, SEBU6127.
Top end overhauls are determined by the projection
of exhaust valve stems. In-frame overhauls are
determined by cylinder compression, crankcase
blowby, and oil consumption. Major overhauls are
determined by the in-frame tests, and by results of
SOS oil analysis.
Some other factors that are important for
determining the overhaul intervals include the
following considerations:
Performance of preventive maintenance
Use of recommended lubricants
Use of recommended coolants
Use of recommended fuels
Proper installation
Operating conditions
Operation within acceptable limits
Engine load
Engine speed
Note: To avoid oil problems, engines that are
turbocharged and aftercooled must be operated at
a minimum of 60 percent of rated load.
Generally, engines that are operated at a reduced
load and/or speed achieve more service life before
an overhaul. However, this is for engines that are
properly operated and maintained.
Overhaul Inspection
Refer to the Service Manual for the disassembly
and assembly procedures that are necessary in
order to perform the required maintenance on the
items that are listed. Consult your Caterpillar dealer
for assistance.
To determine the reusability publications that are
needed to inspect the engine, refer to Guidelines for
Reusable Parts and Salvage Operations, SEBF8029,
Index of Publications on Reusability or Salvage of
Used Parts.
The Guidelines For Reusable Parts and Salvage
Operations is part of an established Caterpillar
parts reusability program. These guidelines
were developed in order to assist Caterpillar
dealers and customers reduce costs by avoiding
unnecessary expenditures for new parts. If the
engine parts comply with the established inspection
specifications, the parts can be reused. New parts
are not necessary if the old parts can be reused,
repaired, or salvaged.
If the parts are not within the inspection
specifications, the parts should be salvaged,
repaired, replaced, or exchanged. The use of
out-of-spec parts could result in unscheduled
downtime and/or costly repairs. The use of
out-of-spec parts can also contribute to increased
fuel consumption and reduction of engine efficiency.
Your Caterpillar dealer can provide the parts that
are needed to rebuild the engine at the least
possible cost.
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
Crankshafts
Cylinder heads
Oil Pumps
 117
Maintenance Section
Prechamber Check Valves - Clean

Starting motors Note: Refer to the engines Disassembly and

Assembly manual for instructions on removal and
Turbochargers installation of the check valves.

Water pumps 1. Remove check valve assembly (3) and gasket

Consult your Caterpillar dealer for details and for a
list of the remanufactured parts that are available.
Your Caterpillar dealer may be offering a variety of
overhaul options.
A Flat Rate Overhaul guarantees the maximum price
that you will pay for an overhaul. Flat rate prices on
preventive maintenance programs or major repair
options are available from many servicing dealers
for all Caterpillar Engines. Consult your Caterpillar
dealer in order to schedule a before failure overhaul.
Overhaul Recommendation
Caterpillar recommends a scheduled overhaul in
order to minimize downtime. A scheduled overhaul
will provide the lowest cost and the greatest value.
Schedule an overhaul with your Caterpillar dealer.
(5).
2. Discard gasket (5). Clean the check valve
assembly with a nonflammable solvent that will
not leave residue.
3. Clean the seat for the check valve assembly
with the 9U-5156 Tool Group. The tool group
includes instructions.
4. Before installation, inspect O-ring seals (2)
and (4) for dirt and cuts. If an O-ring seal is
damaged, discard the O-ring seal and install a
new O-ring seal.
5. Install a new gasket (5). Install the clean, dry
check valve assembly.
i01765759

Overhaul programs vary between dealers. To obtain

Prechamber Check Valves -
specific information about the types of overhaul Replace
programs and services, consult your Caterpillar
dealer. SMCS Code: 1550-510

i01765755

Prechamber Check Valves -

Clean
SMCS Code: 1550-070

g00789869
Illustration 89
(1) Plug
(2) O-ring seal
(3) Check valve assembly
(4) O-ring seal
(5) Gasket

Note: Use of a platform may be necessary to reach

g00789869 the prechamber check valves.
Illustration 88
(1) Plug Note: Refer to the engines Disassembly and
(2) O-ring seal
(3) Check valve assembly
Assembly manual for instructions on removal and
(4) O-ring seal installation of the check valves.
(5) Gasket
1. Remove check valve assembly (3) and gasket
Note: Use of a platform may be necessary to reach (5).
the prechamber check valves.
118
Maintenance Section
Prelube Pump - Inspect

2. Keep plug (1) for reassembly. Discard the other i01113939

parts. Obtain new parts for reassembly.
Starting Motor - Inspect
3. Use the 9U-5156 Tool Group in order to clean
the check valve seat. The tool group includes SMCS Code: 1451-040; 1453-040
instructions.
If the starting motor fails, the engine may not start
4. Install the following new parts: O-ring seal (2), in an emergency situation. A scheduled inspection
check valve assembly (3), O-ring seal (4), and of the starting motor is recommended.
gasket (5).
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine
i01612991 to start properly. The engine will not start if the
starting motor pinion does not engage the flywheel
Prelube Pump - Inspect ring gear. The teeth of the starting motor pinion and
the flywheel ring gear can be damaged because
SMCS Code: 1319-040 of irregular engagement.
Inspect the prelube pump for the following Inspect the starting motor for proper operation.
conditions: Listen for grinding when the engine is started.
Inspect the teeth of the starting motor pinion and
Cracks the flywheel ring gear. Look for patterns of wear on
the teeth. Look for teeth that are broken or chipped.
Pin holes If damaged teeth are found, the starting motor
pinion and the flywheel ring gear must be replaced.
Proper operation
Wear Electric Starting Motor
Inspect the prelube pump for leaks. Replace all of Note: Problems with the electric starting motor can
the seals if a leak is observed. be caused by the following conditions: malfunction
of the solenoid and malfunction of the electric
Inspect the wiring for the following conditions: starting system.

Damage Inspect the electrical system for the following

conditions:
Fraying
Loose connections
Ensure that the wiring is in good condition.
Corrosion
Inspect the electrical connections. Ensure that the
electrical connections are secure. Wires that are worn or frayed
If repair or replacement is necessary, refer to the Cleanliness
engines Disassembly and Assembly manual.
Consult your Caterpillar dealer for assistance. Make repairs, if necessary.

Air Prelube Pump

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

Electric Prelube Pump

Inspect the brushes. Replace the brushes, if
necessary.
 119
Maintenance Section
Turbocharger - Clean

Air Starting Motor Table 48

Materials for Cleaning 3600 Engine Turbochargers
Material Particle Size

Personal injury or death can result from improper- Nut shell 1.7 mm
ly checking for a leak. (1/16 inch)
Formed carbon 1 mm (1/32 inch)
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure, Granulated carbon (70% hardness) 1.2 to 2 mm
(3/64 to 5/64 inch)
even a pin-hole size leak, can penetrate body tis-
sue causing serious injury, and possible death. Granulated dry rice 1.7 mm
(1/16 inch)
If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of
injury.

Inspect all of the components in the air circuit for

the starting motor. Inspect all of the air lines and
connections for leaks.

If the teeth of the starting motor pinion and/or the

flywheel ring gear are damaged, the air circuit for
the starting motor must be examined in order to
determine the cause of the problem.

Removal and Installation of the

g00833073
Starting Motor Illustration 90
(1) Air valve
Refer to the Service Manual, Disassembly and (2) Purge valve
(3) Cap
Assembly module for information on removing the (4) Gate valve
starting motor and installing the starting motor.
Note: During normal engine operation, air valve (1),
Consult your Caterpillar dealer for assistance. purge valve (2), and gate valve (4) are closed.

i01765784 1. Ensure that purge valve (2) is closed. Ensure

Turbocharger - Clean
(Cleaning with Dry Particles)
SMCS Code: 1052-070
Note: Use of a platform may be necessary to reach
the turbocharger.
If the engine has more than one turbocharger, each
turbocharger requires cleaning.
Note: The drain openings in the exhaust housing
of the turbocharger are closed during the cleaning
procedure. Some of the particles will be expelled
through the exhaust stack. The particles that are
expelled will be burned.
The materials that are listed in Table 48 are
recommended for use with this cleaning procedure.
that cap (3) is secure. Open gate valve (4).
2. Open air valve (1) in order to remove deposits
that may be in the connecting pipe. After three
minutes, close air valve (1). Close gate valve (4).
3. Open purge valve (2) in order to relieve any
pressure from the container. Close purge valve
(2).
4. Remove cap (3). Pour 0.5 L (0.5 qt) of the
particles into the container. Tighten cap (3).
5. Ensure that purge valve (2) is closed. Reduce
the output of the engine so that the exhaust
temperature before the turbine is less than
577 C (1070 F).
6. Open gate valve (4). Open air valve (1).
7. After 60 to 90 seconds, close air valve (1). Close
gate valve (4).
120
Maintenance Section
Turbocharger Cleaner Tube - Replace

8. Open purge valve (2) in order to relieve any The exhaust valves and valve seats show the
pressure from the container. Close purge valve greatest wear due to high operating temperatures.
(2). The top end overhaul interval is normally scheduled
according to exhaust valve recession.
i01765785
The actual measurement of the valve recession
Turbocharger Cleaner Tube - inside of the cylinder head is difficult to obtain.
Two simpler methods are used to determine valve
Replace recession:

SMCS Code: 1052-510 Measure the projection of the valve stem above
the cylinder head. It is necessary to remove the
rocker arms in order to obtain this measurement.
This method is more accurate than measuring the
projection of the exhaust valve rotators. Measure
the projection of the exhaust valve stems with the
4C-2980 Cylinder Head Valve Projection Group.

Measure the projection of the valve rotator

above the cylinder head. It is not necessary to
remove the rocker arms in order to obtain this
measurement. Measure the projection of the
exhaust valve rotators with the 148-2997 Valve
Recession Tool Group.

g00790542 Make several copies of this Operation and

Illustration 91 Maintenance Manual, Valve Data Sheet
(1) Air valve (Reference Materials Section). Record the
(2) Purge valve measurements on the sheets.
(3) Gate valve
(4) Tube
Measure the projection of the inlet and exhaust
Note: Use of a platform may be necessary in order valve stems and the exhaust valve rotators at
to reach the cleaner tube. the first 1000 service hours. This measurement
is the baseline. The baseline is a reference for
1. Stop the engine. subsequent measurements.

2. Ensure that air valve (1) and gate valve (3) are
closed.
3. Open purge valve (2) in order to relieve any
pressure from the container.
4. Remove tube (4). Discard the used tube.
5. Install a new tube.
Measure the projection of the inlet and exhaust
valve rotators when the engine valve lash is
checked. Continue this periodic measurement
until the projection of the valve rotator has
increased by a total of 1.6 mm (.063 inch). This
is 70 percent of the maximum limit. Measure the
projection of the valve stems when this occurs.
This measurement will determine the actual wear
of both the valves and the valve seats.

6. Close purge valve (2). After 70 percent of the maximum limit has been
reached, measure the projection of the exhaust
valve stems at every 500 hours of operation.
i00682053
Plan for the top end overhaul as the valve
Valve Stem Projection - stem projection approaches the maximum limit.
Measure/Record Perform the top end overhaul when the valve stem
projection has increased by a total of 2.3 mm
SMCS Code: 1105-082 (.09 inch). Do not allow the valve recession to
exceed this limit. The valve head can break.
Valve Recession The valves and the valve seats This will cause severe damage in the combustion
are worn over time. This causes the valves to chamber and the turbocharger.
recede into the cylinder head. This condition is
called valve recession. Consult your Caterpillar dealer for assistance.

i01492446
Walk-Around Inspection
SMCS Code: 1000-040
Inspect the Engine for Leaks and
for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be
avoided.
For maximum engine service life, thoroughly inspect
the engine room before starting the engine. Look for
items such as leaks, loose bolts, loose connections
and trash buildup. Make repairs, as needed.
The guards must be in the proper place. Repair
damaged guards or replace missing guards.
Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
NOTICE
For any type of leak, clean up the fluid. If leaking is ob-
served, find the source and correct the leak. If leaking
is suspected, check the fluid levels more often than
recommended until the leak is found or fixed, or until
the suspicion of a leak is proved to be unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
Ensure that cooling lines are properly clamped.
Check for leaks. Check the condition of all pipes.
Inspect the water pumps for coolant leaks.
Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small
amount of leakage to occur when the engine cools
and the parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For instructions
on removal and installation of water pumps and/or
seals, refer to the Service Manual, Disassembly
and Assembly module for the engine or consult
your Caterpillar dealer.
Inspect the lubrication system for leaks at the
front crankshaft seal, the rear crankshaft seal, the
oil pan, the oil filters and the valve covers.
121
Maintenance Section
Walk-Around Inspection
NEVER use a flame to check for gas leaks. Use a
gas detector.
An open flame can ignite mixtures of air and fuel.
This will cause explosion and/or fire which could
result in severe personal injury or death.
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.
Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
Inspect the ground straps for good connections
and for good condition.
Check the condition of the gauges. Replace any
gauge that is damaged. Replace any gauge that
can not be calibrated.
Inspect the exhaust system for leaks. If a leak
is found, make repairs.
i00524084
Water Pump - Inspect
SMCS Code: 1361-040
A failed water pump might cause severe engine
overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential
damage to the engine.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of
the water pump seals. Refer to the Service Manual
for the disassembly and assembly procedure.
Inspect the water pump for wear, cracks, pin holes
and proper operation. Refer to the Service Manual
or consult your Caterpillar dealer if repair is needed
or replacement is needed.
i00839511
Water Temperature Regulator -
Replace
SMCS Code: 1355-510
Replace the water temperature regulators for these
systems:
122
Maintenance Section
Water Temperature Regulator - Replace

Jacket water
Oil cooler
Aftercooler
Replace the water temperature regulators before
the water temperature regulators fail. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulators reduces
the chances for unscheduled downtime.

A water temperature regulator that fails in a

partially opened position can cause overheating or
overcooling of the engine.

A water temperature regulator that fails in the

closed position can cause excessive overheating.
Excessive overheating could result in cracking of
the cylinder head or a seizure of the pistons.

A water temperature regulator that fails in the open

position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside
the cylinders. This excessive carbon buildup could
result in an accelerated wear of the piston rings and
wear of the cylinder liner. Also, a low temperature
can allow moisture to condense in the oil. This can
form damaging acids.

NOTICE
Failure to replace the water temperature regulators on
a regularly scheduled basis could cause severe en-
gine damage.

Never operate the engine without the water tempera-

ture regulators installed.

If the water temperature regulator is installed incor-

rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position.

Note: If only the water temperature regulators are

replaced, drain the coolant from the cooling system
to a level that is below the water temperature
regulator housing.
 123
Reference Information Section
Customer Service

Reference Information Latin America, Mexico, Carribean

Caterpillar Americas Co.
Section 701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Customer Service Fax: 305-476-6801

Europe, Africa, and Middle East

i01706971
Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000; 4450 CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
USA and Canada Fax: 22-849-4544
When a problem arises concerning the operation of Far East
an engine or concerning the service of an engine, Caterpillar Asia Pte. Ltd.
the problem will normally be managed by the dealer 7 Tractor Road
in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem Fax: 65-662-8302
that has not been handled to your complete
satisfaction, follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level without additional assistance, use the Hong Kong
phone number that is listed below to talk with a Phone: 852-2848-0333
Field Service Coordinator: Fax: 852-2848-0440
1-800-447-4986 Japan
Shin Caterpillar Mitsubishi Ltd.
The normal hours are from 8:00 to 4:30 Monday SBS Tower
through Friday Central Standard Time. 10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
3. If your needs have not been met still, submit the Japan
matter in writing to the following address: Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Caterpillar Inc.
Manager, Customer Service, Engine Division Japan
Mossville Bldg AC Caterpillar Power Systems, Inc.
P.O. Box 610 8F, AIG Aoyama Bldg.
Mossville, Illinois 61552-0610 2-11-16, Minami-Aoyama
Minato-ku, Tokyo 107-0062
Please keep in mind: probably, your problem will Phone: 81-3-5786-3803
ultimately be solved at the dealership, using the Fax: 81-3-5786-3809
dealerships facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a Australia and New Zealand
problem is experienced. Caterpillar of Australia Ltd.
1 Caterpillar Drive
Outside of the USA and of Canada Private Mail Bag 4
Tullamarine, Victoria 3043
If a problem arises outside the USA and outside Australia
Canada, and if the problem cannot be resolved at Phone: 03-9953-9333
the dealer level, consult the appropriate Caterpillar Fax: 03-9335-3366
office.
124
Reference Information Section
Customer Service

i01028392

Ordering Replacement Parts

SMCS Code: 4450; 7567

When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.

When you order parts, please specify the following

information:

Part number
Part name
Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.

When a Caterpillar engine requires maintenance

and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform the

dealer about the conditions of the problem and
the nature of the problem. Inform the dealer about
when the problem occurs. This will help the dealer
in troubleshooting the problem and solving the
problem faster.
 125
Reference Information Section
Reference Materials

Reference Materials Owners receipts

Maintenance log
i00912149

Maintenance Records
SMCS Code: 1000; 4450

Caterpillar Inc. recommends the retention

of accurate maintenance records. Accurate
maintenance records can be used for the following
purposes:

Determine operating costs.

Establish maintenance schedules for other
engines that are operated in the same
environment.

Show compliance with the required maintenance

practices and maintenance intervals.

Maintenance records can be used for a variety of

other business decisions that are related to engine
maintenance.

Maintenance records are a key element of a

maintenance program that is well managed.
Accurate maintenance records can help your
Caterpillar dealer to fine tune the recommended
maintenance intervals in order to meet the specific
operating situation. This should result in a lower
engine operating cost.

Records should be kept for the following items:

Fuel Consumption A record of fuel consumption

is essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines
overhaul intervals.

Service Hours A record of service hours is

essential to determine when the speed sensitive
components should be inspected or repaired.

Documents These items should be easy to obtain,

and these items should be kept in the engine
history file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number, and engine serial number. The
following types of documents should be kept as
proof of maintenance or repair for warranty:

Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:

Dealer work orders and itemized bills

Owners repair costs
126
Reference Information Section
Reference Materials

i01176304

Maintenance Log
SMCS Code: 1000; 4450
Table 49
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity
Service Item Date Authorization
Hours Of Fuel
 127
Reference Information Section
Reference Materials

i00769479

Valve Data Sheet

SMCS Code: 1000
Table 50
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
128
Reference Information Section
Reference Materials

i01745078 Miscellaneous
Reference Material Application and Installation Guide, LEKQ2368,
Gas Engine Application and Installation Guide
SMCS Code: 1000; 4450
Application and Installation Guide, LEKQ7250,
The following literature can be obtained through any Air Intake, Exhaust, Ventilation
Caterpillar dealer.
Application and Installation Guide, LEKQ7252,
Lubricants G3600 Mounting, Alignment

Special Publication, PECP6026, One Safe
Source
Special Publication, PEDP7036, SOS Fluid
Analysis
Data Sheet, PEHP0002, Multipurpose Lithium
Complex Grease with Molybdenum (MPGM)
Data Sheet, PEHP0003, Multipurpose Lithium
Complex Grease (MPG)
Data Sheet, PEHP0017, Special Purpose Grease
(SPG) Bearing Lubricant
Special Publication, PEHP6001, How To Take A
Good Oil Sample
Application and Installation Guide, LEKQ7255,
G3600 Cooling Systems, Heat Recovery,
Lubrication System
Maintenance Management Schedules,
SEBU6127, Schedules for Industrial and EPG
Spark Ignited Gas Engines
Service Manual, RENR5905, G3600 Engines
Software Program, LEKQ6378, Methane Number
Program
Specifications, SENR3130, Torque Specifications
Special Instruction, GMG00694, Analyzing
Cylinder Condition By Measuring Air Flow

Supplement, SEBU6400, Caterpillar Gaseous Special Instruction, SEHS7332, Do Not Operate

Fueled Spark Ignited Engines Lubrication Tag
Specifications
Special Instruction, SEHS7633, Battery Test
Procedure
Fuels
Special Instruction, SEHS7768, Use of the
Application and Installation Guide, LEKQ7256, 6V-2150 Starting/Chargineg Analyzer
Fuels, Fuel Systems
Special Instruction, SEHS8622, Using the FT-
Application and Installation Guide, LEKQ7260, 1984 Air-To-Air Aftercooler Leak Test Group
Low Energy Fuels
Special Instruction, SEHS8712, Using the
Coolants 8T-2700 Blowby/Airflow Indicator Group

Data Sheet, PEHP7057, Coolant Analysis
Special Publication, PECP6026, One Safe
Source
Special Publication, PEDP7036, SOS Fluid
Analysis
Special Publication, SEBD0518, Know Your
Cooling System
Special Publication, SEBD0970, Coolant and
Your Engine
Special Instruction, SEHS8984, Using the
1U-8860 Large Engine Blowby Pickup Group
Special Instruction, SEHS9031, Storage
Procedure for Caterpillar Products
Special Instruction, SEHS9162, Spring Isolator
Group Installation and Adjustment Procedure
Special Instruction, SEHS9298, Installation and
Maintenance of Gaseous Fuel Filters
Special Publication, NEHS0526, Service
Technician Application Guide

Special Publication, NENG2500, Caterpillar Tools

and Shop Products Guide
 129
Reference Information Section
Reference Materials

Special Publication, SEBF8029, Index to International Organization for Standardization

Guidelines for Reusable Parts and Salvage (ISO)
Operations 1, rue de Varemb
Case postale 56
Special Publication, SEBF8062, Procedure to CH-1211 Genve 20
Inspect and Clean Air Filters Switzerland
Telephone: +41 22 749 01 11
Facsimile: +41 22 733 34 30
i01109461
E-mail: central@iso.ch
Additional Reference Material Web site: http://www.iso.ch

SMCS Code: 1000; 4450 European classifications are established by the

Counseil International Des Machines a Combustion
The EMA Lubricating Oils Data Book can (CIMAC) (International Council on Combustion
be obtained from the following locations: local Engines).
technological society, local library, and local college.
If necessary, consult EMA at the following address: CIMAC Central Secretariat
Lyoner Strasse 18
Engine Manufacturers Associaton 60528 Frankfurt
401 N. Michigan Ave. Germany
Chicago, IL, USA 60611 Telephone: +49 69 6603 1567
Telephone: (312) 644-6610 ext. 3626 Facsimile: +49 69 6603 1566

The Society of Automotive Engineers (SAE) i00382622

Specifications can be found in your SAE handbook.
This publication can also be obtained from the Warranty Information
following locations: local technological society, local
library, and local college. If necessary, consult SAE SMCS Code: 1000
at the following address:

SAE International
Engine Protection Plans
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001 Extended Warranties and Service
Telephone: (724) 776-4841 Contracts
The American Petroleum Institute Publication No. A wide variety of protection plans are available for
1509 can be obtained from the following locations: Caterpillar Engines. Consult your Caterpillar dealer
local technological society, local library, and local for detailed information on the specific programs
college. If necessary, consult API at the following and coverages that are available.
address:
Consult your Caterpillar dealer for information on a
American Petroleum Institute plan that is tailored in order to fit your requirements.
1220 L St. N.W.
Washington, DC, USA 20005
Telephone: (202) 682-8000

The International Organization for Standardization

(ISO) offers information and customer service
regarding international standards and standardizing
activities. ISO can also supply information on the
following subjects that are not controlled by ISO:
national standards, regional standards, regulations,
certification, and related activities. Consult the
member of ISO in your country.
130
Index Section
Index
A Control Panel ......................................................... 37
Actuator Control Linkage - Replace (Replace the Rod
Ends) ................................................................... 73
Additional Reference Material ............................. 129
After Starting Engine ............................................. 45
Engaging the Driven Equipment ........................ 45
After Stopping Engine............................................ 48
Aftercooler Condensation - Drain .......................... 73
Aftermarket Oil Additives ....................................... 51
Air Starting Motor Lines Screen - Clean................ 74
Air Starting Motor Lubricator Bowl - Clean ............ 74
Air Starting Motor Lubricator Oil Level - Check ..... 75
Adjust the Lubricator .......................................... 75
Air Tank Moisture and Sediment - Drain................ 75
Alternator - Inspect ................................................ 76
Alternator Belt - Inspect/Adjust/Replace................ 76
Adjustment ......................................................... 76
Inspection........................................................... 76
Replacement...................................................... 76
B Deposits or Plugging ........................................ 81
Barring Device - Lubricate ..................................... 77
Battery Electrolyte Level - Check .......................... 78
Before Starting Engine .................................... 18, 42
Air Inlet System.................................................. 42
Cooling System.................................................. 42
Driven Equipment .............................................. 42
Electrical System ............................................... 42
Fuel System ....................................................... 43
Hydraulic Actuator System................................. 43
Lubrication System ............................................ 42
Starting System ................................................. 43
Walk-Around Inspection..................................... 42
Burn Prevention..................................................... 15
Batteries............................................................. 15
Coolant............................................................... 15
Oils..................................................................... 15
C Removal and Installation.................................... 86
Cold Weather Starting .......................................... 43
Jacket Water Heaters......................................... 43
Lubricating Oil Heaters ...................................... 43
Requirements for Starting with Air ..................... 44
Combustion Sensor - Clean/Inspect/Replace........ 78
Commercial Heavy-Duty Coolant/Antifreeze and
SCA ..................................................................... 61
DESIRED SPEED Potentiometer .................... 41
EMERGENCY STOP Button ........................... 39
Indicators ........................................................... 39
Machine Information Display System (MIDS) .... 37
MANUAL PRELUBE Switch and PRELUBE
ACTIVE Indicator ............................................ 40
Mode Control Switch.......................................... 40
Control Panel - Inspect .......................................... 80
Record the Data and Review the Data............... 80
Conventional Coolant/Antifreeze Cooling System
Maintenance ........................................................ 61
Adding the SCA to Conventional Coolant/Antifreeze
at the Initial Fill ................................................. 62
Adding the SCA to Conventional Coolant/Antifreeze
For Maintenance .............................................. 62
Cleaning the Cooling System of Heavy-Duty
Coolant/Antifreeze............................................ 63
Coolant Recommendations ................................... 60
Cooling System Coolant (DEAC) - Change ........... 80
Clean the Cooling System ................................. 81
Cleaning a Cooling System that has Heavy
Drain the Cooling System .................................. 80
Fill the Cooling System ...................................... 81
Cooling System Coolant Analysis (Level II) -
Obtain .................................................................. 82
Cooling System Coolant Level - Check ................. 82
Add Coolant ....................................................... 83
Engines That Are Equipped With a Sight
Gauge .............................................................. 82
Engines That Are Not Equipped With a Sight
Gauge .............................................................. 83
Cooling System Level Switch - Inspect.................. 83
Cooling System Specifications .............................. 58
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add.................................................. 84
Add the SCA, If Necessary ................................ 84
SOS Coolant Analysis (Level I)........................ 84
Test the Concentration of the SCA..................... 84
Crankcase Blowby - Measure/Record ................... 85
Crankshaft Vibration Damper - Inspect ................. 85
Crushing Prevention and Cutting Prevention......... 17
Customer Assistance........................................... 123
Outside of the USA and of Canada.................. 123
USA and Canada ............................................. 123
Customer Service ................................................ 123
Cylinder Pressure - Measure/Record .................... 86
Cylinders - Inspect (Inspect the Combustion
Chamber)............................................................. 87
Diesel Engine Antifreeze/Coolant (DEAC) ............ 60

Driven Equipment - Check..................................... 87
Check the Alignment.......................................... 88
Every 10,000 Service Hours .............................. 88
Every 5000 Service Hours ................................. 87
Driven Equipment - Inspect/Replace/Lubricate .... 88
E Valve Bridge..................................................... 103
Electrical System................................................... 18
Grounding Practices .......................................... 19
Electrohydraulic Actuator - Inspect........................ 88
Electrohydraulic Actuator - Recondition ................ 89
Electrohydraulic System - Check/Adjust................ 90
Check the Pressure Relief Valve........................ 90
Electrohydraulic System - Inspect ......................... 91
Check the Oil Level ............................................ 91
Inspect the Lines, Connections, and
Components..................................................... 91
Electrohydraulic System Oil - Change................... 91
Electrohydraulic System Oil Filter - Change .......... 92
Emergency Stopping ............................................. 47
Emergency Stop Button ..................................... 47
Engine Air Cleaner Element - Replace.................. 92
Inspecting Air Cleaner Elements........................ 93
Servicing the Air Cleaner Elements ................... 92
Engine Air Cleaner Service Indicator - Inspect...... 93
Test the Service Indicator .................................. 94
Engine Crankcase Breather - Clean...................... 94
Engine Lifting......................................................... 31
Engine Lifting with a Generator.......................... 31
Engine Lifting and Storage .................................... 31
Engine Mounts - Check ......................................... 95
Engine Oil .............................................................. 49
Commercial Engine Oils .................................... 50
Lubricant Viscosity ............................................. 51
Lubrication for Engines that use Sour Gas and
Bio-Gas ............................................................ 50
Engine Oil - Change .............................................. 95
Change the Engine Oil....................................... 95
Oil Change Interval ............................................ 95
Engine Oil Filter - Change ..................................... 97
Inspect the Used Oil Filter Elements.................. 99
Replacing the Engine Oil Filters During Engine
Operation ......................................................... 98
Replacing the Engine Oil Filters With the Engine
Stopped............................................................ 97
Engine Oil Level - Check ..................................... 100
Engine Oil Sample - Obtain ................................. 101
Obtain the Sample and the Analysis................ 101
Engine Oil Temperature Regulator - Replace...... 101
Engine Operation................................................... 46
Operating the Engine and the Driven
Equipment ........................................................ 46
Partial Load Operation ....................................... 46
Engine Protective Devices - Check ..................... 101
Visual Inspection.............................................. 102
Engine Speed/Timing Sensor - Clean/Inspect..... 102
Engine Starting................................................ 18, 42
Engine Stopping .............................................. 18, 47
131
Index Section
Engine Storage...................................................... 32
Generator Storage ............................................. 32
Engine Valve Lash - Inspect/Adjust ..................... 102
Check the Timing of the Crankshaft and
Camshaft........................................................ 102
Engine Valve Lash ........................................... 103
Gas Admission Valve ....................................... 103
Engine Valve Rotators - Inspect .......................... 103
Exhaust Bypass - Recondition............................. 104
Exhaust Shields - Inspect .................................... 104
F
Features and Controls ........................................... 33
Fire Prevention and Explosion Prevention............. 15
Fire Extinguisher ................................................ 16
Lines, Tubes and Hoses..................................... 17
Foreword.................................................................. 5
California Proposition 65 Warning ....................... 4
Literature Information........................................... 4
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 5
Safety ................................................................... 4
Fuel Recommendations......................................... 54
Bio-Gas .............................................................. 55
Dry Natural Gas ................................................. 54
Gaseous Fuel Filters.......................................... 57
General Fuel Information ................................... 54
Sour Gas............................................................ 54
Wellhead Gas (Field Gas).................................. 55
Fuel Specifications ................................................ 54
Fuel System Fuel Filter Differential Pressure -
Check................................................................. 104
G
Gas Admission Valve - Recondition .................... 105
Gas Admission Valve Seals - Inspect/Replace.... 105
Gas Pressure Regulator - Inspect/Replace ......... 106
Gas Shutoff Valve - Inspect ................................. 106
General Coolant Information ................................. 58
Additives ............................................................ 59
Glycol ................................................................. 59
Water ................................................................. 58
General Hazard Information .................................. 12
Asbestos Information ......................................... 14
Containing Fluid Spillage ................................... 14
Dispose of Waste Properly ................................ 15
Fluid Penetration ................................................ 14
Pressure Air and Water...................................... 13
132
Index Section
H Overhaul (Major)..................................................
Hydraulic Oil ..........................................................
Applications........................................................
Caterpillar Biodegradable Hydraulic Oil
(HEES) .............................................................
Caterpillar Hydraulic Oil (HYDO) .......................
Commercial Oils.................................................
I
Ignition System Spark Plugs - Check/Adjust ....... 107
Cleaning the Spark Plug .................................. 109
Inspecting the Spark Plug................................ 108
Installing the Spark Plug .................................. 109
Removing the Spark Plug ................................ 107
Ignition System Spark Plugs - Replace ............... 110
Ignition Systems .................................................... 17
Important Safety Information ................................... 2
Inlet Air System - Inspect..................................... 110
Inlet Gas Manifold and Piping - Inspect/Replace.. 110
L Programmable System Parameters....................... 33
Lubricant Information............................................. 49
Lubricant Specifications ........................................ 49
M Reference Information Section ............................ 123
Maintenance Interval Schedule (Engines that use
Bio-Gas)............................................................... 69
Maintenance Interval Schedule (Engines with a
10.5:1 Compression Ratio that use Wellhead Gas or
Natural Gas) ........................................................ 71
Maintenance Interval Schedule (Engines with a
9:1 Compression Ratio that use Wellhead Gas or
Natural Gas) ........................................................ 68
Maintenance Log ................................................. 126
Maintenance Records.......................................... 125
Maintenance Section ............................................. 49
Manual Stop Procedure......................................... 47
Model View Illustrations......................................... 20
Model Views and Specifications ............................ 20
Monitoring System................................................. 33
Integrated Combustion Sensing Module
(ICSM).............................................................. 35
Mounting and Dismounting.................................... 17
O Specifications ........................................................ 24
Operation Section.................................................. 31
Ordering Replacement Parts............................... 124
Overhaul (In-Frame) ............................................ 111
In-Frame Overhaul Information ........................ 111
Scheduling an In-Frame Overhaul ................... 111
112
Major Overhaul Information ............................. 113
51 Scheduling a Major Overhaul........................... 112
51 Overhaul (Top End) ............................................. 114
Top End Overhaul Information ......................... 114
52 Overhaul Considerations ..................................... 115
51 Overhaul Information ....................................... 115
52
P
Plate Locations and Film Locations....................... 29
Engine Identification........................................... 29
Information Plate................................................ 29
Serial Number Plate........................................... 29
Prechamber Check Valves - Clean...................... 117
Prechamber Check Valves - Replace .................. 117
Prelube Pump - Inspect ....................................... 118
Air Prelube Pump............................................. 118
Electric Prelube Pump ..................................... 118
Product Description ............................................... 22
Engine Service Life ............................................ 23
Product Identification Information ......................... 29
Product Information Section .................................. 20
R
Reference Information ........................................... 29
Reference Material .............................................. 128
Coolants........................................................... 128
Fuels ................................................................ 128
Lubricants ........................................................ 128
Miscellaneous .................................................. 128
Reference Materials ............................................ 125
Refill Capacities..................................................... 66
Cooling System.................................................. 66
Hydraulic Actuator System................................. 66
Lubrication System ............................................ 66
S
SOS Coolant Analysis ......................................... 64
SOS Coolant Analysis (Level I)........................ 65
SOS Coolant Analysis (Level II)....................... 65
SOS Oil Analysis ................................................. 52
Condemning Limits of the Oil............................. 53
Safety Section ......................................................... 6
Safety Signs and Labels.......................................... 6
Drives and Gear Trains ...................................... 25
Engine Specifications......................................... 24
Reference Weights............................................. 28
Starting Motor - Inspect ....................................... 118
Air Starting Motor............................................. 119
Electric Starting Motor ..................................... 118
Removal and Installation of the Starting
Motor .............................................................. 119
 133
Index Section

Starting the Engine................................................ 44

Automatic Starting ............................................. 44
Manual Starting.................................................. 44
Supplemental Coolant Additive (SCA)................... 61

Table of Contents..................................................... 3
Turbocharger - Clean (Cleaning with Dry
Particles)............................................................ 119
Turbocharger Cleaner Tube - Replace................. 120

Valve Data Sheet................................................. 127

Valve Stem Projection - Measure/Record............ 120

Walk-Around Inspection ...................................... 121

Inspect the Engine for Leaks and for Loose
Connections ................................................... 121
Warranty Information ........................................... 129
Engine Protection Plans................................... 129
Water Pump - Inspect .......................................... 121
Water Temperature Regulator - Replace ............. 121
Water/Supplemental Coolant Additive (SCA) ........ 63
Adding the SCA to Water at the Initial Fill.......... 63
Adding the SCA to Water for Maintenance ........ 63
134
Index Section
Product and Dealer Information
Note: For product identification plate locations, see the section Product Identification Information in the
Operation and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
2002 Caterpillar
All Rights Reserved Printed in U.S.A.