Beruflich Dokumente
Kultur Dokumente
November 2004
Parts
Manual See General Information
for New Parts Manual
Features.
G3612 INDUSTRIAL
BKE259 (Engine) BFSVX00 (ESO)
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
MEMORANDA
MEMORANDA SELP6999
TABLE OF CONTENTS
Name Page Name Page
8. CAPTIONS
Quality Caterpillar replacement parts are available Captions located at the beginning of each information
from Caterpillar dealers throughout the world. Their element identify the part number and part name
parts inventories are up to date and include all along with additional descriptive information. S/N
parts normally required to protect your investment information found in each caption should be used
in Caterpillar Engines. Dealers may offer repair kits to select correct information for a specific engine.
or remanufactured parts to allow selection of the most Field replacement options, identification of optional
effective repair alternative for a particular situation. When attachment components, and where used ("part of")
ordering parts, your order should specify the quantity, information is also provided.
part number, part name, and the serial number/product The first line of a caption is shown in larger type font
identification number of the engine for which the parts to indicate the beginning of an information element.
are needed. Captions for additional pages that may be required
to illustrate an information element will be shown in
3. PARTS MANUAL ORGANIZATION standard type font and will include the term (contd.) .
4. TABLE OF CONTENTS
A table of contents (TOC) is found at the beginning of the
manual. The TOC lists each section of the manual with
a complete list of all information elements organized as
they appear in the manual. Page numbers are provided
for quick reference to detailed parts identification
illustrations and serviceable consist lists.
14. <END>
This symbol indicates the end of an information element.
REMANUFACTURED COMPONENTS
As an option when making repairs consider Caterpillar Remanufactured Components. Components that are available
through the Caterpillar Remanufactured Program are identified three ways in the parts book:
with the letter R in the note field of the parts list
with an R* at the beginning of the first line of the caption
with an *R at the end of the first line of the caption
Typical components included in the Remanufacturing Program for 3600 Series Engines include:
CONNECTING RODS
CYLINDER HEADS
FUEL INJECTORS
OIL COOLERS
OIL PUMPS
WATER PUMPS
Check with your local Caterpillar Dealer for the availability of Remanufactured Components.
CUSTOMER BENEFITS:
Protects against cavitation, foam, erosion, corrosion, and scale buildup in cooling systems.
Provides measured coolant conditioner.
DESCRIPTION:
Additives deplete from the coolant with normal operation. For this reason, Supplemental Coolant Additives (SCA) must
be added to all heavy duty coolants at regular intervals. In addition, when not using a fully formulated, pre-charged
antifreeze, like Caterpillars DEAC, an initial charge of SCA must be added to the cooling system. The amount of SCA
added to the system is dependent on the capacity of the system.
The SCA for initial fill is provided as a liquid. SCAs for maintenance intervals are available in liquid form and as a
spin-on element. (No Spin-on available for 3600 Family of Engines)
NOTE:
The amount of SCA added at initial fill is not the same as the amount added at maintenance intervals.
The coolant additive elements can be used with any ethylene or propylene glycol type antifreeze which meets ASTM
D4985 or ASTM D5345 Specifications.
NOTE:
For use with standard heavy duty coolant only, not for use with Extended Life Coolant.
PARTS NEEDED:
Cooling System Capacity Liquid SCA at Spin-on SCA
Liquid SCA at Initial Fill
Liters Gallons Maintenance* Maintenance Element*
* Normal maintenance period is 250 hrs. See your Operation and Maintenance Manual for complete coolant
maintenance instructions.
( ) Indicates quantity required.
BASIC ENGINE
BELT-SERPENTINE 141-7116 1 MOUNTING GP-ALTERNATOR 49
CAP GP-ENGINE OIL FILLER 7E-1659 1 COVER GP-CYLINDER BLOCK 12
SEAL-O-RING (VALVE COVER) 6V-3602 1 COVER GP-VALVE MECHANISM 20
8T-8883 1 COVER GP-VALVE MECHANISM 20
COOLING SYSTEM
REGULATOR-OIL TEMPERATURE 120-9453 4 LINES GP-OIL COOLER 89
(85-DEG C)
REGULATOR-WATER TEMPERATURE 174-3504 8 REGULATOR GP-TEMPERATURE 100
204-6708 8 REGULATOR GP-TEMPERATURE 102
SEAL-LIP TYPE 3S-9643 4 LINES GP-OIL COOLER 89
SEAL-LIP TYPE 3S-9643 8 REGULATOR GP-TEMPERATURE 100
(TEMPERATURE REGULATOR)
8 REGULATOR GP-TEMPERATURE 102
FUEL SYSTEM
BREATHER (HYDRAULIC TANK) 143-4880 1 TANK GP-HYDRAULIC 144
CAP-FILLER (HYDRAULIC TANK) 7H-1447 1 TANK GP-HYDRAULIC 144
SEAL-O-RING 5D-5957 1 PUMP GP-GEAR 141
LUBRICATION SYSTEM
BREATHER AS (CRANKCASE) 4W-3027 4 BREATHER GP 59
CAP-FILLER (ENGINE OIL) 4P-6979 1 CAP GP-ENGINE OIL FILLER 60
ELEMENT AS-OIL FILTER 179-1502 6 FILTER GP-ENGINE OIL 61
FILTER ELEMENT AS-OIL 1G-8878 1 FILTER GP-ENGINE OIL 63
SCREEN AS-SUCTION 9Y-3307 1 LINES GP-ENGINE OIL 65
SEAL-O-RING 6V-3602 4 BREATHER GP 59
SEAL-O-RING (VALVE COVER) 8T-8883 4 BREATHER GP 59
OPERATOR STATION
FUSE (15-AMPERE) 036-5774 1 BOX GP-CONTROL PANEL 198
FUSE (6-AMPERE) 233-8091 1 BOX GP-CONTROL PANEL 198
LAMP (CLEAR) 3E-1814 1 BOX GP-CONTROL PANEL 202
LAMP-INDICATOR (24-VOLT, AMBER) 153-5042 1 BOX GP-CONTROL PANEL 202
LAMP (24-VOLT) 116-5270 1 BOX GP-CONTROL PANEL 202
LAMP (24-VOLT, GREEN) 153-5040 1 BOX GP-CONTROL PANEL 202
A 14
COVER GP-ENGINE LIFTING EYE . . . . . . . . . . . . 16
ACTUATOR GP-ELECTRONIC . . . . . . . . . . . . . . . . 133 COVER GP-FRONT HOUSING . . . . . . . . . . . . . . . . 17
134 COVER GP-GEAR INSPECTION . . . . . . . . . . . . . . 18
ADAPTER GP-AIR CLEANER . . . . . . . . . . . . . . . . . 104 COVER GP-REAR HOUSING . . . . . . . . . . . . . . . . . . 19
ADAPTER GP-AUXILIARY DRIVE . . . . . . . . . . . . . 1 COVER GP-VALVE MECHANISM . . . . . . . . . . . . . . 20
AFTERCOOLER GP-TREATED WATER . . . . . . . . 105 CRANKSHAFT GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
AIR CLEANER GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 CYLINDER BLOCK AS . . . . . . . . . . . . . . . . . . . . . . . . 22
108 23
ALTERNATOR GP-CHARGING . . . . . . . . . . . . . . . . 145 CYLINDER BLOCK GP . . . . . . . . . . . . . . . . . . . . . . . . 24
26
CYLINDER HEAD AS . . . . . . . . . . . . . . . . . . . . . . . . . 29
B CYLINDER HEAD GP . . . . . . . . . . . . . . . . . . . . . . . . . 30
31
BARRING GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BEARING-CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 24
BELT-SERPENTINE . . . . . . . . . . . . . . . . . . . . . . . . . .
26
49
D
BOX AS-JUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 147 DAMPER GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
BOX GP-CONTROL PANEL . . . . . . . . . . . . . . . . . . . 197 33
198 DRAIN GP-ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . 34
200 DRIVE GP-TIMING & SPEED . . . . . . . . . . . . . . . . . . 35
202
BREATHER AS (CRANKCASE) . . . . . . . . . . . . . . . . 59
BREATHER GPCRANKCASE . . . . . . . . . . . . . . . . 59 E
BREATHER (HYDRAULIC TANK) . . . . . . . . . . . . . . 144
BYPASS GP-EXHAUSTWASTEGATE . . . . . . . . . 109 ELBOW GP-AIR INLET . . . . . . . . . . . . . . . . . . . . . . . . 112
113
ELEMENT AS-OIL FILTER . . . . . . . . . . . . . . . . . . . . . 61
ELEMENT AS-PRIMARY (AIR CLEANER) . . . . . . 108
C
CAMSHAFT AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 F
CAMSHAFT GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FILM (CONTROL PANEL) . . . . . . . . . . . . . . . . . . . . . 202
CAP-FILLER (ENGINE OIL) . . . . . . . . . . . . . . . . . . . 60 FILM-INFORMATION
CAP-FILLER (HYDRAULIC TANK) . . . . . . . . . . . . . 144 (DO NOT LIFT PICTOGRAPH) . . . . . . . . . . . . . . 16
CAP GP-ENGINE OIL FILLER . . . . . . . . . . . . . . . . . 12 FILM-WARNING (CRANKCASE) . . . . . . . . . . . . . . . 208
60 FILTER ELEMENT AS-OIL . . . . . . . . . . . . . . . . . . . . . 63
CHART-PLATE & FILM . . . . . . . . . . . . . . . . . . . . . . . . 208 FILTER GP-ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . 61
CONNECTING ROD GP . . . . . . . . . . . . . . . . . . . . . . . 9 63
CONNECTION GP-WATER . . . . . . . . . . . . . . . . . . . . 83 FLANGE GP-EXHAUST . . . . . . . . . . . . . . . . . . . . . . . 114
84 FLYWHEEL GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
85 FUSE (15-AMPERE) . . . . . . . . . . . . . . . . . . . . . . . . . . 198
CONTROL GP-ELECTRONIC . . . . . . . . . . . . . . . . . . 149 FUSE (6-AMPERE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
150
CONTROL GP-ENGINE ELECTRONIC . . . . . . . . . 151
CONTROL GP-FUEL . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL GP-GAS PRESSURE . . . . . . . . . . . . . .
135
152
G
153 GASKET-SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . 158
155 GAUGE-SIGHT (AIR START MOTOR) . . . . . . . . . . 165
CONTROL GP-UNPROGRAMMED . . . . . . . . . . . . . 156 GEAR GP-FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
COOLER GP-ENGINE OIL . . . . . . . . . . . . . . . . . . . . 87 GEAR GP-REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CORE AS (OIL COOLER) . . . . . . . . . . . . . . . . . . . . . 87 GEAR GP-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
COVER GP-CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . 10 GUARD GP-BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11 GUARD GP-DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . 42
COVER GP-CYLINDER BLOCK . . . . . . . . . . . . . . . . 12 GUIDE GP-OIL LEVEL GAUGE . . . . . . . . . . . . . . . . 64
A8 INDEX SELP6999
INDEX
Name Page Name Page
M
K MANIFOLD GP-EXHAUST . . . . . . . . . . . . . . . . . . . . . 123
KIT-DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 MODULE GP-DISPLAY
KIT-DRIVE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . 182 TRACTOR MANAGEMENT CENTER . . . . . . . . 205
KIT-FASTENER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 MODULE GP-KEYPAD . . . . . . . . . . . . . . . . . . . . . . . . 206
KIT-GASKET (PRELUBRICATION PUMP) . . . . . . 80 MODULE GP-SYSTEM COMMUNICATION
KIT-GASKET (STARTING MOTOR) . . . . . . . . . . . . . 80 CUSTOMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
KIT-MOTOR REPAIR (STARTING MOTOR) . . . . . 80 MODULE GP-SYSTEM COMMUNICATION
KIT-OUTPUT TERMINAL (ALTERNATOR) . . . . . . 145 (CUSTOMER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
KIT-PLUG (2-PIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 MOUNTING GP-ALTERNATOR . . . . . . . . . . . . . . . . 49
169 MOUNTING GP-BELLOWS . . . . . . . . . . . . . . . . . . . . 126
190 MOUNTING GP-ENGINE . . . . . . . . . . . . . . . . . . . . . . 51
KIT-RECEPTACLE (2 PIN) . . . . . . . . . . . . . . . . . . . . . 177 MOUNTING GP-FUEL FILTER . . . . . . . . . . . . . . . . . 139
KIT-RELAY TERMINAL (ALTERNATOR) . . . . . . . . 145 MOUNTING GP-TURBOCHARGER . . . . . . . . . . . . 127
KIT-RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
KIT-RELIEF VALVE (CRANKCASE) . . . . . . . . . . . .
KIT-SEAL & VANE (AIR STARTING MOTOR) . . .
12
182
O
KIT-SEAL (PUMP GP) . . . . . . . . . . . . . . . . . . . . . . . . . 141 ORIFICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
KIT-VALVE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . 135
KIT-VALVE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
KIT-VALVE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 P
161 PAN GP-OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
PISTON & ROD GP . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
L PLATE-IDENTIFICATION (CATERPILLAR) . . . . . .
PLATE-IDENTIFICATION
208
SELP6999 INDEX A9
INDEX
Name Page Name Page
GRAPHIC #1 g00804418
GRAPHIC #1 g00954535
GRAPHIC #1 g00815662
GRAPHIC #1 g01069300
GRAPHIC #1 g00819928
GRAPHIC #1 g00977440
GRAPHIC #1 g01122064
GRAPHIC #1 g01037445
GRAPHIC #1 g01119751
GRAPHIC #2 g01119429
GRAPHIC #3 g01119746
GRAPHIC #1 g01089438
GRAPHIC #2 g01089439
GRAPHIC #3 g01089437
GRAPHIC #4 g01089441
GRAPHIC #5 g01089443
GRAPHIC #1 g01059353
0 61
64
43
45
61
68
0L-1143 . . . . . 24 65 52 72
26 66 64 79
66 68 66 135
68 80 68 1A-5183 . . . . . 68
87 85 74 1A-5822 . . . . . 76
89 91 76 1A-5964 . . . . . 49
141 93 84 96
0L-1351 . . . . . 93 96 85 1A-8063 . . . . . 38
0L-1352 . . . . . 19 98 87 127
68 100 89 139
0L-2070 . . . . . 66 102 91 1A-9579 . . . . . 117
68 105 93 1B-4971 . . . . . 41
91 109 94 158
105 117 96 1B-5357 . . . . . 114
135 135 98 126
142 137 100 1B-7182 . . . . . 79
158 142 102 141
169 144 107 1D-4540 . . . . . 72
197 190 117 1D-4566 . . . . . 38
0S-0509 . . . . . 72 0S-1589 . . . . . 117 121 87
121 0S-1590 . . . . . 10 137 1D-4601 . . . . . 57
158 12 158 1D-4706 . . . . . 49
190 20 163 1F-0750 . . . . . 147
197 32 169 1F-6762 . . . . . 38
0S-1566 . . . . . 117 40 185 1F-7958 . . . . . 49
0S-1569 . . . . . 44 59 190 104
0S-1571 . . . . . 41 65 0S-1595 . . . . . 17 109
66 84 37 117
68 105 66 127
89 109 74 185
91 117 78 1G-8878 . . . . . 63
94 135 197 1H-3244 . . . . . 145
105 169 0S-1615 . . . . . 163 1H-4950 . . . . . 208
109 0S-1591 . . . . . 12 169 1H-5959 . . . . . 80
117 14 197 1J-8668 . . . . . 117
135 32 0S-1617 . . . . . 55 1L-8497 . . . . . 182
137 38 80 1M-0644 . . . . . 82
142 52 170 1M-1462 . . . . . 137
158 61 190 1N-3134 . . . . . 72
163 65 0S-1618 . . . . . 72 1N-3828 . . . . . 37
169 66 0S-1619 . . . . . 94 1N-3834 . . . . . 37
0S-1585 . . . . . 2 68 0S-1620 . . . . . 170 1N-3842 . . . . . 37
42 83 190 1N-4622 . . . . . 66
45 87 0S-1621 . . . . . 42 1N-5998 . . . . . 52
61 89 121 1P-2841 . . . . . 115
66 91 0S-1625 . . . . . 44 1P-5274 . . . . . 72
99 94 0T-0065 . . . . . 87 1P-7346 . . . . . 2
141 96 91 1S-3584 . . . . . 109
0S-1587 . . . . . 49 100 0T-0573 . . . . . 96 117
61 102 105 135
99 105 1S-4589 . . . . . 49
117 117 1S-5772 . . . . . 84
139
161
135
190
1 91
100
163 0S-1594 . . . . . 2 1A-0168 . . . . . 49 102
181 11 1A-1135 . . . . . 38 1S-9593 . . . . . 170
0S-1588 . . . . . 6 14 1A-1460 . . . . . 45 198
12 18 49 1T-0689 . . . . . 79
19 21 52 1W-0098 . . . . . 9
41 24 68 1W-0104 . . . . . 43
45 26 1A-2029 . . . . . 43 1W-0105 . . . . . 24
49 41 44 26
57 42 45 1W-0121 . . . . . 22
PRIMARY REFERENCE
SELP6999 PART NUMBER INDEX B1
PART NUMBER INDEX
Part Page Part Page Part Page Part Page
PRIMARY REFERENCE
B2 PART NUMBER INDEX SELP6999
PART NUMBER INDEX
Part Page Part Page Part Page Part Page
PRIMARY REFERENCE
SELP6999 PART NUMBER INDEX B3
PART NUMBER INDEX
Part Page Part Page Part Page Part Page
PRIMARY REFERENCE
B4 PART NUMBER INDEX SELP6999
PART NUMBER INDEX
Part Page Part Page Part Page Part Page
PRIMARY REFERENCE
SELP6999 PART NUMBER INDEX B5
PART NUMBER INDEX
Part Page Part Page Part Page Part Page
PRIMARY REFERENCE
B6 PART NUMBER INDEX SELP6999
PART NUMBER INDEX
Part Page Part Page Part Page Part Page
PRIMARY REFERENCE
SELP6999 PART NUMBER INDEX B7
PART NUMBER INDEX
Part Page Part Page Part Page Part Page
PRIMARY REFERENCE
B8 PART NUMBER INDEX SELP6999
PART NUMBER INDEX
Part Page Part Page Part Page Part Page
PRIMARY REFERENCE
SELP6999 PART NUMBER INDEX B9
MEMORANDA