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Guidelines for
Maintenance
and Technical
Service
for 3600/C280
Engines
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Caterpillar
Service Training

October 2005 - 4th Edition

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This Maintenance And Technical Handbook (MATH) Book enables dealers and their customers to
benefit from cost reductions made possible through an established parts reusability and salvage
program. Every effort has been made to provide the most current and relevant information known
to Caterpillar Inc. Since the Company makes on going changes and improvements to its products,
this Guideline must be used with the latest technical information available from Caterpillar to
ensure such changes and improvements are incorporated where applicable. This booklet is a
quick reference guide for service information on the 3600 Diesel Engines. This guide
complements, but not replace the following Caterpillar Service Manuals:

- Standard Bolt Torque


- Specifications
- System Operation Testing & Adjusting
- Dis-assembly and Assembly
- Operation & Maintenance Guide
- Parts Book

Please see these manuals for more details on the service needs of the 3600 Diesel Engine. The
ordering numbers for these manuals are in the reference publication section of this pocket guide.

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3600 Engine Family

Whether your needs are marine, industrial, or electric power generation, the Caterpillar 3600
Engine Family will provide you with proven power to get the job done. The 3600 Engines are the
most powerful and reliable power sources ever produced by Caterpillar. Operating economy and
durability make it the logical choice; worldwide product support makes it the only choice.

The 3618 Marine Propulsion Engine is the newest addition to the 3600 Engine Family . It was
specifically designed to meet the needs of our marine fast ferry customers. For more information
on the new Caterpillar 3600 engine, consult your local Caterpillar Dealership.

This 3600 Series Engine "Maintenance and Technical Service Handbook" (MATH) & Check List
will assist certified technicians, dealers and customers as a quick reference to certain engine
history background, part numbers, torques, procedures, troubleshooting, conversions, and
documenting the condition of engine and components during maintenance intervals and at time of
overhaul. After the overhaul is completed, some pages from this document maybe copied and
placed in the engine history file for future reference or this MATS book can be the engines own
history book and kept close to the engine as a quick reference.

Note: This handbook is intended to be used as an aid to the Technician and NOT as a
replacement for the Service Manuals, Parts Books or other Technical Data
Books.

If you have any questions or comments about this booklet please call the 3600 Engine Training
Consultant (309)494-5920.

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Table of Contents:
Service Support

Service Support Center ................................................................................................................1-2


Locations For Information ............................................................................................................1-2
Introduction ..................................................................................................................................1-4
3600 Engine Family......................................................................................................................1-3
Marine Ratings, Conditions, 3600 Engine Features, Engine Model ............................................1-5
Specifications................................................................................................................................1-7
Propulsion Engine Dimensions, Caterpillar Gen Set Dimensions................................................1-8
Service Removal Distance In-line Engine ....................................................................................1-8
Publications ................................................................................................................................1-11
How to order a “Serial Number Specific Parts Book ..................................................................1-11
How to order a “Technical Manual ..............................................................................................1-11
Reference Publication Form Numbers........................................................................................1-11
Guidelines For Reusable Parts & Salvage Operations Publications..........................................1-13
Customer / Dealership Performance Information ......................................................................1-14
Plate Information ........................................................................................................................1-17

Maintenance

Maintenance Interval Schedule - Distillate Fuel of the 3606, 3608, 3612 & 3616 Engines.

Before performing any operation or maintenance procedures, ensure that the Safety Information ,
warnings, and instructions are read and understood.
To determine the maintenance intervals, use service hours or calendar time, which ever occurs
first.

Before each consecutive interval is performed, all of the maintenance requirements from the
previous interval must be performed.

Note: For information on generator maintenance, see the Operation and Maintenance
Manual for the generator.

When Required

Centrifugal Oil Filter - Inspect ....................................................................................................2-13


Cooling System Coolant Sample (Level 2) - Obtain ..................................................................2-21
Engine Air Cleaner Element - Replace ......................................................................................2-27
Engine Crankcase Breather - Clean ..........................................................................................2-32
Engine Oil - Change ..................................................................................................................2-35
Engine Oil Filter - Change ..........................................................................................................2-38
Fuel Analysis - Obtain ................................................................................................................2-50
Fuel System - Prime ..................................................................................................................2-51
Fuel System Primary Filter/Water Separator Element - Replace ..............................................2-53
Fuel System Secondary Filter - Replace....................................................................................2-54
Metal Particle Detector - Inspect ................................................................................................2-60
Zinc Rods - Inspect/Replace ......................................................................................................2-85

Every Service Hour

Trend Data - Record ..................................................................................................................2-75

Daily

Air Starting Motor Lubricator Oil Level - Check ..........................................................................2-10


Air Tank Moisture and Sediment - Drain ....................................................................................2-11
Cooling System Coolant Level - Check......................................................................................2-19
Driven Equipment - Inspect/Replace/Lubricate ..........................................................................2-26
Engine Air Cleaner Service Indicator - Inspect ..........................................................................2-31
Engine Air Precleaner - Clean ....................................................................................................2-31
Engine Oil Level - Check............................................................................................................2-41

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Fuel System Primary Filter/Water Separator - Drain..................................................................2-52


Fuel Tank Water and Sediment - Drain ......................................................................................2-57
Governor Actuator Oil Level - Check..........................................................................................2-62
Instrument Panel - Inspect ........................................................................................................2-59
Walk-Around Inspection..............................................................................................................2-82

Every 50 Service Hours or Weekly

Zinc Rods - Inspect/Replace ......................................................................................................2-85

Every 250 Service Hours or 6 Weeks

Air Shutoff - Test ..........................................................................................................................2-7


Air Starting Motor Lines Screen - Clean ......................................................................................2-8
Cooling System Supplemental Coolant Additive (SCA) - Test/Add ............................................2-21
Engine Oil Sample - Obtain........................................................................................................2-42
Governor Actuator Linkage - Check ..........................................................................................2-58
Oil Mist Detector - Check ..........................................................................................................2-60

Every 250 Service Hours or Monthly

Cooling System Coolant Sample (Level 1) - Obtain ..................................................................2-20

Every 500 Service Hours or 3 Months

Engine Mounts - Inspect ............................................................................................................2-33


Engine Protective Devices - Check ............................................................................................2-45
Oil Mist Detector - Clean/Replace ..............................................................................................2-61

Initial 1000 Service Hours or 6 Months

Engine Timing, Synchronization, and Valve Lash - Inspect/Adjust ............................................2-43


Engine Valve Rotators - Inspect ................................................................................................2-48

Every 1000 Service Hours or 6 Months

Barring Device - Lubricate ..........................................................................................................2-12


Cooling System Coolant Sample (Level 2) - Obtain ..................................................................2-21
Engine Air Cleaner Service Indicator - Inspect ..........................................................................2-31
Engine Mounts - Check ..............................................................................................................2-35
Engine Oil Filter - Change ..........................................................................................................2-38
Exhaust Piping - Inspect ............................................................................................................2-49
Fuel System Primary Filter/Water Separator Element - Replace ..............................................2-53
Fuel System Secondary Filter - Replace....................................................................................2-49
Magnetic Pickups - Clean/Inspect ..............................................................................................2-59
Prelube Pump - Lubricate ..........................................................................................................2-74

Every 2000 Service Hours or 1 Year

Aftercooler Condensation - Drain ................................................................................................2-5


Engine Timing, Synchronization, and Valve Lash - Inspect/Adjust ............................................2-43
Engine Valve Rotators - Inspect ................................................................................................2-48
Oil Mist Detector - Clean/Replace ..............................................................................................2-61

Every 4000 Service Hours or 1 Year

Aftercooler Core - Clean/Test ......................................................................................................2-6


Air Starting Motor Lubricator Bowl - Clean ..................................................................................2-9
Starting Motor - Inspect ..............................................................................................................2-74

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Every 8000 Service Hours or 1 Year

Engine Protection Devices - Calibrate........................................................................................2-45

Every 8000 Service Hours or 3 Years

Camshaft Roller Followers - Inspect ..........................................................................................2-13


Cooling System Coolant (DEAC) - Change ..............................................................................2-14
Cooling System Coolant Extender (ELC) - Add ........................................................................2-17
Crankshaft Vibration Damper - Inspect ......................................................................................2-24
Driven Equipment - Check ........................................................................................................2-25
Engine Oil Temperature Regulator - Replace ............................................................................2-44
Exhaust Shields - Inspect ..........................................................................................................2-49
Governor Actuator Oil - Replace ................................................................................................2-58
Turbocharger - Inspect ..............................................................................................................2-81
Water Pump - Inspect ................................................................................................................2-84
Water Temperature Regulator - Replace....................................................................................2-84

Between 16 000 and 24 000 Service Hours

Overhaul (Top End) ..................................................................................................................2-61


Overhaul Considerations ............................................................................................................2-68

Every 16 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ..................................................................................2-17

Between 36 000 and 44 000 Service Hours

Overhaul (Major) ........................................................................................................................2-64


Overhaul Considerations ............................................................................................................2-68

Maintenance Interval Schedule for the 3618 Engine

Before performing any operation or maintenance procedures, ensure that the Safety Information ,
warnings, and instructions are read and understood.
Before each consecutive interval is performed, all of the maintenance requirements from the
previous interval must be performed.

When Required

Centrifugal Oil Filter - Clean .................................................................................................... 2-94


Engine Air Cleaner Element - Replace ....................................................................................2-107
Engine Crankcase Breather - Clean ........................................................................................2-108
Engine Oil and Filter - Change ................................................................................................2-113
Fuel Analysis - Obtain ..............................................................................................................2-121
Fuel System - Prime ................................................................................................................2-122
Fuel System Primary Filter/Water Separator Element - Replace ............................................2-123
Fuel System Secondary Filter - Replace..................................................................................2-123
Metal Particle Detector - Inspect ..............................................................................................2-123
Oil Mist Detector - Maintain ......................................................................................................2-127

Daily

Air Starting Motor Lubricator Oil Level - Check........................................................................ 2-89


Air Tank Moisture and Sediment - Drain .................................................................................. 2-91
Annunciator Panel - Inspect .................................................................................................... 2-92
Cooling System Coolant Level - Check....................................................................................2-100
Driven Equipment - Inspect/Replace/Lubricate ........................................................................2-106
Engine Oil Level - Check ..........................................................................................................2-111
Fuel System Primary Filter/Water Separator - Drain................................................................2-122
Fuel Tank Water and Sediment - Drain ....................................................................................2-126
Oil Mist Detector - Maintain ......................................................................................................2-127
Trend Data - Record ................................................................................................................2-141
Walk-Around Inspection............................................................................................................2-147
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Every 250 Service Hours or Monthly

Air Starting Motor Lines Screen - Clean .................................................................................. 2-87


Cooling System Coolant Sample (Level 1) - Obtain ................................................................2-101
Cooling System Supplemental Coolant Additive (SCA) - Test/Add ..........................................2-103
Engine Oil Sample - Obtain ......................................................................................................2-111
Oil Mist Detector - Maintain ......................................................................................................2-127

Every 500 Service Hours or 3 Months

Barring Device - Lubricate ..........................................................................................................2-93


Engine Mounts - Inspect ..........................................................................................................2-110
Governor Actuator Linkage - Check ........................................................................................2-127
Oil Mist Detector - Maintain ......................................................................................................2-128

Initial 1000 Service Hours or 6 Months

Engine Timing, Synchronization, and Valve Lash - Inspect/Adjust ..........................................2-118


Engine Valve Rotators - Inspect ..............................................................................................2-120

Every 1000 Service Hours or 6 Months

Cooling System Coolant Sample (Level 2) - Obtain ................................................................2-102


Engine Mounts - Check ............................................................................................................2-108

Every 2000 Service Hours or 1 Year

Centrifugal Oil Filter - Inspect ....................................................................................................2-94


Engine Protective Devices - Check ..........................................................................................2-117
Engine Timing, Synchronization, and Valve Lash - Inspect/Adjust ..........................................2-118
Engine Valve Rotators - Inspect ..............................................................................................2-120
Oil Mist Detector - Maintain ......................................................................................................2-128

Every 4000 Service Hours or 1 Year

Aftercooler Core - Clean/Test ....................................................................................................2-86


Air Starting Motor Lubricator Bowl - Clean ................................................................................2-88
Crankshaft Vibration Damper - Inspect ....................................................................................2-105
Driven Equipment - Check ......................................................................................................2-106
Exhaust Shields - Inspect ........................................................................................................2-120
Starting Motor - Inspect ............................................................................................................2-141
Turbocharger - Inspect ............................................................................................................2-147
Water Pump - Inspect ..............................................................................................................2-149

Every 8000 Service Hours or 2 Years

Cooling System Coolant - Change ............................................................................................2-95

Between 12 605 000 and 14 763 000 L (3 330 000 and 3 900 000 US gal) of Fuel or between
10 000 and 12 000 Service Hours

Camshaft Roller Followers - Inspect ..........................................................................................2-94


Engine Oil Temperature Regulator - Replace ..........................................................................2-113
Overhaul (Top End) ..................................................................................................................2-133
Overhaul Considerations ..........................................................................................................2-135
Water Temperature Regulator - Replace..................................................................................2-149

Between 25 211 000 and 29 526 000 L (6 660 000 and 7 800 000 US gal) of Fuel or Between
20 000 and 24 000 Service Hours

Overhaul (Major) ......................................................................................................................2-129


Overhaul Considerations ..........................................................................................................2-135

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Cylinder Overhaul Procedure

Single Cylinder Overhaul

Procedure ....................................................................................................................................3-3
Cylinder Head Removal Initial Steps ............................................................................................3-4
Cylinder Head Removal (3600) ....................................................................................................3-5
Cylinder Head Removal (3618) ....................................................................................................3-7
Cylinder Head Disassembly ........................................................................................................3-9
Cylinder Head Assembly ............................................................................................................3-11
Rod and Piston Removal (3600) ................................................................................................3-12
Rod and Piston Removal (3618) ................................................................................................3-13
Rod and Piston Disassembly ....................................................................................................3-14
Cylinder Liner Removal ..............................................................................................................3-15
Camshaft Segment and Journal Removal (3600) ......................................................................3-16
Camshaft Bearing Removal........................................................................................................3-17
Camshaft Bearing Installation ....................................................................................................3-17
Camshaft Segment and Journal Installation ..............................................................................3-18
Cylinder Liner Installation ..........................................................................................................3-20
Piston / Connection Rod Assembly ............................................................................................3-21
Piston & Connection Assembly Installation (3600) ....................................................................3-22
Piston & Connection Assembly Installation (3618) ....................................................................3-24
Cylinder Head Installation (3600) ..............................................................................................3-27
Cylinder Head Installation (3618) ..............................................................................................3-29
Post Installation Of Cylinder Head ............................................................................................3-32
Crankshaft Position for Fuel Injector Timing & Valve Lash Adjustments....................................3-33
Crankshaft Main Bearing Removal & Installation (3600) ..........................................................3-35
Crankshaft Main Bearing Removal & Installation (3618) ..........................................................3-40

Common Parts

Common Seals, Gaskets & O-Rings ............................................................................................4-2


3600 Combustion Seal Gasket ....................................................................................................4-5
3600 Combustion Seal Gasket ....................................................................................................4-6
Remanufactured Part Number......................................................................................................4-7
Spare Parts List for 3606 & 3608 Marine ....................................................................................4-9

Torques and Specs

Torques for Standard Fasteners ..................................................................................................5-2


Torques & Specifications ............................................................................................................5-3
Guidelines for Reuse of Studs & Bolts ........................................................................................5-7
Wear Limits for Liners ..................................................................................................................5-7
Wear Limits for Pistons and Rings ..............................................................................................5-8
Piston & Piston Ring Specifications..............................................................................................5-8
Crankshaft Deflection for 3600 Engines ......................................................................................5-9
Crankshaft End Play ....................................................................................................................5-9
ABB Turbocharger Wear Limits ....................................................................................................5-9
Alignment Tolerances (Two Bearing Generator Set) ..................................................................5-10

Adjustments

Valve Lash Check ........................................................................................................................6-2


Bridge Adjustment ........................................................................................................................6-5
Fuel Injector Synchronization ......................................................................................................6-6
Adjusting The Governor Linkage On The 3161 Governor............................................................6-7
Adjusting The Governor Actuator Linkage on the EGB................................................................6-9
Fuel Setting Check ....................................................................................................................6-11
Fuel Setting Adjustment..............................................................................................................6-12
Timing Adjustments for Fuel System ..........................................................................................6-12
Fuel Timing ................................................................................................................................6-13
Crankshaft Position for Fuel Injector Timing & Valve Lash Adjustments....................................6-15
Camshaft Journal & Segment Installation ..................................................................................6-17

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Performance & 900 Numbers

Performance Log Sheets..............................................................................................................7-2


Sea Trial: Location Points ............................................................................................................7-5
900 Number Test Locations for 3600 Inline Separate Circuit ......................................................7-7
900 Number Test Locations for 3600 Inline Separate Circuit ......................................................7-7
900 Number Test Locations for 3600 Inline Separate Circuit ......................................................7-8
900 Number Test Locations for 3600 Inline Separate Circuit ......................................................7-8
900 Number Test Locations for 3600 Inline Separate Circuit ......................................................7-9
900 Number Test Locations for 3600 Inline Combined Circuit ....................................................7-9
900 Number Test Locations for 3600 Inline Separate Circuit ....................................................7-11

Conversion Factors

3600 Performance Analysis (Rules of THumb) Alarms & Shutdowns..........................................8-3


Air Intake System ........................................................................................................................8-3
Exhaust System............................................................................................................................8-4
Lubrication System ......................................................................................................................8-5
Fuel System..................................................................................................................................8-6
Cooling System ............................................................................................................................8-7
Misc. System ................................................................................................................................8-8
Test Locations ..............................................................................................................................8-9
Quick Reference Troubleshooting ..............................................................................................8-10
Problem 1 - The Engine Crankshaft WIll Not Turn When The Start Switch is On ....................8-12
Problem 2, 3 - The Engine Will Not Start. ..................................................................................8-13
Problem 4 - The Engine Overspeeds On Start-up ....................................................................8-13
Problem 5 - The Engine Speed Does Not Have Stability ..........................................................8-14
Problem 6 - The Engine’s High Idle Speed is Too Low ..............................................................8-15
Problem 7 - The Engine’s High Idle Declines After Start-Up ....................................................8-15
Problem 8 - The Engine Cannot Be Shutdown Through The Governor ....................................8-16
Problem 9 - The Engine Is Misfiring Or The Engine Is Running Rough ....................................8-16
Problem 10 - The Engine Stalls At Low RPM ............................................................................8-17
Problem 11 - The Engine Does Not Have Enough Power ........................................................8-18
Problem 12 - The Engine Has Too Much Vibration ....................................................................8-19
Problem 13 - Loud Combustion Noise ......................................................................................8-20
Problem 14 - The Engine Has A Valve Train Noise (Clicking) ..................................................8-20
Problem 15 - The Engine Has A Loud Valve Train Noise ..........................................................8-21
Problem 16 - Oil Is In The Cooling ............................................................................................8-21
Problem 17 - Mechanical Noise (Knock) Is In The Engine ........................................................8-22
Problem 18 - Fuel Consumption Is Too High ............................................................................8-22
Problem 19 - Too Much Valve Lash Is Present ..........................................................................8-23
Problem 20 - The Valve Rotocoil Is Free Or Spring Lock Is Free ..............................................8-23
Problem 21 - Oil is At The Exhaust ............................................................................................8-24
Problem 22 - Little Valve Lash Or No Valve Lash Is Present ....................................................8-24
Problem 23 - The Engine Has Early Wear ................................................................................8-25
Problem 24 - Coolant Is In The Lubrication Oil ..........................................................................8-25
Problem 25 - Too Much Black Smoke Or Gray Smoke Is Present ............................................8-26
Problem 26 - Too Much White Smoke Or Blue Smoke Is Present ............................................8-27
Problem 27 - The Engine Has Low Oil Pressure ......................................................................8-27
Problem 28 - The Engine Has High Oil Pressure ......................................................................8-28
Problem 29 - The Engine Uses Too Much Lubrication Oil ........................................................8-28
Problem 30 - The Prelub Pump Is Inoperative Or Slow ............................................................8-30
Problem 31 - The Engine Coolant Is Too Hot ............................................................................8-30
Problem 32 - The Exhaust Temperature Is Too High ................................................................8-31
Problem 33 - The Engine Oil Temperature Is Too High ............................................................8-32
Problem 34 - The Air Inlet Temperature Is Too High ..................................................................8-33
Problem 35 - The Air Starting Motor Does Not Turn ..................................................................8-33
Problem 36 - The Air Starting Motor Turns Slowly Or Air Starting Motor Has Loss of Power....8-34
Problem 37 - The AIr Starting Motor’s Pinion Does Not Engage With The Flywheel ................8-35
Problem 38 - The Air Starting Motor Runs And The Pinion Engages ........................................8-35
Problem 39 - The Air Starting Motor’s Pinion DOes Not Engage Correctly With The Flywheel 8-36

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Problem 40 - The Air Starting Motor’s Pinion Does Not Disengage From The Flywheel ..........8-36
Problem 41 - The Electric Starter Motor Does Not Turn ............................................................8-37
Problem 42 - The Engine’s Crankcase Pressure Is Too High....................................................8-37
Problem 43 - Turbocharger Surge..............................................................................................8-38
Problem 44 - Low Boost Pressure ............................................................................................8-39
Problem 45 - Low Efficiency ......................................................................................................8-41
Changing A Standard Rotation Engine To A Reverse Rotation Engine......................................8-42

Conversion Factors

Conversion Factors Handy Multipliers for Engineers ..................................................................9-2


Conversions ................................................................................................................................9-11
Unit of Measure, Linear Measurements ....................................................................................9-12
Liquid Measure..................................................................................................................9-13
Volume Conversion ..........................................................................................................9-15
Volume and Capacity Conversion ..............................................................................................9-16
Weight Conversion ....................................................................................................................9-16
Power Conversion ......................................................................................................................9-16
Energy Conversion ....................................................................................................................9-17
Length Conversion ....................................................................................................................9-17
Pressure & Head Conversion ....................................................................................................9-17
Area Conversion ........................................................................................................................9-18
Approximate Conversion ............................................................................................................9-19
Making Metric Parts....................................................................................................................9-20
bar to psi ....................................................................................................................................9-21
Temperature Conversion ............................................................................................................9-22
Celcius (Centigrade) Fahrenheit Conversion Table....................................................................9-23
Temperature Conversions, Physics Formulas ............................................................................9-24
Formula for Calculating Horsepower ..........................................................................................9-26
Calculations - English Fuel Rate ................................................................................................9-27
Heat Rate ..................................................................................................................................9-28
Atlantic Distance Table ..............................................................................................................9-29
Pacific Distance Table ................................................................................................................9-30
Geographic Range Table............................................................................................................9-31

Engine System - Distillate Fuel Oil

Engine Fuel System Description ................................................................................................10-2


Engine Fuel Flow Rates ............................................................................................................10-3
Bulk Storage And Delivery Systems ..........................................................................................10-3
Day Tank (Distillate Fuel Service Tank)......................................................................................10-4
Emergency Pump ......................................................................................................................10-4
Setting Tank ................................................................................................................................10-5
Fuel Cleanliness ........................................................................................................................10-5
Water Separation........................................................................................................................10-5
Centerfuges ................................................................................................................................10-6
Suction Strainer ................................................................................................................10-7
Centrifuge Supply Pump ..................................................................................................10-7
Fuel Heater........................................................................................................................10-7
Customer Connections ..............................................................................................................10-7
Flex Connections ........................................................................................................................10-7
Fuel Lines ..................................................................................................................................10-7
Pressure and Flow Monitoring ..........................................................................................10-7
Fuel Recommendations..............................................................................................................10-8
Cetane Number ..........................................................................................................................10-8
Filtering ......................................................................................................................................10-8
Pour Point ..................................................................................................................................10-8
Cloud Point ................................................................................................................................10-8
Sulfur ..........................................................................................................................................10-8
Viscosity......................................................................................................................................10-8
Additives ....................................................................................................................................10-9
Fuel Sulfur Content ....................................................................................................................10-9
Specific Gravity ........................................................................................................................10-10

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Fuel Temperature......................................................................................................................10-10
Fuel Coolers ............................................................................................................................10-10
Day Tank Sizing As A Heat Sink ..............................................................................................10-10
Specific Gravity and Density ....................................................................................................10-10
Day Tank Calculations ..............................................................................................................10-11
Day Tank Thermal Capacity Calculation ..................................................................................10-11
Fuel Heaters ............................................................................................................................10-12
Useful Fuel Formulas and Data................................................................................................10-12
Burning Used Crankcase Oil ....................................................................................................10-13
Centrifuge No.1, No. 2..............................................................................................................10-13
Metering Pump ........................................................................................................................10-13
Static Mixer ..............................................................................................................................10-13
Reference Material ..................................................................................................................10-13
3606 and 3608 Engine Fuel Flow Schematic ..........................................................................10-14
3612 and 3616 Engines Fuel Flow Schematic ........................................................................10-14
Fuel System Schematic............................................................................................................10-15
Distillate Fuel Supply System ..................................................................................................10-15
Distillate Fuel Centrifuge System ............................................................................................10-16
Centrifuge Module Schematic ..................................................................................................10-16

Fuel System - Distillate

Bulk Storage................................................................................................................................11-2
Auxiliary Tank (Day Tank) ..........................................................................................................11-3
Fuel Cleanliness ........................................................................................................................11-3
Traps ..........................................................................................................................................11-4
Water Separation ........................................................................................................................11-4
Customer Connections ..............................................................................................................11-4
Flex Connections ........................................................................................................................11-4
Fuel Lines ..................................................................................................................................11-4
Pressure Monitoring....................................................................................................................11-5
Fuel Recommendations ..............................................................................................................11-5
Cetane Number ..........................................................................................................................11-5
Filtering ......................................................................................................................................11-5
Pour Point ..................................................................................................................................11-5
Cloud Point ................................................................................................................................11-5
Sulfur ..........................................................................................................................................11-5
Viscosity ......................................................................................................................................11-6
Additives ....................................................................................................................................11-6
Fuel Sulfur Content ....................................................................................................................11-6
Engine Fuel System Description ................................................................................................11-7
Pressure Regulator ....................................................................................................................11-8
Unit Injector ................................................................................................................................11-8
Fuel Temperature........................................................................................................................11-8
Day Tank Sizing as Heat Sink ....................................................................................................11-8
Day Tank Calculations ................................................................................................................11-9
Day Tank Thermal Capacity Calculation ....................................................................................11-9
Calculate Fuel Mass..................................................................................................................11-11
Calculate Fuel Oil Mix Temperature..........................................................................................11-11
Calculate Height of Fuel Contained in Day Tank......................................................................11-12
Calculate Heat Transferred Between Fuel in Day Tank and Atmosphere ................................11-13
Calculate Maximum Power Capability ....................................................................................11-15
Conclusion ................................................................................................................................11-16
Heat Rejection / Fuel Flow Data Sheet ....................................................................................11-16
Burning Used Crankcase Oil ....................................................................................................11-17
Continuous Blending ................................................................................................................11-17
Emergency Pump ....................................................................................................................11-17

Reference Material ..................................................................................................................11-19

Diesel Engine Systems - Lubricating Oil


Engine System Description ........................................................................................................12-2
Oil Pumps ..................................................................................................................................12-2

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Emergency Pumps ............................................................................................................12-3


Prelubrication..............................................................................................................................12-3
Customer Supplied Prelub Pumps ............................................................................................12-4
Intermittent/Continuous ..............................................................................................................12-4
Tilt Capability (Marine)................................................................................................................12-5
Wet Sump ..................................................................................................................................12-5
External Sumps ..........................................................................................................................12-5
Under The Engine ............................................................................................................12-5
Remote Sump With Scavenge Pump................................................................................12-6
Piping ................................................................................................................................12-6
Suction Strainer ................................................................................................................12-6
Lube Oil Centrifuge ....................................................................................................................12-6
Centrifuge Supply Pump ..................................................................................................12-7
Pre-Heater ........................................................................................................................12-7
Sample Points ..................................................................................................................12-7
Lube Oil Storage and Transfer System ............................................................................12-7
Clean Oil............................................................................................................................12-7
Dirty Oil..............................................................................................................................12-8
Renovated Oil....................................................................................................................12-8
Transfer Pumps ................................................................................................................12-8
Storage Tanks....................................................................................................................12-8
Oil Guidelines ............................................................................................................................12-8
Caterpillar Micro-Oxidation Test ........................................................................................12-8
Oil Requirements ..............................................................................................................12-9
Commercial Oils ..............................................................................................................12-10
Lubricant Viscosity ..........................................................................................................12-10
Lubricant Total Base Number (TBN)................................................................................12-11
Lube Oil Experience List for 3600 ..................................................................................12-12
Oil Change Interval..........................................................................................................12-13
S•O•S Analysis ................................................................................................................12-13
Wear Analysis..................................................................................................................12-13
Oil Condition Analysis......................................................................................................12-13
TBN (Total Base Number) ..............................................................................................12-13
Viscosity ..........................................................................................................................12-13
Initial Oil Change Interval ................................................................................................12-13
Oil Change Intervals Without Oil Analysis Results..........................................................12-13
Increasing Oil Change Intervals ......................................................................................12-13
Estimating Oil Consumption ....................................................................................................12-14
Oil Consumption As An Overhaul Guide ..................................................................................12-15
Reference Material ..................................................................................................................12-15

Diesel Engine Systems - Lubricating Oil

Engine System Description ........................................................................................................13-2


Oil Pumps ..................................................................................................................................13-2
Emergency Pumps ....................................................................................................................13-3
Prelubrication..............................................................................................................................13-3
Customer Supplied Prelub Pumps ............................................................................................13-4
Intermittent/Continuous ..............................................................................................................13-4
Tilt Capability (Marine)................................................................................................................13-5
External Sumps ..........................................................................................................................13-5
Under The Engine ......................................................................................................................13-5
Remote Sump With Scavenge Pump ........................................................................................13-6
Piping..........................................................................................................................................13-6
Suction Strainer ..........................................................................................................................13-6
Lube Oil Centrifuge ....................................................................................................................13-6
Centrifuge Supply Pump ............................................................................................................13-6
Pre-Heater ..................................................................................................................................13-6
Sample Points ............................................................................................................................13-7
Lube Oil Storage and Transfer System ......................................................................................13-7
Clean Oil ....................................................................................................................................13-7
Dirty Oil ......................................................................................................................................13-7
Renovated Oil ............................................................................................................................13-7

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Transfer Pumps ..........................................................................................................................13-7


Storage Tanks ............................................................................................................................13-7
Oil Guidelines ............................................................................................................................13-8
Caterpillar Micro-Oxidation Test ................................................................................................13-9
Oil Requirements ........................................................................................................................13-9
Commercial Oils ......................................................................................................................13-10
Lubricant Viscosity....................................................................................................................13-10
Lubricant Total Base Number (TBN) ........................................................................................13-10
Lube Oil Experience List for 3600 ............................................................................................13-11
Oil Change Interval ..................................................................................................................13-12
S•O•S Analysis ........................................................................................................................13-12
Wear Analysis ..........................................................................................................................13-12
Causes & Effects of Contamination & Degradation..................................................................13-12
Viscosity....................................................................................................................................13-13
Oil Change Intervals Without Oil Analysis Results ..................................................................13-16
Total Base Number for Distillate Fuel Engines ........................................................................13-16
Increasing Oil Change Intervals ..............................................................................................13-16
Estimating Oil Consumption ....................................................................................................13-17
Oil Consumption As An Overhaul Guide ..................................................................................13-17
Reference Material ..................................................................................................................13-19

Cooling Systems

Specifications..............................................................................................................................14-2
Water ..........................................................................................................................................14-2
Water Testing ....................................................................................................................14-2
Antifreeze Content ............................................................................................................14-2
Conventional Antifreeze ....................................................................................................14-2
Extended Life Coolant ......................................................................................................14-3
Extended Life Coolant (ELC) Cooling System Maintenance......................................................14-4
Caterpillar ELC Extender ..................................................................................................14-4
Adding Caterpillar ELC Extender ......................................................................................14-4
Formula For Adding Extender to ELC ..............................................................................14-4
Diesel Antifreeze/Coolant (DEAC) ....................................................................................14-4
Supplemental Coolant Additive (SCA) ..............................................................................14-5
Supplemental Coolant Additive (SCA) to Conventional Coolant at Initial Fill ..................14-5
Supplemental Coolant Additive (SCA) to Conventional Coolant for Maintenance............14-6
Water/Supplement Coolant Additive..................................................................................14-6
Adding the SCA to Water at the Initial Fill ........................................................................14-7
Adding the SCA to Water for Maintenance ......................................................................14-7
Procedure for Testing Coolant Conditioner Levels............................................................14-7
S·O·S Coolant Analysis ..............................................................................................................14-9

Diesel Engine Systems - Fresh Water Cooling

Operating Parameters ................................................................................................................15-2


Basic System Configurations......................................................................................................15-2
Combined Circuit ........................................................................................................................15-2
Separate Circuit ..........................................................................................................................15-2
Engine Coolant Flow Control......................................................................................................15-2
Temperature Regulation ............................................................................................................15-3
Water Pumps ..............................................................................................................................15-3
Standby Pumps ..........................................................................................................................15-3
Flow Requirements ....................................................................................................................15-5
Heat Rejection ............................................................................................................................15-5
Aftercooler Correction Factors....................................................................................................15-5
Heat Rejection Tolerances..........................................................................................................15-6
Heat Exchanger ..........................................................................................................................15-6
Heat Exchanger ..........................................................................................................................15-7
Heat Exchanger Sizing ..............................................................................................................15-7
Expansion Tanks ........................................................................................................................15-8
Expansion Tank Volume ............................................................................................................15-9
System Pressures ....................................................................................................................15-11

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Water Pump ..............................................................................................................................15-11


Maximum Operating Pressures ................................................................................................15-11
External Circuit Resistance ......................................................................................................15-11
3606 and 3608 Combined Circuit ............................................................................................15-13
Keel Coolers ............................................................................................................................15-13
Fabricated Cooler Performance and Sizing ............................................................................15-13
Application ................................................................................................................................15-14
Baseline Performance Conditions ............................................................................................15-15
Correction Factors ....................................................................................................................15-16
Worksheet ................................................................................................................................15-17
Design/Installation Considerations ..........................................................................................15-17
Bypass Filters ..........................................................................................................................15-17
Strainers....................................................................................................................................15-17
Packaged Keel Coolers ............................................................................................................15-17
Keel Cooler Location ................................................................................................................15-17
Keel Cooler Sizing Worksheet..................................................................................................15-18
Keel Cooler Circuit Pump ........................................................................................................15-19
Keel Cooler Venting..................................................................................................................15-19
Marine Gear Heat Rejection ....................................................................................................15-19
Piping........................................................................................................................................15-19
Cleanliness ..............................................................................................................................15-19
Venting......................................................................................................................................15-19
Line Sizing ................................................................................................................................15-20
Connections..............................................................................................................................15-20
Jacket Water Heating System ..................................................................................................15-20
Water Treatment ......................................................................................................................15-21
System Monitoring ....................................................................................................................15-22
Serviceability ............................................................................................................................15-22
System Design ........................................................................................................................15-22
Design Forms ..........................................................................................................................15-22
Heat Recovery ..........................................................................................................................15-23
Heat Balance Example ............................................................................................................15-24

Cooling System

Basic Operating Parameters ......................................................................................................16-2


Basic System Configurations......................................................................................................16-2
Coolant Flow Control ..................................................................................................................16-3
Coolant Temperature Control ....................................................................................................16-3
Water Pumps ..............................................................................................................................16-4
Expansion Tanks ........................................................................................................................16-4
Types of Cooling ........................................................................................................................16-5
Radiator Cooling ........................................................................................................................16-5
Heat Exchanger Cooling ............................................................................................................16-7
Central Cooling Systems ............................................................................................................16-7
System Pressures ......................................................................................................................16-7
Venting........................................................................................................................................16-9
Line Sizing ..................................................................................................................................16-9
Connections................................................................................................................................16-9
Heaters ......................................................................................................................................16-9
Cleanliness ................................................................................................................................16-9
System Monitoring ....................................................................................................................16-10
Serviceability ............................................................................................................................16-10
Water Quality, Rust Inhibitors, and Antifreeze ..........................................................................16-10
Radiator Sizing..........................................................................................................................16-11
Heat Exchanger Sizing ............................................................................................................16-11
Fouling Resistance for Water ..................................................................................................16-12
Heat Rejection and Related Parameters..................................................................................16-12
Aftercooler Correction Factors..................................................................................................16-12
Heat Rejection Tolerances........................................................................................................16-12
Heat Exchangers ......................................................................................................................16-13
Radiators ..................................................................................................................................16-13
External Circuit Resistance ......................................................................................................16-14

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System Pressures ....................................................................................................................16-16


Line Velocities ..........................................................................................................................16-16
Temperature Regulation ..........................................................................................................16-16
Expansion Tank Volume ..........................................................................................................16-17
Water Treatment ......................................................................................................................16-18
Emergency Pumps ..................................................................................................................16-18

Engine Systems - Air Intake

Engine Room Intake Air..............................................................................................................17-2


Combustion Air ..........................................................................................................................17-2
Filtered Air To Engine Room ......................................................................................................17-3
Outside Air To Engine Air Filters ................................................................................................17-4
Air Cleaners Outside The Engine Room ....................................................................................17-4
Air Cleaners In The Engine Room..............................................................................................17-4
Cleanliness ................................................................................................................................17-4
Inlet Restriction ..........................................................................................................................17-4
Mass/Volume Flow Conversions ................................................................................................17-4
Caterpillar Air Cleaners ..............................................................................................................17-5
Precleaners ................................................................................................................................17-6
Air Cleaner Dimensions..............................................................................................................17-6
Air Cleaner Restriction................................................................................................................17-6
Air Intake Silencer ......................................................................................................................17-7
Air Inlet Adapters ........................................................................................................................17-7
Flex Connections ........................................................................................................................17-9
Air Inlet Shut Off ........................................................................................................................17-9
Turbocharger Speed Sensor ......................................................................................................17-9
Turbocharger Loading ................................................................................................................17-9
Turbocharger Air Inlet Design ....................................................................................................17-9
Ventilating Air Calculation Guide ................................................................................................17-9
Design Conditions ....................................................................................................................17-10
Engine Room Air Flow Calculations ................................................................................17-10
Combustion Air Flow Requirements ................................................................................17-10
Air Flow Requirements For Removal Of Radiated Heat ..........................................................17-12
Heat Radiated From Propulsion Engine..........................................................................17-12
Heat Radiated From Generator Set Engines ..................................................................17-12
Heat Rejected From Boilers ....................................................................................................17-12
Heat Rejected From Steam And Condensate Pipes ................................................................17-13
Heat Rejected From Electrical Equipment ..............................................................................17-14
Heat Rejected From Exhaust Pipes ........................................................................................17-14
Heat Rejected From Hot Tanks ................................................................................................17-14
Heat Rejected From Other Machinery......................................................................................17-15
Total Air Flow For Removal of Machinery Rejected Heat ........................................................17-15

Air Intake Systems

General ......................................................................................................................................18-2
Outside Ducting ................................................................................................................18-2
Air Cleaners ......................................................................................................................18-2
Engine Air Flow (General) ..........................................................................................................18-2
Turbocharger Air Plenum ..................................................................................................18-2
Aftercooler ........................................................................................................................18-2
Air Cleaner Piping ............................................................................................................18-2
Air Inlet Shut Off ................................................................................................................18-2
Inlet Air Flow ..............................................................................................................................18-2
Ducting ..............................................................................................................................18-3
Flex Connections ..............................................................................................................18-3
Turbocharger Loading ......................................................................................................18-3
Turbocharger Air Inlet Design............................................................................................18-5
Cleanliness ........................................................................................................................18-6
Maximum Loads For Turbocharger Intake ................................................................................18-7
Turbo Vertical Inlet Design Options ............................................................................................18-8

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Inlet Pipe Design Joining Two Turbochargers ............................................................................18-9


Turbocharger Inlet Design Option For Axial Compressor Inlet ................................................18-10
Air Cleaner Dust Calculation ....................................................................................................18-10
Inlet Air Duct Insulation ..................................................................................................18-12
Air Cleaner Icing..............................................................................................................18-13
Extreme Cold ..................................................................................................................18-13

Diesel Engine Exhaust Systems

Manifolds ....................................................................................................................................19-2
Exhaust Back pressure Limits ....................................................................................................19-2
Exhaust Back pressure Calculations ..........................................................................................19-5
Exhaust Flow ..............................................................................................................................19-5
Mass/Volume Conversions ........................................................................................................19-5
Exhaust Connections..................................................................................................................19-5
Turbocharger ..............................................................................................................................19-5
Flexible Connections ..................................................................................................................19-7
Exhaust Piping............................................................................................................................19-9
Cleanliness ................................................................................................................................19-9
Silencer ......................................................................................................................................19-9
Silencer Data ............................................................................................................................19-10
Exhaust Noise ..........................................................................................................................19-13
Exhaust Gas Economizer ........................................................................................................19-13
Exhaust Slobber ......................................................................................................................19-13
Emissions ................................................................................................................................19-13
Nitrogen Oxide..........................................................................................................................19-13
Hydrocarbons ..........................................................................................................................19-14
Particulates ..............................................................................................................................19-14
Carbon Monoxide ....................................................................................................................19-14
Carbon Dioxide ........................................................................................................................19-14
Sulfur Dioxide ..........................................................................................................................19-15
3600 Emissions Data................................................................................................................19-15
Effect of Ambient Conditions ....................................................................................................19-15
Control Methods ......................................................................................................................19-15
Measurement Units and Conversions ......................................................................................19-16

Exhaust Systems

Manifolds ....................................................................................................................................20-3
Exhaust Back Pressure ..............................................................................................................20-3
Piping..........................................................................................................................................20-4
Flexible Connections ..................................................................................................................20-5
Maximum Loads for Turbocharger Exhaust ..............................................................................20-6
Exhaust Connections..................................................................................................................20-7
Exhaust Slobber ................................................................................................................20-7
Cleanliness ........................................................................................................................20-8
Silencer Selection and Installation..............................................................................................20-8

Engine Systems - Crankcase Ventilation


Crankcase Ventilation ................................................................................................................21-2

Ventilation Systems

Engine Room ..............................................................................................................................22-2


Crankcase Ventilation ................................................................................................................22-4

Commissioning Guide

Design Review............................................................................................................................23-2
General ......................................................................................................................................23-2
Explanation of Design Review Report........................................................................................23-2

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Unsatisfactory System Design Review or Installation Audit ......................................................23-2

Explanation of the Installation Audit Report..............................................................................23-12


Air Intake System ............................................................................................................23-12
Cooling System ..............................................................................................................23-12
Starting System ..............................................................................................................23-17
Exhaust System ..............................................................................................................23-19
Fuel System ....................................................................................................................23-20
Governors/Actuators........................................................................................................23-21
Lubrication System..........................................................................................................23-21
Mounting and Alignment..................................................................................................23-22
Driven Equipment............................................................................................................23-22
Safety System ................................................................................................................23-23
Monitoring System ..........................................................................................................23-23
Ventilation ........................................................................................................................23-24
Serviceability ..................................................................................................................23-24
Equipment Safety ............................................................................................................23-25
Propulsion System Control..............................................................................................23-25
Operation and Maintenance ............................................................................................23-26
Crankcase Ventilation System ........................................................................................23-26
Main Propulsion Installation Audit Report ................................................................................23-27
Dock Trials ................................................................................................................................23-36
3600 Commissioning Sensor Points ........................................................................................23-37
3600 Commissioning Instruments Sensing ..............................................................................23-38
Location by Function ......................................................................................................23-39
Sea Trials..................................................................................................................................23-41
Engine Performance Data ........................................................................................................23-42
Performance Analysis Report ..................................................................................................23-44
Sea Trials Conditions................................................................................................................23-45

Commissioning Guide

Design Review............................................................................................................................24-3
Introduction........................................................................................................................24-3
Explanation of Design Review Report ..............................................................................24-3
Design Review Report ......................................................................................................24-3
Design Review Results ..............................................................................................................24-3
3600 Generator Set Design Review Report......................................................................24-4
Explanation of Construction Review Report......................................................................24-4
Design Review Results ....................................................................................................24-6
Construction Review ................................................................................................................24-10
Air Intake System Evaluation....................................................................................................24-17
Combustion Air ................................................................................................................24-17
Remote Mounted Air Cleaners ........................................................................................24-17
Air Inlet Ducting ..............................................................................................................24-18
Filtered Engine Room Air ................................................................................................24-18
Air Cleaner Provided by Others ......................................................................................24-18
Cooling System Evaluation ......................................................................................................24-18
Engine Cooling Circuits ..................................................................................................24-18
System Coolers ..............................................................................................................24-19
Cooling System External Pressure Drop ........................................................................24-19
Expansion Tanks ............................................................................................................24-19
Cooling System Protection ..............................................................................................24-20
Central Cooling Systems ................................................................................................24-20
External System Piping ..................................................................................................24-20
Corrosion Protection........................................................................................................24-21
Heat Recovery ................................................................................................................24-21
Cooling System Performance..........................................................................................24-21
Starting System Evaluation ......................................................................................................24-21
Air Compressor ..............................................................................................................24-21
Air Receiver Tanks ..........................................................................................................24-21
Air Supply Piping ............................................................................................................24-22
Engine Starters and Accessories ....................................................................................24-22

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Alternate Forms of Starting ............................................................................................24-22

Exhaust System Evaluation......................................................................................................24-22


Exhaust System Warnings ..............................................................................................24-22
Exhaust System Piping ..................................................................................................24-23
Distillate Fuel System Evaluation ............................................................................................24-23
Fuel Tanks ......................................................................................................................24-23
Fuel Lines........................................................................................................................24-24
Fuel Filters ......................................................................................................................24-24
Fuel Coolers ....................................................................................................................24-24
Governors and/or Actuators ............................................................................................24-24
Lubrication System Evaluation ................................................................................................24-24
Engine Oil........................................................................................................................24-25
Engine Sump ..................................................................................................................24-25
Engine Prelube................................................................................................................24-25
Oil Pressure and Temperature ........................................................................................24-25
Mounting and Alignment Evaluation ........................................................................................24-25
Vibration Isolators............................................................................................................24-25
Engine Base ....................................................................................................................24-26
Engine to Generator Alignment ......................................................................................24-26
Driven Equipment Evaluation ..................................................................................................24-26
Generator ........................................................................................................................24-26
Safety System Evaluation ..............................................................................................24-27
Engine Contactors ..........................................................................................................24-27
Generator Safety Relays ................................................................................................24-27
External Engine Support Systems ..................................................................................24-27
Emergency Stops ............................................................................................................24-27
Monitoring System ....................................................................................................................24-27
Engine Operating Parameters ........................................................................................24-27
Generator Operating Parameter......................................................................................24-28
External Engine Support Systems ..................................................................................24-28
Daily Log Sheet ..............................................................................................................24-28
Ventilation Evaluation ..............................................................................................................24-28
Engine Room Ventilation ................................................................................................24-28
Switchgear Room Ventilation ..........................................................................................24-29
Serviceability Evaluation ..........................................................................................................24-29
Engine Component Removal ..........................................................................................24-29
Engine Maintenance........................................................................................................24-29
Reserved Work Area ......................................................................................................24-29
Spare Parts Storage ........................................................................................................24-29
Equipment Safety Evaluation ..................................................................................................24-29
Engine Room ..................................................................................................................24-29
Control Room ..................................................................................................................24-30
Generator Control Evaluation ..................................................................................................24-30
Generator Voltage Control ..............................................................................................24-30
Generator Monitoring ......................................................................................................24-30
Switchgear Evaluation ..............................................................................................................24-31
Switchgear Cabinets ......................................................................................................24-31
Current and Potential Transformers ................................................................................24-31
Circuit Breakers ..............................................................................................................24-31
Electrical Cables..............................................................................................................24-31
Generator Protective Relays ..........................................................................................24-31
Control Voltage ................................................................................................................24-31
Paralleling Operations ....................................................................................................24-31
Operation and Maintenance Evaluation ..................................................................................24-32
Engine Operation and Maintenance................................................................................24-32
Engine Support Equipment ............................................................................................24-32
Mechanical Training ........................................................................................................24-32
Maintenance Contracts ..................................................................................................24-32
Crankcase Ventilation System Evaluation................................................................................24-32
Crankcase Breathers ......................................................................................................24-32
Crankcase Ventilation Piping ..........................................................................................24-32
Startup and Shutdown Procedure ............................................................................................24-33
Analysis of Test Data and Physical Systems ..........................................................................24-35
Engine Performance Data Form ..............................................................................................24-39
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C280 ..........................................................................................................................................25-1

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Service Support

Index Page

Service Support Center ................................................................................................................1-2


Locations For Information ............................................................................................................1-2
Introduction ..................................................................................................................................1-4
3600 Engine Family......................................................................................................................1-3
Marine Ratings, Conditions, 3600 Engine Features, Engine Model ............................................1-5
Specifications................................................................................................................................1-7
Propulsion Engine Dimensions, Caterpillar Gen Set Dimensions................................................1-8
Service Removal Distance In-line Engine ....................................................................................1-8
Publications ................................................................................................................................1-11
How to order a “Serial Number Specific Parts Book ..................................................................1-11
How to order a “Technical Manual ..............................................................................................1-11
Reference Publication Form Numbers........................................................................................1-11
Guidelines For Reusable Parts & Salvage Operations Publications..........................................1-13
Customer / Dealership Performance Information ......................................................................1-14
Plate Information ........................................................................................................................1-17

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Service Support Center


A new Service Support Center is available for the products that are assembled at the Large
Engine Center. This new Service Support Center is intended to be the starting point for Customer
Service inquiries about the above engines. This new Service Support Center will primarily be for
North American Dealers. Dealers that are outside of North America should contact the office of the
local Marketing Profit Center with any issues that require additional information. The service
support center will handle questions and issues that are related to the product after the engine
commissioning has occurred. For inquiries that occur before the engine commissioning or during
the engine commissioning, please contact the Application Support Group. The new Service
Support Center is open Monday through Friday during normal working hours. Customer Service
inquiries should be directed to the locations that follow:

Phone: 765-448-2200

Fax: 765-448-2222

E-mail: lecservicesupport@cat.com

internet: https://lecservicesupport.cat.com

Locations For Information About Products That Are Assembled in The


Griffin, Georgia Facility
For information about 3100 - 3500 Generator Sets, call the phone number that follows: Phone:
770-233-5630

For information about Power Modules and Enclosures, call the phone number that follows:
Phone: 770-233-4041

For information about Electronic Modular Control Panels, Uninterruptible Power Supplies and
Automatic Transfer Switches, call the phone number that follows:

Phone: 770-233-5877

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Locations For Information About Custom Kato Generators


The Product Service manager for Custom 3500 Generators and Custom 3600 Generators is
available at the locations that follow: Phone: 507-345-2821

E-mail: soost.john@LSUSA.com
The Warranty and Repair Manager for Custom 3500 Generators and Custom 3600 Generators is
available at the locations that follow: Phone: 507-345-2828

E-mail: kowceun.nick@LSUSA.com

Locations For Information About Remanufactured Products


A Hotline for remanufactured products is available at the locations that follow:

Phone: 888-887-3626

E-mail: reman_help@cat.com

Locations For Information About The Application and Installation Of


The Products That Are Assembled At The Large Engine Center
Information about the application and installation of the products that are assembled at the Large
Engine Center is available at the locations that follow:

Phone: 765-448-2400

Fax: 765-448-2300

E-mail: applicationsupport@cat.com

internet: http://applicationsupport.cat.com

internet: https://3600.cat.com

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Introduction

This Maintenance And Technical Service (MATS) Book enables dealers and their customers to
benefit from cost reductions made possible through an established parts reusability and salvage
program. Every effort has been made to provide the most current and relevant information known
to Caterpillar Inc. Since the Company makes on going changes and improvements to its products,
this Guideline must be used with the latest technical information available from Caterpillar to
ensure such changes and improvements are incorporated where applicable. This booklet is a
quick reference guide for service information on the 3600 Diesel Engines. This guide
complements, but not replace the following Caterpillar Service Manuals:

• Standard Bolt Torque


• Specifications
• System Operation Testing & Adjusting
• Dis-assembly and Assembly
• Operation & Maintenance Guide
• Parts Book
Please see these manuals for more details on the service needs of the 3600 Diesel Engine. The
ordering numbers for these manuals are in the reference publication section of this pocket guide.

3600 Engine Family


Whether your needs are marine, industrial, or electric power generation, the Caterpillar 3600
Engine Family will provide you with proven power to get the job done. The 3600 Engines are the
most powerful and reliable power sources ever produced by Caterpillar. Operating economy and
durability make it the logical choice; worldwide product support makes it the only choice.

The 3618 Marine Propulsion Engine is the newest addition to the 3600 Engine Family. It was
specifically designed to meet the needs of our marine fast ferry customers. For more information
on the new Caterpillar 3600 engine, consult your local Caterpillar Dealership.

This 3600 Series Engine "Maintenance and Technical Service" (MATS) Handbook & Check List
will assist certified technicians, dealers and customers as a quick reference to certain engine
history background, part numbers, torques, procedures, troubleshooting, conversions, and
documenting the condition of engine and components during maintenance intervals and at time of
overhaul. After the overhaul is completed, some pages from this document maybe copied and
placed in the engine history file for future reference or this MATS book can be the engines own
history book and kept close to the engine as a quick reference.

Note: This handbook is intended to be used as an aid to the Technician and NOT as a
replacement for the Service Manuals, Parts Books or other Technical Data
Books.

Rating Definitions
Generator Set Ratings
Continuous Rating: Typical application is base load generator set, 8000 hrs/year, load factor < =
100%, 10% overload.

Prime Power: Typical application is peak shaving, 6000 hrs/year, load factor < = 60%. Rated load
(100%) usage is 1 hour in 12, 10% overload.

Standby: Typical application is emergency generator set, < 200 hrs/year, 100% during emergency
outage, no overload.

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Marine Ratings
Continuous Service Rating (CSR): Typical application is U.S. inland river vessel, continuous
engine operation, fuel stop power equals rated power.

Maximum Continuous Rating (MCR): Typical application is tugboat, 1 hour in 12 at rated power,
fuel stop power equals rated power.

Conditions
The following engine ratings are based on SAE J1995 January 1990 and ISO 3046 standard
conditions of 100 kPa (99 kPa dry barometric pressure) and 25° C air. Performance and fuel
consumption are based on 35 API, 16°C fuel having an LHV of 42 780 kJ/kg used at 29° C with a
density of 838.9 g/L. Tolerances include -0/+5% on specific fuel consumption and ±3% on brake
kilowatt power at the flywheel demonstrated at the Caterpillar production test cell. The maximum
inlet air temperature to the turbocharger is 45° C before derating. Engine ratings are net power
and include deduction for the following parameters: cooling water pumps, lube oil pumps, fuel
pump, typical exhaust restriction, and typical air filter restriction.

3600 Engine Features


The 3600 Engine Family is a modern, highly efficient engine series consisting of in-line six and
eight cylinder engines and vee engines of 12, 16 and 18 cylinders. These are four stroke, non-
reversible engines rated at speeds from 720 to 1000 rpm with the 3618 going to a maximum 1050.
They are turbocharged and aftercooled with a direct injection fuel system that uses unit fuel
injectors.

Engine Model
3606 ---------------------------------------------------------------------------------- In-line 6 cylinder

3608 ---------------------------------------------------------------------------------- In-line 8 cylinder

3612----------------------------------------------------------------------------------- Vee 12 cylinder

3616------ ---------------------------------------------------------------------------- Vee 16 cylinder

3618 ---------------------------------------------------------------------------------- Vee 18 cylinder

1-5 10/2005
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Weights of Piece Parts:


kg. lbs.
Engine 3606 15700 34500
3608 20412 45000
3612 25140 55300
3616 30418 67000
Block 3606 4180 9200
3608 5584 12300
3612 6646 14620
3616 8630 18986
Oil Pan 3606 564 1241
3608 735 1617
3612 628 1385
3616 661 1457
Crankshaft 3606 a900 4185
3608 2400 5290
3612 2091 4600
3616 2602 5750
Main Bearing Cap 69 152
Crankshaft Adapters 77 170
Crankshaft Gear 38 83
Damper Narrow 228 639
Wide 402 886
Flywheel 499 1100
Front Housing 258 569
Rear Housing 456 1005
Engine Support 64 141
Camshaft Drive Gear 44 96
Camshaft Journal 6
Camshaft Segment 29 63
Piston 38 82
Piston Pin 20 42
Connecting Rod 61 134
Connecting Rod Cap 16 35
Piston Rod Assembly 102 225
Cylinder Head 235 517
Cylinder Liner 128 282
Oil Pump 104 230
Water Pump 120 265
Oil Coolers 137 302
Aftercooler Housing 236 520
Aftercooler Cover 45 99
Aftercooler Core 104 232
Turbocharger 401 883

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Specifications
Bore - mm (in) ------------------------------------------ 280 (11)

Stroke - mm (in) ---------------------------------------- 300 (11.8)

Displacement per cyl. L (in 3 -------------------------- 18.5 (1127)

Rotation (from flywheel end) --------------------------- cw or ccw

Compression Ratio (Distillate/HFO) ----------------- 13.0:1/12.4:1

Aspiration --------------------------------------------------- Turbocharged/Aftercooled

Rated Speed (3606, 3608, 3612, 3616)------------- 720-1000 rpm

Rated Speed (3618)-------------------------------------- 1050

Piston Speed m/s (ft/s) --------------------------------- 7.2 (23.6) -10.0 (32.8)

Engine blocks are made from a heavily ribbed, one piece gray iron alloy casting. Integral air
intake plenums run the full length of the block, providing an even air distribution to the cylinders.
The engine block is designed for four or six point mounting.

Crankshafts are forged with a continuous grain flow, induction hardened, and re-grindable.
Counterweights at each cylinder are welded to the crankshaft and ultrasonically inspected to
assure weld integrity. The crankshaft end flanges are identical, allowing full power to be taken
from either end.

Pistons are two-piece with a forged steel crown and forged aluminum skirt. This piston
construction ensures excellent strength and durability, and minimal weight. Pistons have four
rings - two in hardened grooves in the piston crown, and two in the skirt. The top ring is plasma
coated; this provides extra wear resistance and lowers lube oil resistance and consumption. The
two middle rings are taper faced and chrome plated. The lower oil control ring is double rail and
chrome faced with a spring expander.

Main bearings are made of steel backed aluminum with a nickel bonded lead/tin/copper overlay.
Rillenlager technology, which alternates stripes of aluminum and overlay on the surface, is used.
This provides higher load carrying capability and reduces wear rates when compared to trimetal
aluminum bearings. The bearings have no grooves in the lower bearing shell. This greatly
reduces unit pressure loading when compared to grooved bearings.

Rod and camshaft bearings are made of steel backed aluminum with a copper bonded lead/tin
overlay. Aluminum bearing material provides better characteristics in the areas of heat
conduction, resistance against corrosion, and ability to embed small particles that may otherwise
damage journal surfaces. Bearings have no grooves, greatly reducing unit pressure load on the
bearings.

Cylinder liners are induction hardened. The combination of induction hardened liners, one
chrome/plasma-coated piston top ring, and three chrome-coated piston rings provides the lowest
wear on running surfaces. The 3600 liners are plateau honed for better oil control. Located at the
top of the liner is a sleeve or "cuff" that removes carbon deposits from the top land of the piston.
This sleeve prevents the loss of oil control and reduced cylinder liner life by preventing carbon
deposits from accumulating and polishing the cylinder liner.

Connecting rods are forged, heat treated, and shot peened before machining. The special four-
bolt design and the elimination of bearing grooves allows for an extra large bearing which
reduces bearing load and extends bearing life.

Valves seat on replaceable induction-hardened inserts. Rotators on all valves maintain uniform
temperature and wear pattern across the valve face and seat. The exhaust valves used in heavy
fuel engines are given special attention to extend their life. The exhaust valve temperature is
reduced to approximately 410° C to minimize the possibility of vanadium induced corrosion. A
mnemonic 80A material is used in the exhaust valve. The valve head is coated with ceramics
and water-cooled valve seats are used to maintain the low valve temperatures.

1-7
12/2004
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Propulsion Engine Dimensions

Caterpillar Generator Set Dimensions

1-8 10/2005
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1-9 10/2005
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1 - 10 10/2005
01 Maint-Serv_ServSupport.qxd 2/20/2006 12:28 PM Page 11

Publications
A set of the following publications should have been sent with engine.

- Service Manual (contains):

• Product Safety
• Service Manual Contents Sheet
• Torque Specifications
• Engine Specifications
• System Operation / Testing & Adjusting
• Disassembly & Assembly
- The Parts Book (serial number specific custom parts book contains all the standard Caterpillar
production parts).

- Technical Manual (contains all the custom iron for that specific engine(s).

- Special Instructions (any related)

How to order a "Serial Number Specific Parts Book.”


- Place a Caterpillar literature order media number: SEBP3600 and specify the serial number of
the engine.

How to order a "Technical Manual.”


- Place a "Miscellaneous Engine Order" with the Caterpillar Subsidiary specifying the price list
sales code (905.5) and the engine serial number.

Reference Publication Form Numbers


SEBU6965 3600 Diesel Operation & Maintenance Manual (Distillate)
SEBU6966 3600 Diesel Operation & Maintenance Manual (Heavy Fuel)
SENR3599 System Operation Testing & Adjusting (inline)
SENR3593 System Operation Testing & Adjusting (vee)
SENR3600 Dis-assembly & Assembly Manual (inline)
SENR3594 Dis-assembly & Assembly Manual (vee)
SENR3598 Specifications Manual (inline)
SENR3592 Specifications Manual (vee)
RENR1338 UG Actuators
SENR3585 2301A Governor
SENR6473 721 Digital Governor
SENR2228 723 Plus Governor
SENR3028 3161 Governor
SENR6444 PGEV & PGE Governors (Locomotive application)
SENR4622 Heinzman Governor (Generator Set)
SENR4661 Heinzman Governor (Marine)
LECQ4021 3600 Family of Heavy Fuel Engines
LECQ4022 3600 Family of Engines

1 - 11 10/2005
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Reference Publication Form Numbers (cont.)


LEXQ7766 3600 Engine Family Pocket Guide
YEHS0201 3600 Diesel Service Pocket Guide
LEDQ8363 3600 Diesel Lube Oil Selection
LEHX5458 3600 Family Generator Sets for Heavy Fuel (spec sheet)
LEHX5459 3600 Family Generator Sets (spec sheet) Performance Data
PEHP7076 Understanding the S.O.S Oil Analysis Test
RENR1357 Diesel Plant Operation Handbook
RENR1358 3600 Diesel Service Handbook (3-Volume Set)
SEBD0640 Oil & Your Engine
SEBD0717 Diesel Fuels & Your Engine
SEBD0970 Coolant & Your Engine
SEBD9129 3600 Engine News Special Edition (all Articles from 10/85 to 10/99)
SEBU7003 3600 Fluids Recommendations for Lube Oil, Fuel & Coolants
SELU6965 Maintenance Wall Chart (distillate)
SELU6966 Maintenance Wall Chart (heavy fuel)
SENR4619 3600 Marine Propulsion Emergency Repair Procedures
LEKM9011 3600 Marine Monitoring System
SEBU7134 Marine Monitoring System (MMS) Owners Manual
RENR2458 Electric Schematic for MMS
REHS0257 Installation & Commissioning Special Instructions
LEXM8589 Product News (MMS)
RENR2225 Service Manual for Oil Mist Detector
SEBP3773 Parts Book for 3612
SEBP3768 Parts Book for 3608
SEBP3762 Parts Book for 3616
SEBP3771 Parts Book for 3616
SEBU6103 Schedules for Equipment Maintenance
SELU6121 3600 Maintenance Mgt. Recommendation
SEBR3595 Service Manual 3606-3608
SEBR3590 Service Manual 3612-3616
SEHS9031 Special Instructions Storage
NENG7002 3600 Tool Guide
LEBV0546 Maintenance and Technical Handbook (MATH)
LEKQ4028 Oil Consumption Data
SEHS9929 Turbo Wash Procedure
LEKQ6070 Blending Crankcase Oil with Fuel
RENR5851 Service Manual for 150-7700 Tachometer
RENR2493 Service Manual for Engine Control Panel
LERV0530 CD of Maintenance And Technical Handbook (Math)
REHS0285 D&A of the NAPIER NA297 Turbocharger
PELE0776 New Service Center for 3600 Engine Components
RENR2459 Electrical System Schematics for 3600 MMS II & GMS II

1 - 12 10/2005
02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 1

Maintenance Interval Schedule - Distillate Fuel of the 3606, 3608, 3612


& 3616 Engines.

Before performing any operation or maintenance procedures, ensure that the Safety
Information , warnings, and instructions are read and understood.
To determine the maintenance intervals, use service hours or calendar time, which ever occurs
first.

Before each consecutive interval is performed, all of the maintenance requirements from the
previous interval must be performed.

Note: For information on generator maintenance, see the Operation and Maintenance
Manual for the generator.

When Required

Centrifugal Oil Filter - Inspect ....................................................................................................2-13


Cooling System Coolant Sample (Level 2) - Obtain ..................................................................2-21
Engine Air Cleaner Element - Replace ......................................................................................2-27
Engine Crankcase Breather - Clean ..........................................................................................2-32
Engine Oil - Change ..................................................................................................................2-35
Engine Oil Filter - Change ..........................................................................................................2-38
Fuel Analysis - Obtain ................................................................................................................2-50
Fuel System - Prime ..................................................................................................................2-51
Fuel System Primary Filter/Water Separator Element - Replace ..............................................2-53
Fuel System Secondary Filter - Replace....................................................................................2-54
Metal Particle Detector - Inspect ................................................................................................2-60
Zinc Rods - Inspect/Replace ......................................................................................................2-85

Every Service Hour

Trend Data - Record ..................................................................................................................2-75

Daily

Air Starting Motor Lubricator Oil Level - Check ..........................................................................2-10


Air Tank Moisture and Sediment - Drain ....................................................................................2-11
Cooling System Coolant Level - Check......................................................................................2-19
Driven Equipment - Inspect/Replace/Lubricate ..........................................................................2-26
Engine Air Cleaner Service Indicator - Inspect ..........................................................................2-31
Engine Air Precleaner - Clean ....................................................................................................2-31
Engine Oil Level - Check............................................................................................................2-41
Fuel System Primary Filter/Water Separator - Drain..................................................................2-52
Fuel Tank Water and Sediment - Drain ......................................................................................2-57
Governor Actuator Oil Level - Check..........................................................................................2-62
Instrument Panel - Inspect ........................................................................................................2-59
Walk-Around Inspection..............................................................................................................2-82

Every 50 Service Hours or Weekly

Zinc Rods - Inspect/Replace ......................................................................................................2-85

Every 250 Service Hours or 6 Weeks

Air Shutoff - Test ..........................................................................................................................2-7


Air Starting Motor Lines Screen - Clean ......................................................................................2-8
Cooling System Supplemental Coolant Additive (SCA) - Test/Add ............................................2-21
Engine Oil Sample - Obtain........................................................................................................2-42
Governor Actuator Linkage - Check ..........................................................................................2-58
Oil Mist Detector - Check ..........................................................................................................2-60

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Every 250 Service Hours or Monthly

Cooling System Coolant Sample (Level 1) - Obtain ..................................................................2-20

Every 500 Service Hours or 3 Months

Engine Mounts - Inspect ............................................................................................................2-33


Engine Protective Devices - Check ............................................................................................2-45
Oil Mist Detector - Clean/Replace ..............................................................................................2-61

Initial 1000 Service Hours or 6 Months

Engine Timing, Synchronization, and Valve Lash - Inspect/Adjust ............................................2-43


Engine Valve Rotators - Inspect ................................................................................................2-48

Every 1000 Service Hours or 6 Months

Barring Device - Lubricate ..........................................................................................................2-12


Cooling System Coolant Sample (Level 2) - Obtain ..................................................................2-21
Engine Air Cleaner Service Indicator - Inspect ..........................................................................2-31
Engine Mounts - Check ..............................................................................................................2-35
Engine Oil Filter - Change ..........................................................................................................2-38
Exhaust Piping - Inspect ............................................................................................................2-49
Fuel System Primary Filter/Water Separator Element - Replace ..............................................2-53
Fuel System Secondary Filter - Replace....................................................................................2-49
Magnetic Pickups - Clean/Inspect ..............................................................................................2-59
Prelube Pump - Lubricate ..........................................................................................................2-74

Every 2000 Service Hours or 1 Year

Aftercooler Condensation - Drain ................................................................................................2-5


Engine Timing, Synchronization, and Valve Lash - Inspect/Adjust ............................................2-43
Engine Valve Rotators - Inspect ................................................................................................2-48
Oil Mist Detector - Clean/Replace ..............................................................................................2-61

Every 4000 Service Hours or 1 Year

Aftercooler Core - Clean/Test ......................................................................................................2-6


Air Starting Motor Lubricator Bowl - Clean ..................................................................................2-9
Starting Motor - Inspect ..............................................................................................................2-74

Every 8000 Service Hours or 1 Year

Engine Protection Devices - Calibrate........................................................................................2-45

Every 8000 Service Hours or 3 Years

Camshaft Roller Followers - Inspect ..........................................................................................2-13


Cooling System Coolant (DEAC) - Change ..............................................................................2-14
Cooling System Coolant Extender (ELC) - Add ........................................................................2-17
Crankshaft Vibration Damper - Inspect ......................................................................................2-24
Driven Equipment - Check ........................................................................................................2-25
Engine Oil Temperature Regulator - Replace ............................................................................2-44
Exhaust Shields - Inspect ..........................................................................................................2-49
Governor Actuator Oil - Replace ................................................................................................2-58
Turbocharger - Inspect ..............................................................................................................2-81
Water Pump - Inspect ................................................................................................................2-84
Water Temperature Regulator - Replace....................................................................................2-84

Between 16 000 and 24 000 Service Hours

Overhaul (Top End) ..................................................................................................................2-61


Overhaul Considerations ............................................................................................................2-68

2-2 10/2005
02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 3

Every 16 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ..................................................................................2-17

Between 36 000 and 44 000 Service Hours

Overhaul (Major) ........................................................................................................................2-64


Overhaul Considerations ............................................................................................................2-68

Maintenance Interval Schedule for the 3618 Engine


Before performing any operation or maintenance procedures, ensure that the Safety
Information , warnings, and instructions are read and understood.
Before each consecutive interval is performed, all of the maintenance requirements from the
previous interval must be performed.

When Required

Centrifugal Oil Filter - Clean ......................................................................................................2-94


Engine Air Cleaner Element - Replace ....................................................................................2-107
Engine Crankcase Breather - Clean ........................................................................................2-108
Engine Oil and Filter - Change ................................................................................................2-113
Fuel Analysis - Obtain ..............................................................................................................2-121
Fuel System - Prime ................................................................................................................2-122
Fuel System Primary Filter/Water Separator Element - Replace ............................................2-123
Fuel System Secondary Filter - Replace..................................................................................2-123
Metal Particle Detector - Inspect ..............................................................................................2-123
Oil Mist Detector - Maintain ......................................................................................................2-127

Daily

Air Starting Motor Lubricator Oil Level - Check ..........................................................................2-89


Air Tank Moisture and Sediment - Drain ....................................................................................2-91
Annunciator Panel - Inspect ......................................................................................................2-92
Cooling System Coolant Level - Check....................................................................................2-100
Driven Equipment - Inspect/Replace/Lubricate ........................................................................2-106
Engine Oil Level - Check ..........................................................................................................2-111
Fuel System Primary Filter/Water Separator - Drain................................................................2-122
Fuel Tank Water and Sediment - Drain ....................................................................................2-126
Oil Mist Detector - Maintain ......................................................................................................2-127
Trend Data - Record ................................................................................................................2-141
Walk-Around Inspection............................................................................................................2-147

Every 250 Service Hours or Monthly

Air Starting Motor Lines Screen - Clean ....................................................................................2-87


Cooling System Coolant Sample (Level 1) - Obtain ................................................................2-101
Cooling System Supplemental Coolant Additive (SCA) - Test/Add ..........................................2-103
Engine Oil Sample - Obtain ......................................................................................................2-111
Oil Mist Detector - Maintain ......................................................................................................2-127

Every 500 Service Hours or 3 Months

Barring Device - Lubricate ..........................................................................................................2-93


Engine Mounts - Inspect ..........................................................................................................2-110
Governor Actuator Linkage - Check ........................................................................................2-127
Oil Mist Detector - Maintain ......................................................................................................2-128

Initial 1000 Service Hours or 6 Months

Engine Timing, Synchronization, and Valve Lash - Inspect/Adjust ..........................................2-118


Engine Valve Rotators - Inspect ..............................................................................................2-120

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Every 1000 Service Hours or 6 Months

Cooling System Coolant Sample (Level 2) - Obtain ................................................................2-102


Engine Mounts - Check ............................................................................................................2-108

Every 2000 Service Hours or 1 Year

Centrifugal Oil Filter - Inspect ....................................................................................................2-94


Engine Protective Devices - Check ..........................................................................................2-117
Engine Timing, Synchronization, and Valve Lash - Inspect/Adjust ..........................................2-118
Engine Valve Rotators - Inspect ..............................................................................................2-120
Oil Mist Detector - Maintain ......................................................................................................2-128

Every 4000 Service Hours or 1 Year

Aftercooler Core - Clean/Test ....................................................................................................2-86


Air Starting Motor Lubricator Bowl - Clean ................................................................................2-88
Crankshaft Vibration Damper - Inspect ....................................................................................2-105
Driven Equipment - Check ......................................................................................................2-106
Exhaust Shields - Inspect ........................................................................................................2-120
Starting Motor - Inspect ............................................................................................................2-141
Turbocharger - Inspect ............................................................................................................2-147
Water Pump - Inspect ..............................................................................................................2-149

Every 8000 Service Hours or 2 Years

Cooling System Coolant - Change..........................................................................................2-95

Between 12 605 000 and 14 763 000 L (3 330 000 and 3 900 000 US gal) of Fuel or between
10 000 and 12 000 Service Hours

Camshaft Roller Followers - Inspect ..........................................................................................2-94


Engine Oil Temperature Regulator - Replace ..........................................................................2-113
Overhaul (Top End) ..................................................................................................................2-133
Overhaul Considerations ..........................................................................................................2-135
Water Temperature Regulator - Replace..................................................................................2-149

Between 25 211 000 and 29 526 000 L (6 660 000 and 7 800 000 US gal) of Fuel or Between
20 000 and 24 000 Service Hours

Overhaul (Major) ......................................................................................................................2-129


Overhaul Considerations ..........................................................................................................2-135

2-4 10/2005
02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 5

Aftercooler Condensation - Drain


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 moisture.

3606 and 3608 Engines

3606 and 3608 Engines have one drain plug for draining moisture from the aftercooling system.

Note: Prepare a suitable container for the moisture.

1. Remove plug from the right rear corner .


2. Drain the moisture into a suitable container.
3. Install the plug.

3612 and 3616 Engines

3612 and 3616 Engines have two drain plugs for draining moisture from the aftercooling system.
One of the plugs is located at the right rear of the cylinder block and the other is at the front left
corner of the cylinder block

Note: Prepare a suitable container for the moisture.

1. Remove plugs.
2. Drain the moisture into a suitable container.
3. Install the plugs.

2-5 10/2005
02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 6

Aftercooler Core - Clean/Test


Before cleaning the aftercooler core, determine if the aftercooler requires cleaning. Use the 152-
2067 Differential Pressure Gauge to measure the differential pressure of the air side of the
aftercooler. If the differential pressure of the air side is greater than 2 kPa (8 inches of H2O), clean
the aftercooler core.

Cleaning the Aftercooler

See the Service Manual, "Disassembly and Assembly" module for instructions on removal,
disassembly, assembly, and installation.

Note: The following procedure may be used for cleaning both the aftercooler core
and the oil cooler core.

1. Remove the core. Disassemble the core.


2. Turn the core upside-down in order to remove debris.

NOTICE
Do not use a high pressure spray for cleaning the fins of the core. A high pressure spray
can damage the surface of the fins and reduce the flow of air through the core.

NOTICE
Do not use a high concentration of caustic cleaner to clean the core. A high concentration
of caustic cleaner can attack the internal metals of the core and cause leakage. Only use
the recommended concentration of cleaner.

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolv liquid cleaner. Consult your Caterpillar
dealer for the part numbers and quantities that are available.

Use a two to five percent concentration of the cleaner at temperatures up to 93 °C (200


°F). Refer to Application Guide, NEHS0526 or consult your Caterpillar dealer for more
information.

4. Steam clean the core in order to remove any residue. Flush the fins of the aftercooler
core. Remove any other trapped debris.

5. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 7

WARNING!
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When using pressure air,
wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning
purposes.

6. Dry the core with compressed air. Direct the air in the reverse direction of the normal
flow.
7. Inspect the core in order to ensure cleanliness. Pressure test the core. Many shops that
service radiators are equipped to perform pressure tests. If necessary, repair the core.
8. Install the core.

For more information on cleaning the core, consult your Caterpillar dealer.

Air Shutoff - Test


The air shutoff must operate properly in case an emergency shutdown is needed. Test the
operation of the air shutoff. It is not necessary for the engine to be operating in order to test the
shutoff.

1. To activate the air shutoff, pull knob on top of the air shutoff.

A plate that is inside of the apparatus will cover the air inlet. This prevents air from entering
the inlet manifold.

Reset lever on the side of the air shutoff should move to the "CLOSED" position. If this fails
to occur, investigate the problem. See the Service Manual, "Disassembly and
Assembly" topic.

DO NOT operate the engine if the air shutoff will not activate.

Note: The air shutoff must be reset before the engine can be started.

2. To reset the air shutoff, move reset lever to the "OPEN" position.

2-7 10/2005
02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 8

Air Starting Motor Lines Screen - Clean


If the engine is equipped with an air starting motor, use the following procedure:

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


2. Remove plug on the end of the filter screen .
3. Carefully remove screen. Clean the screen with nonflammable solvent. Inspect the
screen for damage. If the screen is damaged, replace the damaged screen with a
new screen.
4. Install clean, dry screen. Clean plug and reinstall the plug.

2-8 10/2005
02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 9

Air Starting Motor Lubricator Bowl - Clean


If the engine is equipped with an air starting motor, use the following procedure:

WARNING!

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

Failure to relieve pressure can cause personal injury.

Do not disconnect or remove hoses or fittings until all pressure in the system has been
relieved.

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


2. Slowly loosen filler plug on top of the lubricator housing in order to release the
pressure from the lubricator.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid
with suitable containers before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for
tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

3. Place a suitable container under bowl and open drain valve in order to drain the oil
from the bowl.
4. Remove bowl. 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. Inspect the gasket. If the gasket is damaged,
replace the gasket.
6. Install the bowl.
7. Make sure that drain valve is closed.
8. For instructions on filling the lubricator, see this Operation and Maintenance Manual,
"Air Starting Motor Lubricator Oil Level - Check" topic.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 10

Air Starting Motor Lubricator Oil Level - Check

NOTICE
Never allow the lubricator bowl to become empty. The air starting motor will be damaged
by a lack of lubrication. Ensure that sufficient oil is in the lubricator bowl.

1. Observe the oil level in sight gauge. If the oil level is less than 1/2, add oil to the
lubricator bowl.

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

Failure to relieve pressure can cause personal injury.

Do not disconnect or remove hoses or fittings until all pressure in the system has been
relieved.

2. Ensure that the air supply to the lubricator is OFF. Slowly loosen filler plug on top of
the lubricator housing in order to release pressure from the lubricator bowl.
3. Remove filler plug (4). Pour oil into the lubricator bowl. Use nondetergent SAE 10W
oil for temperatures that are greater than 0 °C (32 °F). Use air tool oil for
temperatures that are below 0 °C (32 °F).
4. Install filler plug (4) .

Adjust the Lubricator


Note: Adjust the lubricator with a constant rate of air flow. After the adjustment, the
lubricator will release oil in proportion to variations of the air flow.

1. Ensure that the fuel supply to the engine is OFF.

NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor
to cool for two minutes before cranking the engine again.

2. Operate the air starting motor. Observe the drops of oil that are released in dome (1)
.

Note: Some lubricators have an adjustment screw rather than a knob.

3. If necessary, adjust the lubricator in order to release from one to three drops of oil
per second. To increase the rate, turn knob (2) counterclockwise. To decrease the
rate, turn the knob clockwise.

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Air Tank Moisture and Sediment - Drain

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

• Freezing
• Corrosion of internal parts
• Malfunction of the air starting system

WARNING!

When opening the drain valve, wear protective gloves, a protective face shield, protective
clothing, and protective shoes. Pressurized air could cause debris to be blown and result
in personal injury.

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.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 12

Barring Device - Lubricate

NOTICE

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

WARNING!

Guards must be in place prior to operating barring device motor.

Remove all hand tools prior to operating barring device motor.

Note: Prelube of the engine is recommended before the crankshaft is rotated for
normal maintenance.

The barring device provides a means for slowly turning the flywheel in order to service the engine.

The barring device can also be used to prevent rotation of the crankshaft. When the barring
device is in the engaged position, the engine starting system is disabled.

When the barring device is not used, the barring device must be fully disengaged from the
flywheel and secured in the disengaged position.

NOTICE

Do not operate the engine starting motor until the barring group pinion gear is fully
disengaged from the flywheel ring gear. Serious damage to the engine could result.

Lubricating the Pinion

1. Ensure that the barring device is locked in the disengaged position.


2. Lubricate grease fitting with MPGM until the grease is visible at vent.

Lubricating the Reducer

1. Ensure that the barring device is locked in the disengaged position.


2. Remove level plugs on the end of the barring device and check the lubricant level.
3. If necessary, remove fill cap and add Caterpillar 4C-6767 Synthetic Oil until the oil is
visible at the level plugs.
4. Reinstall the level plugs and reinstall the cap.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 13

Camshaft Roller Followers - Inspect


For instructions on disassembly and assembly of the valve lifter group, see the Service Manual,
"Disassembly and Assembly" module.

Inspect the following components for wear at each metal to metal contact point:

· Rollers for the valve lifters

· Camshaft

Inspect each roller for wear, excessive movement, and end play.

If excessive wear or other signs of deterioration are found, replace the damaged components.

Centrifugal Oil Filter - Inspect

WARNING!

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

Note: If the engine is operating, close the filter shut off valve to the centrifugal oil
filter that will be cleaned. Prepare a cover for base. The cover will prevent the
oil mist from flowing through the orifice in the base.

1. Disassemble the centrifugal oil filter according to the instructions in the Service
Manual.
2. Thoroughly clean all of the parts of the centrifugal oil filter. Carefully inspect all of the
parts.
3. Measure the clearance between the bearing and the base and measure the
clearance between the bearing and the spindle. Follow the instructions that are in
the Service Manual. Replace any part that does not meet the specifications that are
in the Service Manual.

NOTICE

Ensure that all of the rotor components are thoroughly clean before assembling the rotor.
Failure to do so can cause an out of balance condition that can cause rapid wear to the
bearings and the spindle.

Note: Install a new paper liner when the centrifugal oil filter is assembled.

4. Assemble the centrifugal oil filter according to the instructions in the Service Manual.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 14

Cooling System Coolant (DEAC) - Change


Clean the cooling system before the recommended maintenance interval if the following conditions
exist:

• The engine overheats frequently.


• The coolant is foaming.
• Oil or fuel has entered the cooling system and the coolant is contaminated.

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.
3. Open the cooling system drain valves (if equipped). Remove the cooling system
drain plugs. Allow the coolant to drain.

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 (CSTG):
Outside U.S.A.: (309) 675-6277Inside U.S.A.: 1-800-542-TOOLInside Illinois: 1-800-541-
TOOLCanada: 1-800-523-TOOLCSTG COSA Geneva, Switzerland: 41-22-849 40 56

Clean the Cooling System

NOTICE

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

1. After the cooling system has been drained, 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.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 15

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 components.

To avoid damage to the cooling system, make sure to completely flush the cooling system
with clear water. Continue to flush the system until all signs of the cleaning agent are gone.

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

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. After the cooling system has been drained, flush the cooling system with clean water
in order to remove any debris.
2. Close the cooling system drain valves (if equipped). Clean the cooling system drain
plugs and install the cooling system drain plugs.
3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting
Cooling System Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L (1 to 2 US gal)
of the cooling system capacity. Install the cooling system filler cap.
4. Start the engine. Operate the engine for a minimum of 90 minutes with a coolant
temperature of at least 82 °C (180 °F).
5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap
slowly in order to relieve any pressure. Remove the cooling system filler cap. Open
the cooling system drain valves (if equipped). Remove the cooling system drain
plugs. Allow the water to drain.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 16

NOTICE

Improper or incomplete rinsing of the cooling system can result in damage to copper and
other metal components.

To avoid damage to the cooling system, make sure to completely flush the cooling system
with clear water. Continue to flush the system until all signs of the cleaning agent are gone.

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

Fill the Cooling System

NOTICE

Fill the cooling system no faster than 19 L (5 US gal) per minute 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 this Operation and Maintenance
Manual, "Refill Capacities" (Maintenance Section).

1. Fill the cooling system with coolant/antifreeze.

The water lines for the turbochargers must be vented when the cooling system is
filled. Remove plug (1). Press a small screwdriver into the check valve in order to
vent the line.

After filling the cooling system, 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.

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
maintain the correct pressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system for leaks and for proper operating
temperature.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 17

Cooling System Coolant (ELC) - Change


Use only clean water to flush the cooling system when Extended Life Coolant (ELC) is drained
and replaced.

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.
3. Open the cooling system drain valves (if equipped). Remove the cooling system
drain plugs. Allow the coolant to drain.

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 U.S.A.: (309) 675-6277Inside U.S.A.: 1-800-542-TOOLInside Illinois: 1-800-541-
TOOLCanada: 1-800-523-TOOLCSTG COSA Geneva, Switzerland: 41-22-849 40 56

Clean the Cooling System

1. After the cooling system has been drained, flush the cooling system with clean
water in order to remove any debris.
2. Close the cooling system drain valves (if equipped). Clean the drain plugs and install
the 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 clean water. Install the cooling system filler cap. Install
the vent plug. Operate the engine until the temperature reaches 49 °C (120 °F) to
66 °C (150 °F).
4. Stop the engine and allow the engine to cool. Ensure that the engine will not start
when the cooling system is drained. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling system filler cap.
5. Open the cooling system drain valves (if equipped). Remove the drain plugs. See
Illustration 1. Allow the coolant to drain. Flush the cooling system with clean water.
Close the cooling system drain valves (if equipped). Install the drain plugs.
6. Repeat Steps 3, 3, 4, and 5.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 18

Fill the Cooling System

NOTICE

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

1. Fill the cooling system with Extended Life Coolant (ELC).

The water lines for the turbochargers must be vented when the cooling system is filled.
Remove plug. Press a small screwdriver into the check valve in order to vent the line.

After filling the cooling system, 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 ELC 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 within 13 mm
(.5 inch) below the bottom of the filler pipe.

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
maintain the correct pressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system for leaks and for proper operating
temperature.

Cooling System Coolant Extender (ELC) - Add

Cat ELC (Extended Life Coolant) does not require the frequent Supplemental Coolant Additive
(SCA) additions which are associated with the present conventional coolants.

The Extender only needs to be added once.

Check the cooling system only when the engine is stopped and cool.

1. Loosen the cooling system filler cap slowly in order to relieve pressure. Remove the
cooling system filler cap.

2. It may be necessary to drain enough coolant from the cooling system in order to
add the Extender.

3. Add Extender according to the requirements for your engine's cooling system
capacity. Refer to the Operation and Maintenance Manual, "Refill Capacities and
Recommendations" in the Maintenance Section for more information concerning the
Cat ELC Extender additions.

4. Clean the cooling system filler cap. Inspect the gaskets on the cooling system filler
cap. Replace the cooling system filler cap if the gaskets are damaged. Install the
cooling system filler cap.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 19

Cooling System Coolant Level - Check

WARNING!

Climbing equipment may be required to access this service point. Refer to the Operation
and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

Engines That Are Equipped With a Sight Gauge

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

Engines That Are Not Equipped With a Sight Gauge

WARNING!

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler
cap, stop the engine and wait until the cooling system components are cool. Loosen the
cooling system pressure cap slowly in order to relieve the pressure.

Check the coolant level when the engine is stopped and cool. Check the coolant level only after
the engine has been stopped and the cooling system filler cap is cool enough to touch with your
bare hand.

Remove the cooling system filler cap slowly in order to relieve any pressure. Maintain the coolant
within 13 mm (0.5 inch) below the bottom of the filler pipe.

Add Coolant

Note: For the proper coolant mixture to use, see this Operation and Maintenance
Manual, "Refill Capacities and Recommendations" (Maintenance Section).

1. Stop the engine. Allow the engine to cool.


2. Remove the cooling system filler cap slowly in order to relieve any pressure. Pour
the proper coolant mixture into the filler pipe.
3. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler
cap. If the gaskets are damaged, replace the old cooling system filler cap with a new
cooling system filler cap. Install the cooling system filler cap.
4. Start the engine. Inspect the cooling system for leaks.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 20

Cooling System Coolant Sample (Level 1) - Obtain

NOTICE

Always use a designated pump for oil sampling, and use a separate designated pump for
coolant sampling. Using the same pump for both types of samples may contaminate the
samples that are being drawn. This contaminate may cause a false analysis and an
incorrect interpretation that could lead to concerns by both dealers and customers.

For conventional heavy-duty coolant/antifreeze, check the concentration of supplemental coolant


additive (SCA) regularly. The concentration of SCA can be checked with an S·O·S coolant analysis
(Level 1).

Obtain the sample of the coolant as close as possible to the recommended sampling interval. In
order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In
order to establish a pertinent history of data, perform consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from your Caterpillar dealer.

Use the following guidelines for proper sampling of the coolant:

- Never collect samples from expansion bottles.

- Never collect samples from the drain for a system.

- Keep the unused sampling bottles stored in plastic bags.

- Keep the lids on empty sampling bottles until you are ready to collect the sample.

- Complete the information on the label for the sampling bottle before you begin to
take the samples.

- Obtain coolant samples directly from the coolant sample port. You should not obtain
the samples from any other location.

- In order to avoid contamination, immediately place the sample in the tube that is
provided for mailing.

Submit the sample for Level 1 analysis.

Note: Level 1 results may indicate a need for Level 2 Analysis.

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

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 21

Cooling System Coolant Sample (Level 2) - Obtain

NOTICE

Always use a designated pump for oil sampling, and use a separate designated pump for
coolant sampling. Using the same pump for both types of samples may contaminate the
samples that are being drawn. This contaminate may cause a false analysis and an
incorrect interpretation that could lead to concerns by both dealers and customers.

Obtain the sample of the coolant as close as possible to the recommended sampling
interval. Supplies for collecting samples can be obtained from your Caterpillar dealer.

Refer to this Operation and Maintenance Manual, "Cooling System Coolant Sample
(Level 1) Obtain" (Maintenance Section) for the guidelines for proper sampling of the
coolant.

Submit the sample for Level 2 analysis.

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

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


This maintenance procedure is required for conventional coolants such as DEAC and for mixtures
of water and SCA. This maintenance is NOT required for cooling systems that are filled with
Extended Life Coolant.

WARNING!

Cooling system coolant additive contains alkali. To help prevent personal injury, avoid
contact with the skin and eyes. Do not drink cooling system coolant additive.

Note: Caterpillar recommends an S·O·S coolant analysis (Level 1).

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 22

Test the Concentration of the SCA


Coolant/Antifreeze and SCA

NOTICE

Do not exceed the recommended six percent supplemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit .

Water and SCA

NOTICE

Do not exceed the recommended eight percent supplemental coolant additive


concentration.

Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. Use the
instructions that follow:

1. Fill the syringe to the "1.0 ml" mark with the coolant.
2. Dispense the 1.0 mL coolant sample from the syringe into the empty mixing bottle.
3. Add tap water to the mixing bottle in order to bring the level up to the "10 ml" mark.
Place the cap on the bottle and shake the bottle.
4. Add 2 to 3 drops of the "NITRITE INDICATOR SOLUTION B" to the mixing bottle.
Move the bottle in a circular motion in order to mix the solution.
5. Add 1 drop of "NITRITE TEST SOLUTION A" to the mixing bottle. Move the bottle in
a circular motion in order to mix the solution.
6. Repeat 5 until the solution changes color from red to light gray, green, or blue.
Record the number of drops of "NITRITE TEST SOLUTION A" that were required to
cause the color change.
7. Use Table 1 to interpret the results.
Table 1

Number of Drops Concentration of SCA Maintenance


Required

Less than 25 Less than the recommended Add SCA


concentration of SCA Retest the coolant

25 to 30 The recommended concentration None


of SCA

More than 30 More than the recommended Remove the coolant


concentration of SCA Replace with water
Retest the coolant

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 23

Add the SCA, If Necessary

WARNING!

Pressurized System: Hot coolant can cause serious burns. To open the cooling system
filler cap, stop the engine and wait until the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order to relieve the pressure.

1. Remove the cooling system filler cap slowly.

Note: Always dispose of fluids according to local regulations.

2. If necessary, drain some coolant in order to allow space for the addition of the SCA.

NOTICE

Excessive supplemental coolant additive concentration can form deposits on the higher
temperature surfaces of the cooling system, reducing the engine's heat transfer
characteristics. Reduced heat transfer could cause cracking of the cylinder head and other
high temperature components.

Excessive supplemental coolant additive concentration could also result in blockage of the
heat exchanger, overheating, and/or accelerated wear of the water pump seal.

Do not exceed the recommended amount of supplemental coolant additive concentration.

3. Add the proper amount of SCA. For the proper amount of SCA, refer to this
Operation and Maintenance Manual, "Refill Capacities and Recommendations"
topic. The proper concentration of SCA depends on the type of coolant that is used.
For the proper concentration of SCA, refer to Special Publication, SEBU6251,
"Caterpillar Commercial Diesel Engine Fluids Recommendations".

4. Clean the cooling system filler cap. Install the cooling system filler cap.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 24

Crankshaft Vibration Damper - Inspect


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 may be the result of excessive friction. This could be due to misalignment.
Use an infrared thermometer to monitor the temperature of the damper during operation. If the
temperature reaches 93 °C (200 °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 and smooth.

If the fluid leak is oil, inspect the crankshaft seals for leaks. If a leak is observed, replace all of the
seals.

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.

· The crankshaft bearings are showing excessive wear.

· There is a large amount of gear train wear that is not caused by a lack of oil.

Dampers With Sampling Ports

Some dampers have ports for fluid samples. If the damper has no external damage, collect a 2 to
5 mL sample of the damper fluid. The fluid should be analyzed in order to check for a loss of
viscosity. Use the results of the analysis to determine if the damper should be rebuilt or replaced.
Kits for fluid samples are available from the address that follows. Return the kits to the same
address for analysis.

Hasse & Wrede GmbH


Mohriner Allee 30-42
D-12347 Berlin
Germany
Phone: 49 30 / 70 181 195
Fax: 49 30 / 70 09 08-11

Dampers Without Sampling Ports

Some dampers do not have a port for a fluid sample. These dampers must be rebuilt or the
dampers must be replaced when one of the following criteria has been met:

· The damper has reached 20,000 hours of operation.

· The engine is undergoing a major overhaul.

Removal and Installation

Refer to the Service Manual or consult your Caterpillar dealer for information about damper
replacement.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 25

Driven Equipment - Check


Check the Alignment

To minimize bearing problems and vibration of the engine crankshaft and the driven equipment,
the alignment between the engine and driven equipment must be properly maintained.

Check the alignment according to the instructions that are provided by the following
manufacturers:

· Caterpillar
· OEM of the drive coupling
· OEM of the driven equipment

Torque all of the fasteners to the proper specifications.

Inspect the Drive Coupling

Inspect the drive coupling according to the instructions that are provided by the OEM of the
coupling. For the following service information, see the literature that is provided by the OEM of
the coupling:

· Lubrication requirements
· Specifications for the end play
· "Reusability Guidelines"
· Replacement instructions

Inspect the Rear Gear Train

Inspect the crankshaft gear. If excessive wear is found, replace the crankshaft gear and the large
cluster idler.

If any gear causes damage to other gears through failure, replace the entire rear gear train.

For the correct parts, see the Parts Manual for the engine. For removal and replacement
instructions, see the Service Manual, "Disassembly and Assembly" module. Consult your
Caterpillar dealer for assistance.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 26

Driven Equipment - Inspect/Replace/Lubricate

Observe the driven equipment during operation. Look for the following items:

· Unusual noise and vibration


· Loose connections
· Damaged parts

Perform any maintenance that is recommended by the OEM of the driven equipment. Refer to the
literature of the OEM of the driven equipment for the following service instructions.

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

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 27

Engine Air Cleaner Element - Replace

NOTICE

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

NOTICE

Never service the air cleaner element with the engine running since this will allow dirt to
enter the engine.

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air pressure can split the filter material of the
element. Unfiltered air will drastically accelerate internal engine wear. Your Caterpillar dealer has
the proper air cleaner elements for your application.

- Check the precleaner (if equipped) daily for accumulation of dirt and debris.
Remove any dirt and debris, as needed.
- Operating conditions (dust, dirt and debris) may require more frequent service of
the air cleaner element.
- Replace the element when the air restriction reaches 3.75 kPa (15 inches of H2O).
- Replace the element when the red piston of the service indicator locks in the visible
position.
- The air cleaner element may be cleaned up to six times if the element is properly
cleaned and inspected.
- Replace the element at least one time per year. Perform this replacement regardless
of the number of cleanings.

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

1. Open access door and remove element.


2. Seal the air inlet to the turbocharger with a cover or tape. This will help to prevent
dirt from entering the turbocharger when the body of the air cleaner is cleaned.
3. Loosen clips. Remove cup. Clean the inside of the cup.
4. Clean screen with pressurized air or water.
5. Use a cloth to clean the inside of the access door and the body of the air cleaner.
6. Install cup. Fasten clips.
7. Inspect a clean, dry air cleaner element for good condition.
8. Remove the tape or the cover from the air inlet to the turbocharger. Install the air
cleaner element.
9. Secure the access door.
10. If necessary, reset the air cleaner service indicator.

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02 Maint-Serv_Maint.qxd 2/24/2006 1:50 PM Page 28

Replace the Soot Filter

Some applications use an air silencer that is wrapped in a washable soot filter. The soot filter
helps prevent airborne dust and debris from entering the air inlet. As the soot filter becomes dirty,
the air restriction increases. Replace the soot filter when the air restriction reaches 3.75 kPa (15
inches of H2O).

1. Remove the dirty soot filter from the air silencer.

2. Inspect the air silencer. Clean the air silencer, if necessary.

3. Inspect a clean, dry soot filter for good condition. Install the soot filter.

Cleaning the Air Cleaner Elements

The air cleaner element can be used up to six times if the element is properly cleaned and
inspected. When the element is cleaned, check the filter material for rips or tears. Replace the
element at least one time per year regardless of the number of cleanings.

Use clean elements while dirty elements are being cleaned.

NOTICE

Do not clean the air cleaner elements by bumping or tapping.

This could damage the seals. Do not use elements with damaged pleats, gaskets or seals.
Damaged elements will allow dirt to pass through. Engine damage could result.

Visually inspect the elements before cleaning. Inspect the elements for damage to the seal, the
gaskets, and the outer cover. Discard any damaged elements.

Four methods are used to clean air cleaner elements:

· Pressurized water
· Pressurized air
· Vacuum cleaning
· Washing with nonsudsing detergent

Pressurized Water

Pressurized water will clean the element unless carbon and oil have accumulated on the surface
of the element. The maximum water pressure for cleaning purposes must be below 275 kPa
(40 psi). Do not use a spray nozzle.

Note: When the element is cleaned, always begin with the clean side (inside) in order
to force dirt particles toward the dirty side (outside).

Aim the hose so that the water flows inside the element along the length of the filter in order to
help prevent damage to the paper pleats. Do not aim the stream of water directly at the element. A
direct stream of water could cause dirt to be forced into the pleats.

Note: Refer to "Drying the Air Cleaner Elements". Refer to "Inspecting the Air Cleaner
Elements".

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Pressurized Air

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

Note: When the elements are cleaned, always begin with the clean side (inside) in
order to force dirt particles toward the dirty side (outside).

Aim the hose so that the air flows inside the element along the length of the filter in order to help
prevent damage to the paper pleats. Do not aim the stream of air directly at the element. Dirt
could be forced into the pleats.

Note: Refer to "Inspecting the Air Cleaner Elements".

Vacuum Cleaning

Vacuum cleaning is a good method for cleaning elements which require daily cleaning because of
a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning.
Vacuum cleaning will not remove deposits of carbon and oil.

Note: Refer to "Inspecting the Air Cleaner Elements".

Washing the Air Cleaner Elements with Nonsudsing Detergent

WARNING!

Do not wash air cleaner elements in any flammable solution such as diesel fuel or gasoline.
Doing so can cause fire or an engine runaway and can result in personal injury.

Washing with nonsudsing detergent is effective for cleaning elements that have deposits of carbon
or oil. Use a cleaning agent that is specifically manufactured for cleaning air cleaner elements.
Cleaning with pressurized water, pressurized air, or a vacuum cleaner is recommended prior to
washing with nonsudsing detergent.

1. Place the element into a wash tank so that the gasket is up. The wash tank should
be equipped with a rack so that the element does not rest on the bottom of the
wash tank.

Note: Caterpillar does not recommend agitating the element. Agitating may cause
carbon particles to be distributed.

2. Fill the wash tank with the cleaning agent and warm water to a maximum
temperature of 60 °C (140 °F). Follow the manufacturers recommendations for the
cleaning agent. Allow the element to soak for six hours.

3. Drain the wash tank. Do not use the cleaning agent more than one time. Remove
the element from the wash tank. Rinse the element with the method for using
pressurized water.

Note: Refer to "Drying the Air Cleaner Elements". Refer to "Inspecting the Air Cleaner
Elements".

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Drying the Air Cleaner Elements

The oven method may be used in order to dry the elements. If an oven is used, do not expose the
elements to temperatures that exceed 82 °C (160 °F).

Note: Do not use compressed air in order to dry the elements.

The elements may be allowed to air dry. Allow two days for the elements to air dry before the
elements are inspected and installed.

Inspecting the Air Cleaner Elements

Inspect the clean, dry 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.

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 immediately, store the element for future use.

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
Inhibiter (VCI) paper.

Place the element into a cardboard box for storage. For identification, mark the outside of the
container and mark the element. Include the following information:

· Date of cleaning
· Number of cleanings

Store the container in a dry location.

For more detailed information on cleaning the air cleaner element, refer to Special Publication,
SEBF8062, "Procedure to Inspect and Clean Air Filters".

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Engine Air Cleaner Service Indicator - Inspect


A service indicator may be mounted on the air cleaner or in a remote location.

Some engines may be equipped with a different service indicator.

Observe the service indicator. Clean the air cleaner element or replace the element when the
following conditions occur:

· The yellow diaphragm enters the red zone.


· The red piston locks in the visible position.
· The air restriction reaches 3.75 kPa (15 inches 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 After Every 1000 Service Hours


Service indicators are important instruments. Use the following procedure to verify that the service
indicator is operating properly.

1. Unscrew the service indicator from fitting. A porous filter is part of the fitting.
2. Inspect the porous filter for cleanliness. Clean the filter, if necessary. Use
compressed air or a clean, nonflammable solvent.
3. Apply vacuum (suction) to the service indicator.
4. The yellow diaphragm should enter the red zone and the piston should lock into
position. If this does not occur, obtain a new service indicator.
5. Reset the service indicator by pressing reset button. If the service indicator does not
reset easily, obtain a new service indicator.

Note: Excessive force may crack the top of the service indicator.

6. Install the service indicator. Tighten the service indicator to a torque of 2 N·m (18 lb
in).

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.

Engine Air Precleaner - Clean


Note: More frequent cleaning may be required in dusty environments.

1. Loosen clips. Remove cup.


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

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Engine Crankcase Breather - Clean

Clean the crankcase breather elements and replace the O-ring seals at every oil change. Perform
this maintenance when the engine is stopped.

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 may cause
crankshaft seal leakage.

1. Loosen hose clamps. Remove tee.


2. Loosen retaining clamps. Remove breather assemblies and O-ring seals.
3. Wash the breather elements in clean nonflammable solvent. Inspect tee for cracks
that can be caused by vibration. Replace the old tee with a new tee if cracking is
found.
4. Install new O-ring seals.
5. 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.
6. Install the retaining clamps and the hose clamps. See the Service Manual,
"Specifications" module for the proper torque.

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Engine Mounts - Check

Measure the Isolators

Spring Type Isolators

Obtain the overall height dimension for each isolator. If any of the following conditions are found,
adjust the isolators:

- If the overall height dimension is different from the original dimension that was
obtained during the engine commissioning.

-If the overall height dimension is not within 3 mm (.12 inch) for all of the isolators.

-Snubber bolts are not finger tight against the plates.

For instructions on adjustment, see Special Instruction, SEHS9162, "Spring Isolator Group
Installation and Adjustment Procedure".

Resilient Isolators

Measure the loaded height of each isolator. Use an inside micrometer and measure dimension
between the top of the soleplate and the bottom of the engine support assembly. Measure each
corner of each isolator in order to ensure that the top and the bottom of each isolator is parallel.
The four measurements for each isolator should not differ by more than 0.5 mm (.02 inch).

Compare the measurements to the specifications from the engine commissioning. Adjust the
height of the engine support assembly in order to maintain the specifications for alignment.

Adjust the Height Of the Engine Support Assembly, If Necessary

Note: When shims are used in order to maintain the height of the engine support
assembly, the alignment of the engine and the driven equipment must be
verified.

To adjust the height of the engine support assembly, use setscrew. To raise the height of the
engine support assembly, add shims. To reduce the height of the engine support assembly,
remove shims.

Maintain a record of all of the shims that are added from the time of the engine commissioning.
When the combined total of the shims that are added to any isolator exceeds 5 mm (.2 inch), the
isolator must be repaired or replaced.

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Engine Mounts - Inspect

Inspect the condition of the isolators. The isolators must be kept clean and dry. Ensure that the
isolators are free of oil and contamination.

Resilient Isolators

Each isolator has four rubber elements. The most usual cause for failure of the isolator is oil
contamination of the rubber elements. Inspect the rubber elements of each isolator for the
following conditions.

· Swelling
· Blistering
· Cracking

Perform the following procedures when deterioration of the rubber elements is initially observed:

· Record the observation in a log.


· Check the alignment of the driven equipment.

After deterioration of the rubber elements is initially observed, the rubber elements must be
carefully inspected. Any further deterioration of the rubber elements must be recorded. The
isolator must be repaired or replaced if rapid deterioration of the rubber elements is observed.

Deterioration of the rubber elements is usually accompanied by settling of the isolator. Settling of
the isolator will result in misalignment between the engine and the driven equipment.

Check the Center Bolt

Check the tightness of locknut on the center bolt. Use a minimum torque of 100 N·m (75 lb ft).

If locknut is loose, perform the following Steps:

1. Tighten locknut to 140 N·m (105 lb ft).


2. Measure clearance above adjustable assembly.
3. Compare the clearance to the specification from the engine commissioning. The
clearance and the specification from the engine commissioning must be equal.

Any difference in the dimension indicates that the height of the isolator has changed. A change in
the height of the isolator will result in misalignment between the engine and the driven equipment.

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Engine Oil - Change


Oil Change Interval

Considerations for the oil change interval include the type of fuel and the engine application. The
establishment of an S·O·S oil analysis program will enable an evaluation of the used oil. The
evaluation can be used to determine the oil change interval that is suitable for your specific
engine. Change the engine oil when oil analysis determines that the oil has reached the
condemning limit.

In the absence of oil analysis, change the engine oil according to the interval that is listed in
Table 1.

Table 1

Oil Change Intervals For 3600 Engines (Distillate Fuel )

Engine Lube Oil Capacity (1) Oil Change Interval (2)

Industrial Engines and Generator Set Engines

3606 880 L (229 US gal) 1400 Service Hours

3608 1112 L (289 US gal) 1350 Service Hours

3612 1302 L (339 US gal) 1000 Service Hours

3616 1677 L (443 US gal) 1000 Service Hours

Marine Engines (Zero Degree Tilt)

3606 731 L (190 US gal) 1000 Service Hours

3608 795 L (207 US gal) 900 Service Hours

3612 943 L (245 US gal) 800 Service Hours

3616 1091 L (284 US gal) 600 Service Hours

( 1 ) The capacity includes the oil sump plus oil filters that are installed at the factory.
Engines with auxiliary oil filters will require additional oil. The capacity is
approximate. The actual capacity may vary by five percent. Caterpillar recommends
using the capacity that is listed and then adjusting the oil level according to the oil
level gauge (dipstick).

( 2 ) Use this oil change interval in the absence of oil analysis.

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Change the Engine Oil

WARNING!

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

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 method allows the waste particles to be removed.

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.

NOTICE

Ensure that the engine is stopped before performing this procedure. Attach a DO NOT
OPERATE tag to the starting controls.

Note: Drain the oil into a suitable container. Dispose of fluids according to local
regulations.

2. Open drain valve in order to drain used oil. After the oil has drained, close drain
valve.

Note: If a suction device is used in order to remove the oil from the oil pan, ensure
that the suction device is clean. This will prevent dirt from entering the oil pan.
Be careful not to strike the engine oil suction tubes or the piston cooling jets.

3. Clean the oil suction screen.

Note: Approximately 1 L (1 qt) of oil will remain in the housing after the sump has
been completely drained. This oil will pour out of the housing when the cover
for the oil suction screen is removed. Prepare to catch the oil in a suitable
container. Clean up any spilled oil with absorbent wipes or pillows. DO NOT
use absorbent particles to clean up the oil.

a. Remove cover and sea. Discard the used seal. Slide screen assembly from the
tube.
b. Wash the screen assembly in clean nonflammable solvent. Allow the screen
assembly to dry before installation.

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4. Clean the bottom of the sump. Remove side covers in order to gain access to the
sump. When the bottom of the sump is clean, install the side covers.
5. Install the oil suction screen. Install the cover and a new seal.
6. Change the engine oil filters. See this Operation and Maintenance Manual, "Engine
Oil Filter - Change" topic (Maintenance Section).
7. Clean the centrifugal oil filters.
8. Disassemble the centrifugal oil filters according to the instructions in the Service
Manual.

a. Thoroughly clean all of the parts of the centrifugal oil filter. Carefully inspect all
of the parts.

NOTICE

Ensure that all of the rotor components are thoroughly clean before assembling the rotor.
Failure to do so can cause an out of balance condition that can cause rapid wear to the
bearings and the spindle.

Note: Install a new paper liner when the centrifugal oil filter is assembled.

b. Assemble the centrifugal oil filters according to the instructions in the Service
Manual.

NOTICE

Only use oils that are recommended by Caterpillar. For the proper oil to use, refer to this
Operation and Maintenance Manual, "Engine Oil" topic (Maintenance Section).

NOTICE

Engine damage can occur if the crankcase is filled above the "FULL" mark on the oil level
gauge (dipstick).

An overfull crankcase can enable the crankshaft to dip into the oil. This will reduce the
power that is developed and also force air bubbles into the oil. These bubbles (foam) can
cause the following problems: reduction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling of the pistons, oil blowing 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. Deposits in the combustion chamber lead to the following problems:
guttering of the valves, packing of carbon under the piston rings and wear of the cylinder
liner.

If the oil level is above the "FULL" mark on the oil level gauge, drain some of the oil
immediately.

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9. Remove the oil filler cap. Fill the crankcase through the oil filler tube only. Clean
the oil filler cap. Install the oil filler cap.
10. Start the engine according to this Operation and Maintenance Manual, "Engine
Starting" topic (Operation Section).
11. Operate the engine at low idle for two minutes. Inspect the engine for oil leaks.
a. Ensure that the oil level is at the "FULL" mark on the "LOW IDLE" side
of the oil level gauge.
12. Stop the engine and allow the oil to drain back into the sump for a minimum of ten
minutes.
13. Remove the oil level gauge and check the oil level. Maintain the oil level to the
"FULL" mark on the "ENGINE STOPPED" side of the oil level gauge.

Engine Oil Filter - Change

Replace the engine oil filters when the following conditions are met:

· Every oil change


· The engine oil filter differential pressure reaches 100 kPa (15 psi).
· The oil filters have been used for 1000 service hours or six months.

Note: Do not attempt to clean the used oil filters. Used oil filters will retain waste
particles. The used oil filters would not filter the oil properly.

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

Replacing the Engine Oil Filters With the Engine Stopped

WARNING!

Hot oil and components can cause personal injury. Do not allow hot oil or components to
contact skin.

Perform the following procedure after the oil has been drained.

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

1. Connect a hose from each drain valve to a suitable container in order to catch the
oil.
2. Open both drain valves. Allow the oil to drain.

Note: Some oil will remain in the housing after the oil has been drained. This oil will
pour out of the housing when cover 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.

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WARNING!

Personal injury can result from parts and/or covers under spring pressure.

Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

3. Be alert to the spring force. The cover has a spring force up to 240 N (54 lb).
Gradually loosen but do not remove the last two bolts or nuts that are located at
opposite ends of covers. 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.
4. Elements are mounted on wire racks inside the housing. Use a pan to catch the oil
that drips when wire racks are removed. Remove wire racks. Remove used
elements. Clean up any oil that is spilled.

NOTICE

Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not
recommended by Caterpillar could result in severe engine damage to the engine bearings,
crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recommended by Caterpillar.

5. Ensure that the new oil filter elements are in good condition. Place the elements on
wire rack. Install the wire rack and the elements.
6. Ensure that the surfaces for O-ring seals are clean. Inspect the O-ring seals. If the
old O ring seals are damaged or deteriorated, replace the old O-ring seals with
new O-ring seals. Install the O-ring seals.
7. Install covers. Ensure that the spring is seated properly between elements and
covers. Close drain valves.
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

WARNING!

Filter contains hot pressurized fluid when engine is running.

Follow instructions on control valve to avoid personal injury.

If rapid air movement exists to blow fluid, Stop the engine to avoid fire.

If it is necessary to replace the oil filters during engine operation, perform the following procedure.

1. Connect a hose from drain valve to a suitable container in order to catch the oil.
2. Rotate control valve to the "LOWER SERVICE" position.
3. Open drain valve and drain the lower oil filter housing. Observe pressure gauge
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 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.

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WARNING!

Personal injury can result from parts and/or covers under spring pressure.

Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

4. After zero pressure has been reached, remove cover. 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. 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.
5. Elements are mounted on wire rack inside the housing. Use a pan to catch the oil
that drips when wire rack is removed. Remove wire rack. Remove used elements.
Clean up any oil that is spilled.

NOTICE

Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not
recommended by Caterpillar could result in severe engine damage to the engine bearings,
crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recommended by Caterpillar.

6. Ensure that the new oil filter elements are in good condition. Place the elements on
wire rack. Install the wire rack and the elements.
7. Ensure that the surfaces for O-ring seal 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. Ensure that the spring is seated properly between element and cover.
Close drain valve.
9. Rotate control valve to the "LOWER FILL" position. Observe pressure gauge.
Check cover 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 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 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.

Aluminum debris may indicate problems with the bearings of the front gears. If aluminum debris is
found, inspect the crankshaft vibration damper and the bearings of the front idler gear.

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.

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Engine Oil Level - Check

The most accurate check of the oil level is performed when the engine is stopped. Perform this
maintenance on a surface that is as level as possible.

1. Ensure that oil level gauge is seated.


a. If the engine is stopped, remove oil level gauge. Observe the oil level on
"ENGINE STOPPED WITH OIL COLD" side.
b. If the engine is operating, reduce the engine speed to low idle. Remove oil level
gauge and observe the oil level on "ENGINE AT LOW IDLE WITH WARM OIL"
side.

The oil level should be between "ADD" mark and "FULL" mark.

NOTICE

Engine damage can occur if the crankcase is filled above the "FULL" mark on the oil level
gauge (dipstick).

An overfull crankcase can cause the crankshaft to dip into the oil. This will reduce the
power that is developed and also force air bubbles into the oil. These bubbles (foam) can
cause the following problems: reduction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the crankcase breathers and excessive oil
consumption.

Excessive oil consumption will cause deposits to form on the pistons and in the
combustion chamber. Deposits in the combustion chamber lead to the following problems:
guttering of the valves, packing of carbon under the piston rings and wear of the cylinder
liner.

If the oil level is above the "FULL" mark on the oil level gauge, drain some of the oil
immediately.

2. If necessary, remove oil filler cap and add oil. For the correct oil to use, see this
Operation and Maintenance Manual, "Refill Capacities and Recommendations" topic
(Maintenance Section). Do not fill the crankcase above "FULL" mark. 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 oil change. This will
help to provide the most accurate oil analysis.

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Engine Oil Sample - Obtain


In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S 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

WARNING!

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot
components to contact the skin.

After zero pressure has been reached, remove cover. Be alert to the spring force.

Before taking the sample, complete the Label, PEEP5031 for identification of the sample. To help
obtain the most accurate analysis, provide the following information:

· Engine model
· Service hours on the engine
· The oil's hours of use
· 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 is 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 8T-9190 Fluid Sampling Bottle Group is recommended for use with the sampling valve. The
bottle group includes the parts that are needed for obtaining oil samples. Instructions are also
provided.

NOTICE

Do not use the same vacuum sampling pump for extracting 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.

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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 S·O·S program
for your engine.

Engine Timing, Synchronization, and Valve Lash - Inspect/Adjust


For instructions on the following procedures, see the Service Manual, "Systems Operation/Testing
and Adjusting". Consult your Caterpillar dealer for assistance.

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. The camshafts must be correctly timed with the
crankshaft before the fuel timing is adjusted.

NOTICE

If the camshaft is rotated with the timing pin installed, the timing pin will break. This can
result in further damage. Make sure to remove the timing pin before the camshaft is
rotated.

NOTICE

DO NOT use the starting motor to rotate the crankshaft. The lubrication oil can drain out
from between the crankshaft and the engine bearings if the engine has not been operated
for a period of time. Damage can result if the crankshaft is rotated on dry bearing surfaces.
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 continuously for extended periods of time. If,
during repairs, the prelube pump has run continuously for a period of three hours or more,
it will be necessary to remove any oil that may have collected in the cylinders and/or above
the valves.

Prelube of the engine is required before the crankshaft is rotated for normal maintenance. Activate
the prelube pump for rotating the engine crankshaft.

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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.

Fuel Injector Timing (Fuel Timing)

The camshafts must be correctly timed with the crankshaft before the fuel timing is adjusted. The
fuel timing dimension is stamped on the engine Information Plate.

Fuel Injector Clamp

The top surface of the clamp for the fuel injector must be parallel to the top surface of the cylinder
head.

Fuel Injector Synchronization

Synchronize the fuel injectors. When this maintenance procedure is complete, ensure that the
barring device is disengaged from the flywheel and ensure that the handle of the barring device is
secured in the disengaged position.

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 bridge and adjust the valve bridge, if necessary. Perform the procedure for both
valve bridges for each cylinder. After the valve bridge is satisfactory, check the valve lash.

Engine Valve Lash

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

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.

Engine Oil Temperature Regulator - Replace


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.

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Engine Protection Devices - Calibrate


A calibration check of the engine protective devices will ensure that the alarms and shutoffs
activate at the setpoints.

To prevent damage to the engine, only authorized service personnel or your Caterpillar dealer
should perform the tests.

· For the calibration of temperature contactors, see Special Instruction, SEHS9827,


"Calibration of Temperature Contactors".
· For the calibration of pressure contactors, see Special Instruction, SEHS9828,
"Calibration of Pressure Contactors".
· For engines with the Caterpillar Marine Monitoring System, see Owner's Manual,
SEBU7134, "3600 Diesel Marine Monitoring System".

Consult your Caterpillar dealer or refer to the Service Manual for more information.

Engine Protective Devices - Check


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.

NOTICE

During testing, abnormal operating conditions must be simulated.

The tests must be performed correctly in order to prevent possible damage to the engine.

Perform a Static Test

Inspect the components of the alarm and shutoff systems for good condition. Test the operation of
the alarms and shutoffs.

A static test of the engine protective devices will ensure that the alarms and shutoffs are
functioning properly.

To prevent damage to the engine, only authorized service personnel or your Caterpillar dealer
should perform the tests.

Consult your Caterpillar dealer or refer to the Service Manual for more information.

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Inspect the Connections of the Engine Protective Devices

Inspect the wiring and the electrical connections for these components:

• Connectors
• Control panel
• Junction box
• Sensors

1. Turn the engine control switch to the "OFF/RESET" position. Open the circuit
breaker
or circuit breakers of the main power supply.
2. Inspect all of the wiring for the following conditions:

• Fraying
• Damaged insulation
• Corrosion

Make repairs, as needed.

3. Check the wiring for secure connections at these points of the junction box and the
control panel:

• Connectors
• Relays
• Switches
• Terminal strips

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

a. Pull each wire with approximately 45 N (10 lb) of force. Pull the wire
firmly.
If a wire is loose, repair the connection.

4. Inspect the wiring at the relays and terminal strips for these conditions:

• Corrosion
• Fraying

a. If corrosion is found, scrape large deposits. Use cotton swabs with


denatured alcohol to clean any corrosion that remains.
Investigate the source of the corrosion. Correct the condition.
If damage is found, replace the part.

• Remove frayed strands of wire or tin the wire.

b. Perform Steps 6 and 7 for the connectors of the control panel and the
junction box.

Note: The wiring is soldered to the pins and sockets of Military Standard and Jaeger
connectors. The wiring is crimped into the pins and sockets of Deutsch DT
connectors.
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5. Check the wiring for secure connections at these points:

• Connectors
• Sensors

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

a. For wiring that is attached to a connector, hold the body of the


connector with one hand. Pull each wire with approximately 45 N (10 lb)
of force. Pull the wire firmly.
b. Before testing the wiring of the sensors, ensure that the sensors are
securely installed. Then pull each wire with approximately 45 N (10 lb)
of force.

If a wire is loose, repair the connection.

6. Disconnect the connectors at the following locations. Inspect the connectors.

• Engine sensors
• Junction box
• Modules of the control panel

a. Inspect each pin and each socket for corrosion and damage.

If corrosion is found, scrape large deposits. Use cotton swabs with


denatured alcohol to clean any corrosion that remains.

Investigate the source of the corrosion. Correct the condition.

If damage is found, replace the part.

7. Reconnect the connectors.

a. For Military Standard and Jaeger connectors, ensure the following


conditions:

• The connection is threaded properly.


• The connection is threaded completely. Very little thread or no thread is
visible.

b. For Deutsch DT connectors, ensure that the plug and the receptacle are
securely connected.

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

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Engine Valve Rotators - Inspect

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.

Exhaust Piping - Inspect

WARNING!

Hot engine components can cause injury from burns. Before performing maintenance on
the engine, allow the engine and the components to cool.

Inspect the components of the exhaust system. Repair the components or replace the
components for any of the following conditions:

• Damage
• Cracks
• Leaks
• Loose connections

For information on removal and installation, see the Service Manual, "Disassembly and Assembly"
module. Consult your Caterpillar dealer for assistance.

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Exhaust Shields - Inspect

WARNING!

Hot engine components can cause injury from burns. Before performing maintenance on
the engine, allow the engine and the components to cool.

NOTICE

The exhaust shields can be damaged if work is performed on the exhaust shields or
around the exhaust shields.

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

Do not tear the foil that is inside of the exhaust shields. Torn foil will allow the insulation to
absorb flammable liquids and a fire can result from engine heat.

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

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Fuel Analysis - Obtain


To ensure optimum performance of the engine, obtain a complete fuel analysis when fuel is
delivered. Obtain the analysis before using the fuel.

1. Ask the supplier of the fuel for the fuel specifications.


2. Obtain samples of the fuel.

Note: If a fuel supply is delivered to the site by trucks, obtain samples from
approximately five percent of the supply tanks.

a. Submit a sample of the fuel immediately to an independent laboratory


for analysis.

The fuel analysis must include all of the properties that are listed in
Special Publication, SEBU7003, "3600 Diesel Engine Fluids
Recommendations For Lubricants, Fuels, and Coolants".

b. Retain samples of the fuel in case future analysis is needed. Label the
samples accurately for future identification. The samples may be
needed for future analysis if questions about quality, stability, or
compatibility arise.

3. Compare the supplier's report to the report from the analysis.

The reports may indicate variations within the fuel. If the reports are inconsistent,
obtain another analysis of the fuel. This will eliminate the possibility of testing error.

4. Compare the reports to Special Publication, SEBU7003, "3600 Diesel Engine Fluids
Recommendations For Lubricants, Fuels, and Coolants".

If the fuel does not meet the minimum requirements, deposits and/or corrosion could
cause excessive wear on the fuel system and/or failure of the fuel system.

Clean fuel that meets the fuel recommendations will help ensure rated engine performance and
maximum engine service life.

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Fuel System - Prime

WARNING!

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system
component that will be disconnected. Fit a suitable cover over disconnected fuel system
component.

Prime the fuel system in order to fill dry fuel filters and purge air from the fuel system. Prime the
fuel system after the following occurrences:

• The fuel filter elements are replaced.


• The engine is run dry.
• The fuel lines have been disconnected.
• The engine has been overhauled.
• The engine is removed from storage.

1. Loosen the vent plugs that are on the top of the fuel filter covers.
2. Operate priming pump. Turn the handle clockwise until fuel appears at the openings
of the vent plugs. Operate the priming pump until the fuel flows free of air bubbles.
Clean up any spilled fuel immediately.
3. Tighten the vent plugs.

Priming the Fuel System After Disconnecting Fuel Lines or After an


Overhaul

1. Loosen connector. The connector is above the fuel pressure regulator valve. Use a
cloth to catch any fuel and clean up any fuel that overflows.
2. Operate priming pump. Turn the handle clockwise until fuel appears at the opening
of the connector. Operate the priming pump until the fuel flows free of air bubbles.
Clean up any spilled fuel immediately.
3. Tighten connector.

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Fuel System Primary Filter/Water Separator - Drain

WARNING!

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

NOTICE

Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel
immediately.

Primary Filter

1. To drain filter, lift lock and turn lever to the "FILTER 2 RUN" position. Release the
lock.
2. Hold a suitable container under drain valve. Open the drain valve. Allow the
moisture to drain. Close the drain valve.
3. Lift lock and move lever to the "BOTH RUN" position for one minute.
4. To drain filter, lift lock and turn lever to the "FILTER 1 RUN" position. Release the
lock.
5. Repeat Steps 2 and 3 for filter.

Water Separator

For specific instructions on draining the water separator, see the service information that is
provided by the OEM of the water separator.

NOTICE

The water separator is under suction during normal engine operation. Ensure that the drain
valve is tightened securely to help prevent air from entering the fuel system.

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Fuel System Primary Filter (Water Separator) Element - Replace

WARNING!

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help
prevent possible injury, turn the start switch off when changing fuel filters or water
separator elements. Clean up fuel spills immediately.

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system
component that will be disconnected. Fit a suitable cover over disconnected fuel system
component.

Primary Filter

Servicing the Primary Filters During Engine Operation

1. To service "FILTER 2", lift lock and turn lever to the "FILTER 1 RUN" position.
Release the lock.
2. Hold a suitable container under drain valve. Open the drain valve. Allow the
moisture to drain. Close the drain valve.
3. Remove nut. Remove the filter case.
4. Remove element and seals.
5. Clean the filter case, the element, and the seals with clean, nonflammable solvent.
Allow the parts to dry.
6. Inspect the element and the seals for good condition. Obtain new parts, if
necessary. See the Parts Manual for the engine.
7. Assemble the clean, dry element, seals, and filter case. Use clean diesel fuel on
the seals to make installation easier. Tighten nut. Close drain valve.
8. Lift lock and move lever to the "BOTH RUN" position for one minute.
9. To service "FILTER 1", lift lock and turn lever to the "FILTER 2 RUN" position.
Release the lock.
10. Repeat Steps 2 through 8 for "FILTER 1".

Servicing the Primary Filters With the Engine Stopped

1. Ensure that the fuel to the engine is OFF.

2. Refer to "Servicing the Primary Filters During Engine Operation". Perform Steps 2
through 7 for both filters.

It may be necessary to prime the fuel system before the engine will start. See this Operation and
Maintenance Manual, "Fuel System - Prime" topic (Maintenance Section).

Water Separator

Replace the water separator element according to the instructions that are provided by the OEM
of the water separator.

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Fuel System Secondary Filter - Replace


Replace the secondary fuel filter elements when either of the following conditions occur:

• The engine is operating at rated speed and at operating temperature and the fuel
filter
differential pressure reaches 69 kPa (10 psi).
• The fuel filter elements have been used for 1000 hours of operation.

Service tools are available to aid in the service of oil filters and fuel filters. Consult your Caterpillar
dealer for the part names and the part numbers. Follow the instructions that are supplied with the
service tools. If the service tools are not used, perform the following appropriate procedure.

Replacing the Secondary Filters With the Engine Stopped

WARNING!

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help
prevent possible injury, turn the start switch off when changing fuel filters or water
separator elements. Clean up fuel spills immediately.

1. Stop the engine. Connect one end of a hose to each drain valve. Insert the other
end of the hoses into a suitable container in order to catch the fuel.

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system
component that will be disconnected. Fit a suitable cover over disconnected fuel system
component.

NOTICE

Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel
immediately.

2. Remove both vent plugs. Open both drain valves in order to drain the secondary
fuel filters.

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WARNING!

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

3. Gradually loosen but do not remove the last two bolts or nuts that are located at
opposite ends of cover. Before removing the last two bolts or nuts, pry the cover
loose in order to relieve any spring pressure. Remove covers from both fuel filter
housings.

4. Four elements are installed on wire rack. Remove wire racks. Discard the used
elements. Remove O-ring seals. Discard the used O-ring seals.

5. Clean covers. Clean wire racks. Install new O-ring seals.

6. Inspect new elements for good condition. Install elements and wire racks.

7. Install covers. Ensure that the spring is seated properly between covers and
elements.

8. Close drain valves. Clean vent plugs. Install the vent plugs loosely. Prime the fuel
system. See this Operation and Maintenance Manual, "Fuel System - Prime" topic
(Maintenance Section).

9. Start the engine and check for fuel leaks.

Replacing the Secondary Filters During Engine Operation

WARNING!

Filter contains hot pressurized fluid when engine is running.

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

WARNING!

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

1. To service the lower secondary fuel filter, turn control valve to the "UPPER RUN"
position.

2. Connect one end of a hose to drain valve. Insert the other end of the hose into a
suitable container in order to catch the fuel.

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NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system
component that will be disconnected. Fit a suitable cover over disconnected fuel system
component.

NOTICE

Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel
immediately.

3. Remove vent plug. Open drain valve in order to drain the lower secondary fuel
filter.

WARNING!

Personal injury can result from parts and/or covers under spring pressure.

Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

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

5. Four elements are installed on wire rack. Remove wire rack. Discard the used
elements. Remove O-ring seal. Discard the used O-ring seal.

6. Clean covers. Clean wire racks. Install new O-ring seals.

7. Inspect new elements for good condition. Install elements and wire rack.

8. Install cover. Ensure that the spring is seated properly between cover and
elements.

9. Close drain valve. Clean vent plug. Install the vent plug loosely. Slowly turn control
valve to the "LOWER FILL" position. After five minutes, turn control valve to the
"BOTH RUN" position. Tighten vent plug.

10. To service the upper secondary fuel filter, turn control valve to the "LOWER RUN"
position. Perform Steps 1 through 9 for the upper secondary fuel filter.

11. After both of the secondary fuel filters have been serviced, turn control valve to the
"BOTH RUN" position.

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Fuel Tank Water and Sediment - Drain

Day Tank

Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel
can cause excessive wear to the fuel system. Condensation occurs during the heating and cooling
of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns
to the day tank. This causes water to accumulate in the day tank. Draining the day tank regularly
and obtaining fuel from reliable sources can help to eliminate water from the fuel.

Day tanks should have a provision for draining water and sediment.

Open the drain valve on the bottom of the day tank in order to drain the water and the sediment.
Close the drain valve.

Drain the water and sediment from the day tank daily. The quality of the fuel or the operating
conditions may require the water and sediment to be drained more often.

Fill the day tank after operating the engine in order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The fuel expands as the fuel gets warm. The tank
may overflow.

Some day tanks use supply pipes that allow water and sediment to settle below the end of the fuel
supply pipe. Some day tanks use supply lines that take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular maintenance of the fuel system filter is important.

Fuel Storage Tanks

Drain the water and the sediment from the fuel storage tank daily. Ensure that the water and
sediment is drained from the fuel storage tank when the tank is refilled. This will help prevent
water and/or sediment from being pumped from the fuel storage tank into the engine fuel tank.

If a bulk storage tank has been refilled or moved recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the
fuel. When possible, water separators should be used.

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Governor Actuator Linkage - Check


Check the governor actuator linkage for proper operation. Refer to the Service Manual for the
procedure to adjust the governor actuator linkage.

Governor Actuator Oil - Replace

NOTICE

Contamination of oil is a major cause of problems for governor actuators. Only use new oil.
A container that is used to fill the governor actuator must be clean. Rinse the container
with the new oil before filling the container.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid
with suitable containers before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for
tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Attach one end of a hose to drain cock (1). Insert the other end of the hose into a
suitable container. Open filler cap (3). Open drain cock (1). Allow the oil to drain.
2. Close drain cock (1). Pour clean engine oil into the oil filler until the oil flows out of
the vent hole in sight gauge (2). Approximately 1.4 L (1.50 qt) of oil will be required.
Clean filler cap (3). Install the filler cap.
3. Check the oil level in sight gauge (2) immediately after the engine is started. Add
more oil or drain oil until the oil level is at the center of the sight gauge. Remove the
hose from drain cock (1). Clean up any oil that has spilled.

Check the Operation of the Governor Actuator

After the oil has been replaced, check the governor actuator for proper operation. Refer to the
instructions that are provided by the OEM of the governor actuator or refer to the Service Manual.
Consult your Caterpillar dealer for assistance.

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Governor Actuator Oil Level - Check

NOTICE

Contamination of oil is a major cause of problems for governor actuators. Only use new oil.
A container that is used to fill the governor actuator must be clean. Rinse the container
with the new oil before filling the container.

Instrument Panel - Inspect


Inspect the instrument panel for good condition. Perform the self-test. All of the warning lamps
should illuminate. If a warning lamp does not illuminate, replace the bulb immediately. If the alarm
does not sound, investigate the problem and correct the problem.

Check the condition of all of the gauges. If a gauge is broken, repair the gauge or replace the
gauge immediately.

Frequently monitor the gauges during normal operation.

Record the data in a log. Compare the new data to the data that was previously recorded.
Comparing the new data to the recorded data will help to establish the trends of engine
performance. A gauge reading that is abnormal may indicate a problem with operation or a
problem with the gauge.

Magnetic Pickups - Clean/Inspect


1. Remove the magnetic pickup from the flywheel housing.
2. Clean the face of the magnet. Check the condition of the magnetic pickup.
3. Install the magnetic pickup in the flywheel housing. Turn the magnetic pickup
clockwise until the magnet contacts a tooth of the flywheel ring gear.
4. Turn the magnetic pickup counterclockwise for 1 1/4 turns (450 ± 30 degrees).
Maintain a clearance of 0.70 ± 0.15 mm (.028 ± .006 inch) between the magnetic
pickup and the tooth of the flywheel ring gear. Tighten the locknut to 47 ± 7 N·m (35
± 5 lb ft).

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Metal Particle Detector - Inspect


If the metal particle detector causes a shutdown, inspect the detector.

Note: For instructions on servicing the metal particle detector, see the literature that
is provided by the OEM of the detector.

1. Remove the grid from the inside of the detector.


2. If metal particles are found, determine the source of the particles.

NOTICE

Metal particles in the lube oil may indicate a serious condition that requires immediate
attention.

If metal particles are found in the grid of the detector, do not start the engine until the
source of the particles is found and the condition is corrected. Failure to do so could cause
severe damage to the engine.

3. Clean the grid with nonflammable solvent. Install the clean, dry grid.

Oil Mist Detector - Check

Drain the Condensation

Note: More frequent draining may be required in humid environments.

Inspect vent line for proper ventilation.

Open drain in order to drain the condensation trap. Drain the condensation into a suitable
container. Close the drain.

Check the Vacuum in the Measuring Track

Check the vacuum in the measuring track according to the service instructions that are provided
by the OEM of the oil mist detector. Adjust the driving air pressure, if necessary. Refer to the
Testing and Adjusting, RENR2225 for additional information about the oil mist detector or the
literature that is provided by the OEM of the oil mist detector.

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Oil Mist Detector - Clean/Replace


Note: For all maintenance and service procedures for the oil mist detector, refer to
the Testing and Adjusting, RENR2225 for additional information about the oil
mist detector or refer to the service instructions that are provided by the OEM
of the oil mist detector.

Every Three Months

Perform the following maintenance items according to the instructions that are provided by the
OEM of the oil mist detector.

• Clean the two fresh air bores in the measuring device.


• Clean the glasses for the infrared filter in the measuring device.
• Replace the sintered bronze filters in the measuring device.

Yearly

Replace the sintered bronze filters in the pressure regulator.

Follow the instructions that are provided by the OEM of the oil mist detector.

Overhaul (Top End)


A top end overhaul involves the removal, the inspection, and the rework of the cylinder head
components. Some additional components are replaced and serviced.

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

Note: The driven equipment may also require service when the engine is overhauled.
Refer to the literature that is provided by the OEM of the driven equipment.

If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the
following recommendations.

Fuel Consumption Before A Top End Overhaul

The overhaul interval that is listed in this Operation and Maintenance Manual, "Maintenance
Interval Schedule" is expressed in service hours. A more accurate figure to use is fuel
consumption. Fuel consumption corresponds more accurately to the engine load.

Table 1 lists an average range of fuel consumption for a reasonable load factor before a top end
overhaul. Use the range of fuel consumption only as a guideline.

Table 1

Approximate Fuel Consumption Before A Top End Overhaul

Engine Model Fuel Consumption

3606 5 685 000 L (1,500,000 US gal)

3608 7 580 000 L (2,000,000 US gal)

3612 11 370 000 L (3,000,000 US gal)

3616 15 160 000 L (4,000,000 US gal)

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Remanufacturing or Rebuilding of Components

Rework the following components:

• Air shutoff valve


• Cylinder heads
• Cylinder dowels
• Exhaust valves
• Exhaust valve seat inserts
• Inlet valves
• Inlet valve seat inserts
• Inner valve springs
• Outer valve springs
• Unit injectors
• Valve spring guides
• Valve spring locks
• Valve rotators
Note: The angles of the valves and seats are different.

If the valves and seats are not replaced, lap the valves and seats. The valve and the outer
diameter of the seat must have 360 degrees of contact. If the valves and the seats require
regrinding, see the Service Manual, "Specifications" module for the angles.

Inspection and/or Replacement of Components

Inspect the following components according to the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index
of Publications on Reusability or Salvage of Used Parts". Replace the components, if necessary.

• Cylinder sleeves
• Exhaust shields
• Starting motor
• Thermocouples

Replacement of Components

Replace the following components.

• Connecting rod bearings


• Cylinder head gaskets and seals
• Exhaust manifold gaskets
• Fuel transfer pump seals
• Inlet air line seals
• Oil cooler seals
• Oil pump bearings and seals
• Oil temperature regulators and seals
• Turbocharger bearings, bushings, and seals
• Valve lubricator pump (if equipped)
• Water pump bearings and seals
• Water temperature regulators and seals

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Cleaning and Inspection of Components


Clean the following components. Inspect the components for good condition. Replace the
components, if necessary.

• Oil cooler core


• Oil suction screen

Oil Cooler Core

For cleaning the oil cooler core, see this Operation and Maintenance Manual, "Aftercooler Core -
Clean/Test" procedure. The procedure may be used for cleaning both the aftercooler core and the
oil cooler core.

Oil Suction Screen

For cleaning the oil suction screen, see this Operation and Maintenance Manual, "Engine Oil -
Change" procedure.

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Overhaul (Major)
The need for a major overhaul is determined by several factors.

• An increase of oil consumption


• An increase of crankcase blowby
• A decrease and variation of cylinder compression

Other factors must also be considered for determining a major overhaul:

• The total amount of fuel consumption


• The service hours of the engine
• The wear metal analysis of the lube oil
• An increase in the levels of noise and vibration

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

Note: It is possible for oil analysis to indicate a decrease of wear metals in the lube
oil. The cylinder liners may be worn so that polishing of the bore occurs. Also,
the increased use of lube oil will dilute the wear metals.

Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.

Note: The driven equipment may also require service when the engine is overhauled.
Refer to the literature that is provided by the OEM of the driven equipment.

A major overhaul includes all of the work that is done for top end overhauls. A major overhaul
includes additional parts and labor. Additional parts and labor are required in order to completely
rebuild the engine.

For the major overhaul, all of the bearings, seals, gaskets, and components that wear are
disassembled. The parts are cleaned and inspected. If necessary, the parts are replaced. The
crankshaft is measured for wear. The crankshaft may require regrinding. Alternatively, the
crankshaft may be replaced with a Caterpillar replacement part.

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

If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the
following recommendations.

Fuel Consumption Before A Major Overhaul

The overhaul interval that is listed in this Operation and Maintenance Manual, "Maintenance
Interval Schedule" is expressed in service hours. A more accurate figure to use is fuel
consumption. Fuel consumption corresponds more accurately to the engine load.

Table 1 lists an average range of fuel consumption for a reasonable load factor before a major
overhaul. Use the range of fuel consumption only as a guideline.

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Table 1

Approximate Fuel Consumption Before A Major Overhaul

Engine Model Fuel Consumption

3606 11 370 000 L (3,000,000 US gal)

3608 15 160 000 L (4,000,000 US gal)

3612 22 740 000 L (6,000,000 US gal)

3616 30 320 000 L (8,000,000 US gal)

Remanufacturing or Rebuilding of Components

Rework the following components.

• Air shutoff valve


• Centrifugal oil filter bearings
• Cylinder heads
• Starting motor

Replacement of Components

Replace the following components.

• Accessory group bearings


• Connecting rod bearings
• Cylinder head gaskets
• Cylinder head valves and valve guides
• Cylinder head valve spring guides
• Exhaust manifold gaskets
• Exhaust manifold seals and bellows
• Exhaust shields
• Front gear train bearings
• Inlet air line seals
• Oil temperature regulators and seals
• Unit injectors
• Water pump bearings and seals
• Water temperature regulators and seals

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Inspection and/or Replacement of Components

Inspect the following components according to the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index
of Publications on Reusability or Salvage of Used Parts". Replace the components, if necessary.

• Aftercooler core
• Alarm and shutoff controls
• Camshafts
• Camshaft bearings
• Connecting rod bearings
• Crankshaft
• Cylinder liners
• Cylinder sleeves
• Exhaust manifolds
• Front gear group
• Fuel transfer pump seals
• Main bearings
• Oil cooler seals
• Oil pump bushings and seals
• O-Ring seals and plugs
• Pistons and piston rings
• Priority valve
• Rear gear group
• Rear gear train bearings and seals
• Rocker arm bearings
• Thermocouples
·• Thrust bearings
• Turbocharger bearings, bushings, and seals
• Valve lubricator pump, gaskets, and seals
• Valve mechanism group
• Water pump bearing and seals

Inspect the camshaft for damage to the journals and the lobes. Inspect the following components
for signs of wear and/or for signs of scuffing:

• camshaft bearings
• camshaft followers

Inspect the crankshaft for any of the following conditions:

• deflection
• damage to the journals
• bearing material that has seized to the journals

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Check the journal taper and the profile of the crankshaft journals. Check these components by
interpreting the wear patterns on the following components:

• rod bearing
• main bearings

Note: If the crankshaft or the camshaft are removed for any reason, use the magnetic
particle inspection process to check for cracks.

Replace the crankshaft vibration damper if any of the following conditions occur:

• Engine failure due to a broken crankshaft


• Excessive wear of the front bearing for the crankshaft
• Excessive wear of the gear train that is not caused by a lack of lubrication

Inspect the gears of the gear train and inspect the gear train bushings for the following conditions:

• Worn gear teeth


• Unusual fit
• Unusual wear

Cleaning and Inspection of Components

Clean the following components. Inspect the components for good condition. Replace the
components, if necessary.

Replace the gaskets and seals for the components.

• Air inlet lines


• Camshaft front covers
• Camshaft drive gear covers
• Central structure covers
• Crankcase side covers
• Crankshaft
• Crankshaft vibration damper
• Front housing group
• Fuel lines
• Fuel transfer pump
• Gear inspection group
• Oil cooler core
• Oil lines
• Oil suction screen
• Piston undercrown
• Power take-off covers
• Priority valve group
• Rear housing group
• Rear structure covers
• Valve covers
• Water lines

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Overhaul Considerations
Severe Operation

Severe operation is the use of an engine that exceeds current published standards for that engine.
Caterpillar maintains standards for the following engine parameters:

• Horsepower
• Range of rpm
• Fuel consumption
• Fuel quality
• Altitude
• Maintenance intervals
• Selection of oil
• Selection of coolant
• Environmental qualities
• Installation

Refer to the standards for your engine or consult your Caterpillar dealer in order to determine if
your engine is operating within the defined parameters.

Severe operation can accelerate component wear. Engines that are operating under severe
conditions may need more frequent maintenance intervals for the following reasons:

• Maximum reliability
• Retention of full service life

Because of individual applications, it is not possible to identify all of the factors which can
contribute
to severe operation. Consult your Caterpillar dealer about the maintenance that is needed for your
specific engine.

The following factors can contribute to severe operation: environment, improper operating
procedures and improper maintenance practices.

Environmental Factors
Extreme Ambient Temperatures

Extended operation in environments that are extremely cold or hot can damage components.
Valve components can be damaged by carbon buildup if the engine is frequently started and
stopped in very cold temperatures. Extremely hot inlet air reduces the performance capabilities of
the engine.

Note: See this Operation and Maintenance Manual, "Cold Weather Operation" topic
(Operation Section), or see Supplement, SEBU5898, "Cold Weather
Recommendations".

Cleanliness

Unless the equipment is cleaned regularly, extended operation in a dirty environment and in a
dusty environment can damage components. Built up mud, dirt, and dust can encase components.
This can make maintenance difficult. The buildup can contain corrosive chemicals. Corrosive
chemicals and salt can damage some components.

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Improper Operating Procedures


• Extended operation at low idle
• Minimum cool down periods after high load factor operation
• Operating the engine beyond the guidelines for the engine rating
• Operating the engine at loads that are greater than the rated load
• Operating the engine at speeds that are greater than the rated speed
• Use of the engine for an application that is not approved

Improper Maintenance Practices


• Extension of maintenance intervals
• Not using recommended fuel, lubricants, and coolant/antifreeze

Overhaul Information

An overhaul is replacing the major worn components of the engine. An overhaul interval 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

Most owners will save money by overhauling the engine at the intervals that are recommended in
this Operation and Maintenance Manual which represents the maintenance and repair costs for an
owner that followed the recommendations for inspection, maintenance, and repair.

By following the "repair-before-failure" guidelines in this Operation and Maintenance Manual could
significantly reduce the overhaul cost. By not following this philosophy the cost of overhaul could
be higher, because of two key factors:

• Delaying an overhaul until a breakdown increases the chance of a catastrophic


failure.
This type of failure requires more parts, labor, and cleanup.
• Excessive wear means that fewer components will be reusable. More labor may be
required for salvage or repair of the components.

When all of the costs are considered, "repair-before-failure" is the least expensive alternative for
most components and engines.

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.

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Overhaul Intervals

Some 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

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.

Other factors must also be considered for determining a major overhaul:

• The total amount of fuel consumption


• The service hours of the engine
• An increase of oil consumption
• An increase of crankcase blowby
• The wear metal analysis of the lube oil
• An increase in the levels of noise and vibration

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

Note: It is possible for oil analysis to indicate a decrease of wear metals in the lube
oil. The cylinder liners may be worn so that polishing of the bore occurs. Also,
the increased use of lube oil will dilute the wear metals.

Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.

Note:The driven equipment may also require service when the engine is overhauled.
Refer to the literature that is provided by the OEM of the driven equipment.

Using Fuel Consumption For Calculating the Overhaul Intervals

Experience has shown that maintenance intervals are most accurately based on fuel consumption.
Fuel consumption corresponds more accurately to the engine load. Tables 1, 2, and 3 list average
ranges of fuel consumption for a load factor of approximately 60 percent.

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Table 1
Maintenance Intervals for Overhaul
Fuel Consumption for 3508B Engines and 3508 Engines with the EUI System
High High High
Interval Rated Up To Rated 1301 To Rated 1601 To Performance B Performance D
1300 RPM (1) 1600 RPM (1) 1800 RPM (1) and C Ratings (1) and E Ratings (2)
666,667 L 500,000 L
Top End 1,000,000 L
(176113.4214 (132,085
Overhaul (264,170 US gal)
US gal) US gal)
Second
2,000,000 L
Top End n/a n/a
(528,340 US gal)
Overhaul

Major 3,000,000 L 2,000,000 L 1,500,000 L


Overhaul (792,510 US gal) (792,510 US gal) (396,255 US gal)

(1) Fuel consumption is based on a load factor of approximately 60 percent.


(2) Fuel consumption is based on a load factor of approximately 40 percent.

Table 2
Maintenance Intervals for Overhaul
Fuel Consumption for 3512B Engines and 3512 Engines with the EUI System
High High High
Interval Rated Up To Rated 1301 To Rated 1601 To Performance B Performance D
1300 RPM (1) 1600 RPM (1) 1800 RPM (1) and C Ratings (1) and E Ratings (2)
1,000,000 L 750,000 L
Top End 1,500,000 L
(264,170 (198,127
Overhaul (296,255 US gal)
US gal) US gal)
Second
3,000,000 L
Top End n/a n/a
(792,510 US gal)
Overhaul

Major 4,500,000 L 3,000,000 L 2,250,000 L


Overhaul (1,188,765 US gal) (792,510 US gal) (594,382 US gal)

(1) Fuel consumption is based on a load factor of approximately 60 percent.


(2) Fuel consumption is based on a load factor of approximately 40 percent.

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Table 3
Maintenance Intervals for Overhaul
Fuel Consumption for 3516B Engines and 3516 Engines with the EUI System
Rated Up Rated 1301 Rated 1601 High High High
Interval To 1300 To 1600 To1800 Performance Performance B Performance D
RPM (1) RPM (1) RPM (1) A Ratings (2) and C Ratings (1) and E Ratings (3)

Top End 2,000,000 L 1,000,000 L


Overhaul (528,340 US gal) (264,170 US gal)

Second
4,000,000 L
Top End n/a n/a n/a
(1,056,680 US gal)
Overhaul

Major 6,000,000 L 4,000,000 L 3,000,000 L


Overhaul (1,585,020 US gal) (1,056,680 US gal) (792,510 US gal)

(1) Fuel consumption is based on a load factor of approximately 60 percent.


(2) Fuel consumption is based on a load factor of approximately 80 percent.
(3) Fuel consumption is based on a load factor of approximately 40 percent.

Table 4
Equation For Calculating Overhaul Intervals
F/R = H
"F" is the estimated total amount of fuel consumption of the engine.
"R" is the rate of fuel consumption in liters per hour or gallons per hour.
"H" is the number of estimated hours until the overhaul interval

Use the actual records of fuel consumption, when possible. If the actual records are not available,
use the following procedure in order to estimate the fuel consumption.

1. Estimate the average percent of the load for the operation of the engine.
2. Refer to the fuel consumption data in the Technical Marketing Information (TMI) for
your engine. This will determine the fuel consumption for the percent of the load that
was estimated in Step 1. Use this figure as variable "F" for the equation in Table 4.
For more information about the Technical Marketing Information (TMI) for your
engine, consult your Caterpillar dealer.

Oil Consumption as an Overhaul Indicator

Oil consumption, fuel consumption, and maintenance information can be used to estimate the total
operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable for the maintenance intervals.

Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of
the engine load is increased, the amount of oil that is consumed per hour also increases.

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The oil consumption rate (brake specific oil consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC) depends on the engine load. Consult your
Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine.

When an engine's oil consumption has risen to three times the original oil consumption
rate due to normal wear, an engine overhaul should be scheduled.

There may be a corresponding increase in blowby and a slight increase in fuel consumption.

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.

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. New parts are not necessary if the old parts can be reused, repaired, or salvaged.
Otherwise, the old parts can be replaced or exchanged.

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:

• Cylinder heads
• Oil Pumps
• Turbochargers
• Water pumps
Consult your Caterpillar dealer for details and for a list of the remanufactured parts that are
available.

Your Caterpillar dealer may be offering a variety of overhaul options.

A Flat Rate Overhaul guarantees the maximum price that you will pay for an overhaul. Flat rate
prices on preventive maintenance programs or major repair options are available from many
servicing dealers for all Caterpillar Engines. Consult your Caterpillar dealer in order to schedule a
before failure overhaul.

Overhaul Recommendation

Caterpillar recommends a scheduled overhaul in order to minimize downtime. A scheduled


overhaul will provide the lowest cost and the greatest value. Schedule an overhaul with your
Caterpillar dealer.

Overhaul programs vary between dealers. To obtain specific information about the types of
overhaul programs and services, consult your Caterpillar dealer.

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Prelube Pump - Lubricate


Lubricate the two motor bearings. Apply one pump of MPGM to each fitting with a hand operated
grease gun.

Starting Motor - Inspect


If the starting motor fails, the engine may not start in an emergency situation. A scheduled
inspection of the starting motor is recommended.

The starting motor pinion and the flywheel ring gear must be in good condition in order for the
engine to start properly. The engine will not start if the starting motor pinion does not engage the
flywheel ring gear. The teeth of the starting motor pinion and the flywheel ring gear can be
damaged because of irregular engagement.

Inspect the starting motor for proper operation. Listen for grinding when the engine is started.
Inspect the teeth of the starting motor pinion and the flywheel ring gear. Look for patterns of wear
on the teeth. Look for teeth that are broken or chipped. If damaged teeth are found, the starting
motor pinion and the flywheel ring gear must be replaced.

Electric Starting Motor

Note: Problems with the electric starting motor can be caused by the following
conditions: malfunction of the solenoid and malfunction of the electric starting
system.

Inspect the electrical system for the following conditions:

• Loose connections
• Corrosion
• Wires that are worn or frayed
• Cleanliness

Make repairs, if necessary.

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Air Starting Motor


WARNING!

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

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

If fluid is injected into your skin, it must be treated immediately by a doctor familiar with
this type of injury.

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

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 Starting Motor

Refer to the Service Manual, "Disassembly and Assembly" module for information on removing the
starting motor and installing the starting motor.

Consult your Caterpillar dealer for assistance.

Trend Data - Record


Records of engine performance are an important element of a maintenance program. The data on
engine performance can help to predict problems with operation. Also, the data can provide
information that is useful for achieving optimum operation.

Traditionally, data on engine performance might be recorded regularly. However, the data might
not be reviewed until the occurrence of a problem. This method of monitoring engine operation
has several disadvantages:

• The engine may not be providing optimum performance. This may not be noticed
because the engine does not exhibit excessive changes in performance.
• Because a problem occurs, the engine may be in an alarm condition that requires a
quick response.
• Repairs may cause more downtime.
• The cost of downtime is compounded by the cost of parts and labor for repairs.
The absence of an alarm condition does NOT guarantee normal operation. Not all parameters
have alarms and/or shutdowns. Setpoints for alarms are outside of the normal ranges in order to
avoid occasional nuisance warnings. An alarm indicates a serious condition that requires
immediate attention. Service or repair is a reaction to an alarm condition.

A different approach is necessary in order to schedule service before an alarm condition occurs.

Monitor the trends of the engine's performance. The following benefits can be realized:

• Reduction of engine performance will be noticed sooner.


• Problems can be predicted. This enables prevention of the problems. Service can be
planned before an alarm condition occurs.
• Planning for downtime will also reduce downtime.
• The cost of parts and labor for service that is planned will be less than the cost of
repairs that are not anticipated.

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Monitoring the Trends of Engine Performance


To maintain a program that is successful, several factors are important:

• Record the data regularly when the engine is operating at similar loads and speeds.
• Obtain accurate data.
• At regular intervals, review the data in a graphic format.
• Perform corrections before damage and/or downtime occurs.

Accurate data is provided by accurate instruments and proper use of the instruments. The gauges
and the sensing devices must be in good condition. This is especially true for thermocouples.
Establish a program for calibrating the instruments periodically. Avoid using infrared thermometers
for obtaining data. Be sure to read the gauges properly. Accurate recording of the data is also
important.

Use the following Steps to establish a program:

1. Establish a baseline for the engine parameters. The baseline is necessary in order to
know the normal gauge readings. The new data will be compared to the baseline.
• Use the data from the engine commissioning. The data is recorded for various loads.
The data is recorded before any wear or deterioration takes place.
• If there is no data from the engine commissioning, use data from the engine test cell.
Understand that the data will not be specific to the site.
• If data is not available from the engine commissioning or the engine test cell,
calculate an average of the existing data.
• Establish a new baseline after an overhaul.

2. Frequently record the new data during engine operation. For an example of a log to
use, see this Operation and Maintenance Manual, "Hourly Performance Log"
(Reference Information Section).

Be aware that the readings of some parameters depend on the engine load. Record
the data when the engine is operating at a high load. This increases the accuracy of
the data. Also, any reduction in performance will be revealed sooner. A load of 75 to
100 percent is recommended.

• For operations with a consistent load cycle, record the data at the same time for
each day.
• If the load can be controlled, set the load to the same amount for each reading.

Some parameters that are NOT affected by the load ARE affected by the engine rpm.
Obtain the readings for these parameters when the engine is operating at the same
rpm.

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Some parameters are not affected by either the load or the rpm. See Table 1.
Table 1

Parameters of Engine Operation

Parameters That Depend On the Load

Aftercooler and oil cooler water temperature (outlet)

Exhaust manifold pressure

Exhaust manifold temperature

Exhaust port temperature

Generator stator temperature

Inlet air restriction

Inlet manifold air pressure (boost pressure)

Inlet manifold air temperature

Jacket water coolant temperature (outlet)

Parameters That Depend On the RPM

Fuel filter differential pressure

Jacket water pressure

Lube oil pressure

Oil filter differential pressure

Parameters That Are Independent of the Load and RPM

Aftercooler and oil cooler water temperature (inlet)

Jacket water coolant temperature (inlet)

Lube oil temperature

Note: A gauge reading that is abnormal may indicate a problem with operation or a
problem with the gauge.

3. Average the data for each day. Use a computer or graph paper in order to produce
a graph of the data. Compare the new data to the baseline. This will help to reveal
the trends of the engine performance.
4. Compare the new data to the data from previous months. This comparison will be
useful for scheduling reconditioning for the engine.

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Monitoring the Trends of Fuel Consumption

Fuel consumption depends on the following factors:

• Engine load
• The fuel efficiency of the engine
• The service hours of the engine

Use these two methods in order to obtain accurate data on fuel consumption:

• Calculate the Specific Fuel Consumption. For this calculation, the weight of the fuel
that was burned is divided by the electrical energy that was produced.
• Calculate the Heat Rate. This calculation compensates for the fuel energy content of
different fuels. For this calculation, the low heat value (LHV) of the fuel is divided by
the electrical energy that was produced.

Calculating the Specific Fuel Consumption

Use the equation that is in Table 2 to calculate the Specific Fuel Consumption.

Table 2
Equation For Calculating the Specific Fuel Consumption
FžD
= SFC
ekW-hr
F is the liters of fuel that have been burned.
D is the density of the fuel. The density is expressed in grams per liter.
ekW-hr is th electrical kilowatt hours that were produced with the fuel.
SFC is the specific fuel consumption.

Table 3 is an example for using the equation that is in Table 2. The data in the example assumes
the following conditions:

• During this operation, the engine used 18 440 liters of fuel.


• The density of the fuel was 987 grams per liter.
• The operation generated 88 800 ekW.

Table 3
Example of the Equation For Calculating the Specific Fuel Consumption
18 440 ž 987 g/L 1 205 g
ž =
88 800 ekW-hr L ekW-hr

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Calculating the Heat Rate

The specific fuel consumption must be determined before the heat rate can be calculated. Use the
equation that is in Table 4 to calculate the heat rate.

Table 4
Equation For Calculating the Heat Rate
SFC ž LHV = HR
SFC is the specific fuel consumption.
LHV is the low heat value of the fuel.
HR is the heat rate.

Table 5 is an example for using the equation that is in Table 4. The data in the example assumes
the following conditions:

• The specific fuel consumption is 205 grams per ekW-hr.


• The LHV of the fuel is 42 000 kilojoules per kilogram.

Table 5
Example of the Equation For Calculating the Specific Fuel Consumption
205g 42,000 kJ kg 8608 kJ
ž ž =
ekW-hr kg 1000 g ekW-hr

The equation in Table 6 includes a conversion factor for calculating BTU from kJ. The data is from
the example in Table 5.

Table 6
Conversion of kJ From the Heat Rate to BTU
8608 kJ 1 BTU 8159 BTU
ž =
ekW-hr 1.055 kJ 1000 g

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Monitoring the Trends of Oil Consumption

The consumption of lube oil depends on the following factors:

• Engine load
• Hours of operation
• Type of oil

Monitor the engine's oil consumption by calculating the Specific Oil Consumption on a daily basis.
Be aware that the following conditions can produce misleading data on oil consumption:

• Improper operation of the lube oil centrifuge


• Inaccurate measurement of additions of oil
• Leaking of lube oil
• Overfilling of the oil sump

To measure additions of oil accurately, use a meter to monitor additions of oil at the engine. Also,
check the total oil consumption against the delivery of oil.

Calculating Specific Oil Consumption

Use the equation that is in Table 7 in order to calculate the Specific Oil Consumption.

Table 7
Equation For Calculating the Specific Fuel Consumption
0žD
= SOC
ekW-hr
0 is the liters of oil that have been consumed.
D is the density of the oill. The density is expressed in grams per liter.
ekW-hr is th electrical kilowatt hours that have been produced during
consumption of the oil.
SOC is the specific oil consumption.

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Table 8 is an example for using the equation that is in Table 7. The data in the example assumes
the following conditions:

• The engine consumed 66 liters of oil during the operation.


• The operation generated 88 800 ekW.

Table 8
Example of the Equation For Calculating the Specific Fuel Consumption
66L 910 g 1 0.676 g
ž ž =
1 L 88 888 ekW-hr ekW-hr

Turbocharger - Inspect
Periodic inspection and cleaning is recommended for the turbocharger compressor housing (inlet
side).

Fouling of the compressor can contribute to loss of engine power, increased black smoke and
overall loss of engine efficiency.

If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the turbocharger compressor wheel could allow parts
from the compressor wheel to enter an engine cylinder. This can cause additional damage to the
pistons, the valves, and the cylinder head.

NOTICE

Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and
exhaust systems. Loss of engine lubricant can result in serious engine damage.

Minor leakage of a turbocharger housing under extended low idle operation should not
cause problems as long as a turbocharger bearing failure has not occurred.

When a turbocharger bearing failure is accompanied by a significant engine performance


loss (exhaust smoke or engine rpm up at no load), do not continue engine operation until
the turbocharger is repaired or replaced.

An inspection of the turbocharger can minimize unscheduled downtime. An inspection of the


turbocharger can also reduce the chance for potential damage to other engine parts.

Note: Turbocharger components require clearances that are precise. The


turbocharger cartridge must be balanced due to high rpm. Severe service
applications can accelerate the wear of the components. Severe service
applications may require more frequent inspections of the turbocharger.

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Removal and Installation

For options regarding the removal, installation, repair and replacement, consult your Caterpillar
dealer. Refer to the Service Manual for this engine or consult your Caterpillar dealer for the
procedure and specifications.

Cleaning and Inspecting

1. Remove the exhaust outlet piping and remove the air inlet piping from the
turbocharger. Visually inspect the piping for the presence of oil.
2. Turn the compressor wheel and the turbine wheel by hand. The assembly should
turn freely. Inspect the compressor wheel and the turbine wheel for contact with the
turbocharger housing. There should not be any visible signs of contact between the
turbine wheel or compressor wheel and the turbocharger housing. If there is any
indication of contact between the rotating turbine wheel or the turbocharger wheel
and the turbocharger housing, the turbocharger should be reconditioned or
replaced.
3. Check the compressor wheel for cleanliness. If only the blade side of the wheel is
dirty, dirt and/or moisture is passing through the air filtering system. If oil is found
only on the back side of the wheel, there is a possibility of a failed turbocharger oil
seal.

The presence of oil may be the result of extended engine operation at low idle. The presence of
oil may also be the result of a restriction of the line for the inlet air (plugged air filters), which
causes the turbocharger to slobber.

4. Inspect the bore of the turbine housing for corrosion.


5. Clean the turbocharger housing with standard shop solvents and a soft bristle
brush.
6. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing.

Walk-Around Inspection

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 compartment 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.

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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.

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 and tight. 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 the removal
of water pumps and the installation of water pumps and/or seals, refer to the Service Manual 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 cover.
• Inspect 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.
• Drain the water and the sediment from fuel tanks on a daily basis in order to ensure
that only clean fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for loose connections and for worn wires
or frayed wires.
• Inspect the ground strap for a good connection 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. Inspect the gaskets and the exhaust bellows
joint. If a leak is found, make repairs.

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Water Pump - Inspect


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.

Cooling System Water Temperature Regulator - Replace


Replace the water temperature regulators for these systems:

• Jacket water
• Oil cooler
• Aftercooler

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

A water temperature regulator that fails in a partially opened position can cause overheating or
overcooling of the engine.

A water temperature regulator that fails in the closed position can cause excessive overheating.
Excessive overheating could result in cracking of the cylinder head or a seizure of the pistons.

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

NOTICE

Failure to replace the water temperature regulator on a regularly scheduled basis could
cause severe engine damage. Never operate an engine without the water temperature
regulator installed.

If the water temperature regulator is installed incorrectly, the engine may overheat, causing
cylinder head damage. Ensure that the new water temperature regulator is installed in the
original position.

Note: If only the water temperature regulators are replaced, drain the coolant from
the cooling system to a level that is below the water temperature regulator
housing.

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Zinc Rods - Inspect/Replace


Corrosion in sea water circuits can result in premature deterioration of cooling system
components, leaks, and possible cooling system contamination. The corrosion may be caused by
the lack of zinc rods in the sea water system.

Zinc rods are installed in the sea water cooling system of the engine in order to help prevent the
corrosive oxidation that is caused by sea water. Electrical current is conducted through the contact
of the zinc rods with the cooling system components. The zinc rods oxidize rather than the cooling
system components. Rapid deterioration of zinc rods may indicate the presence of uncontrolled
electrical currents from improperly installed electrical attachments or improperly grounded
electrical attachments.

The engineer for the operation must determine the interval for inspecting the zinc rods. The
interval for inspecting the zinc rods will depend on the size of the zinc rods and the number of zinc
rods that are installed.

For the location of the zinc rods, see the literature that is provided by the OEM of the installation.

Inspect the Zinc Rods

1. Remove the zinc rod.

2. Inspect the zinc rod.

Ensure that the zinc rod will remain effective until the next scheduled inspection.

a. If the zinc rod has deteriorated excessively, install a new zinc rod.

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Aftercooler Core - Clean/Test

Before cleaning the aftercooler core, determine if the aftercooler requires cleaning. Use the 152-
2067 Differential Pressure Gauge to measure the differential pressure of the air side of the
aftercooler. If the differential pressure of the air side is greater than 10 kPa (40 inches of H2O),
clean the aftercooler core.

Cleaning the Aftercooler

See the Service Manual, "Disassembly and Assembly" module for instructions on removal,
disassembly, assembly, and installation.

1. Remove the core.

2. Turn the core upside-down in order to remove debris.

NOTICE

Do not use a high pressure spray for cleaning the fins of the core. A high pressure spray
can damage the surface of the fins and reduce the flow of air through the core.

NOTICE

Do not use a high concentration of caustic cleaner to clean the core. A high concentration
of caustic cleaner can attack the internal metals of the core and cause leakage. Only use
the recommended concentration of cleaner.

3. Back flush the core with cleaner. Table 1 lists liquid cleaners that are available from
your Caterpillar dealer.

Use a two to five percent concentration of the cleaner at temperatures up to 93 °C


(200 °F). Refer to Application Guide, NEHS0526 or consult your Caterpillar dealer
for more information.

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Table 1

Liquid Cleaners (1)

Part Number Description Size

1U-5490 Hydrosolv 4165 19 L (5 US gallon)

174-6854 Caterpillar Cabinet


and Tank Liquid Cleaner 19 L (5 US gallon)

174-6855 Caterpillar Cabinet


and Tank Liquid Cleaner 208 L (55 US gallon)

( 1 ) Use a two to five percent concentration of the cleaner at temperatures up to 93°C (200°F).
Refer to Application Guide, NEHS0526 or consult your Caterpillar dealer for more information.

4. Steam clean the core in order to remove any residue. Flush the fins of the
aftercooler core. Remove any other trapped debris.

5. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.

WARNING!

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air,
wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning
purposes.

6. Dry the core with compressed air. Direct the air in the reverse direction of the
normal flow.

7. Inspect the core in order to ensure cleanliness. Pressure test the core to a
pressure of 1.5 times the working pressure of the cooling circuit for one hour.
Many shops that service radiators are equipped to perform pressure tests. If
necessary, repair the core.

8. Install the core.

For more information on cleaning the core, consult your Caterpillar dealer.

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Air Starting Motor Lines Screen - Clean

If the engine is equipped with an air starting motor, use the following procedure:

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


2. Remove plug from screen housing.
3. Carefully remove screen. Clean the screen with nonflammable solvent. Inspect the
screen for damage. If the screen is damaged, replace the damaged screen with a
new screen.
4. Install clean, dry screen. Clean plug and re-install the plug.

Air Starting Motor Lubricator Bowl - Clean

If the engine is equipped with an air starting motor, use the following procedure:

WARNING!

Personal injury can result from removing hoses or fittings in a pressure system. Failure to
relieve pressure can cause personal injury. Do not disconnect or remove hoses or fittings
until all pressure in the system has been relieved.

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


2. Slowly loosen filler plug on top of housing in order to release the pressure from the
lubricator.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid
with suitable containers before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for
tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

3. Place a suitable container under bowl of the lubricator bowl and open drain valve in
order to drain the oil from the bowl.
4. Remove bowl . 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. Inspect the gasket. If the gasket is damaged,
replace the gasket.
6. Install the bowl.
7. Make sure that drain valve is closed.
8. For instructions on filling the lubricator, see this Operation and Maintenance
Manual, "Air Starting Motor Lubricator Oil Level - Check" topic.

Air Starting Motor Lubricator Oil Level - Check

NOTICE

Never allow the lubricator bowl to become empty. The air starting motor will be damaged
by a lack of lubrication. Ensure that sufficient oil is in the lubricator bowl.

1. Observe the oil level in sight gauge. If the oil level is less than 1/2, add oil to the
lubricator bowl.

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WARNING!

Personal injury can result from removing hoses or fittings in a pressure system. Failure to
relieve pressure can cause personal injury.

Do not disconnect or remove hoses or fittings until all pressure in the system has been
relieved.

2. Ensure that the air supply to the lubricator is OFF. Slowly loosen filler plug in order
to release pressure from the lubricator bowl.
3. Remove filler plug. Pour oil into the lubricator bowl. Use nondetergent SAE 10W oil
for temperatures that are greater than 0 °C (32 °F). Use air tool oil for temperatures
that are below 0 °C (32 °F).
4. Install filler plug.

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 .

Note: Some lubricators have an adjustment screw rather than a knob.

3. If necessary, adjust the lubricator in order to release from one to three drops of oil
per second. To increase the rate, turn knob counterclockwise. To decrease the rate,
turn the knob clockwise.

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Air Tank Moisture and Sediment - Drain

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

• Freezing
• Corrosion of internal parts
• Malfunction of the air starting system

WARNING!

When opening the drain valve, wear protective gloves, a protective face shield, protective
clothing, and protective shoes. Pressurized air could cause debris to be blown and result
in personal injury.

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.

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Annunciator Panel - Inspect

Inspect the annunciator panel for good condition. Perform a lamp test. All of the warning lamps
should illuminate. If a warning lamp does not illuminate, replace the bulb immediately. If the alarm
does not sound, investigate the problem and correct the problem.

Check the Gauges

Check the condition of all of the gauges. If a gauge is broken, repair the gauge or replace the
gauge immediately.

Record the Data and Review the Data

Check the oil pressure and the fuel pressure on an hourly basis during normal operation. Record
the data in a log. Compare the new data to the data that was previously recorded. Comparing the
new data to the recorded data will establish the normal gauge readings for the engine. A gauge
reading that is abnormal may indicate a problem with operation or a problem with the gauge.

Oil Pressure

Normal oil pressure at low idle rpm and at operating temperature is 172 kPa (25 psi). Normal oil
pressure at rated rpm and at operating temperature is 448 kPa (65 psi).

Oil Filter Differential Pressure

Replace the oil filter elements when one or more of the following situations occur:

• The engine is operating at rated speed and at operating temperature and the oil filter
differential pressure reaches 103 kPa (15 psi)
• The engine oil is changed

Fuel Pressure

The typical fuel pressure range is from 450 kPa (65 psi) at low idle to 700 kPa (102 psi) at high
idle.

Fuel Filter Differential Pressure

Replace the fuel filter elements when either of the following situations occur:

• The engine is operating at rated speed and at operating temperature and the fuel
filter differential pressure reaches 69 kPa (10 psi)
• The fuel filter elements have been used for 1000 hours of operation

Air Restriction

When the air restriction reaches 3.7 kPa (15 inch of H2O) then replace the soot filter. If the air
restriction exceeds this limit, excessive fuel consumption and exhaust temperatures will result.

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Barring Device - Lubricate

NOTICE

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

WARNING!

Guards must be in place prior to operating barring device motor. Remove all hand tools
prior to operating barring device motor.

Note: Prelube of the engine is recommended before the crankshaft is rotated for
normal maintenance.

The barring device provides a means for slowly turning the flywheel in order to service the engine.
The barring device can also be used to prevent rotation of the crankshaft. When the barring
device is in the engaged position, the engine starting system is disabled.

When the barring device is not used, the barring device must be fully disengaged from the
flywheel and secured in the disengaged position.

NOTICE

Do not operate the engine starting motor until the barring group pinion gear is fully
disengaged from the flywheel ring gear. Serious damage to the engine could result.

Lubricating the Pinion

1. Ensure that the barring device is locked in the disengaged position.


2. Lubricate grease fitting with MPGM until the grease is visible at vent.

Lubricating the Reducer

1. Ensure that the barring device is locked in the disengaged position.


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

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Camshaft Roller Followers - Inspect


For instructions on disassembly and assembly of the valve lifter group, see the Service Manual,
"Disassembly and Assembly" module.
Inspect the following components for wear at each metal to metal contact point:

• Rollers for the valve lifters


• Camshaft

Inspect each roller for wear, excessive movement, and end play.
If excessive wear or other signs of deterioration are found, replace the damaged components.

Centrifugal Oil Filter - Clean

WARNING!

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

Intervals for cleaning the centrifugal oil filters depend on the buildup of sludge in the centrifugal oil
filters. After disassembling the centrifugal oil filter, measure the buildup of sludge in the rotor
cover.

If the buildup of sludge is more than 12 mm (.47 inch) thick, the centrifugal oil filters must be
cleaned more often.

If the buildup of sludge is not more than 12 mm (.47 inch) thick, clean the centrifugal oil filters after
every 100 operating hours.

If the buildup of sludge is less than 12 mm (.47 inch) thick, the interval for cleaning the centrifugal
oil filters can be increased. Increase the interval in 50 hour increments until a suitable interval is
determined.

Note: To prevent oil from spraying, shut down the engine prior to removal of the
centrifugal oil filter. The shutoff valve for the centrifugal oil filter must also be
in the closed position.

1. Disassemble the centrifugal oil filter according to the instructions in the Service
Manual, "Disassembly and Assembly".
2. Thoroughly clean all of the parts of the filter. Carefully inspect all of the parts.

NOTICE

Ensure that all of the rotor components are thoroughly clean before assembling the rotor.
Failure to do so can cause an out of balance condition that can cause rapid wear to the
bearings and the spindle.

Note: Install a new paper liner when the filter is assembled.

3. Assemble the filter according to the instructions in the Service Manual,


"Disassembly and Assembly".

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Centrifugal Oil Filter - Inspect

WARNING!

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

Note: To prevent oil from spraying, the engine should be shut down prior to removal
of the centrifugal oil filter. The shutoff valve for the filter must also be in the
closed position.

1. Disassemble the centrifugal oil filter according to the instructions in the Service
Manual, "Disassembly and Assembly".
2. Thoroughly clean all of the parts of the filter. Carefully inspect all of the parts.
3. Measure the clearance between the bearing and the base and measure the
clearance between the bearing and the spindle. Follow the instructions that are in
the Service Manual. Replace any part that does not meet the specifications that are
in the Service Manual.

NOTICE

Ensure that all of the rotor components are thoroughly clean before assembling the rotor.
Failure to do so can cause an out of balance condition that can cause rapid wear to the
bearings and the spindle.

Note: Install a new paper liner when the filter is assembled.

4. Assemble the centrifugal oil filter according to the instructions in the Service
Manual, "Disassembly and Assembly".

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Cooling System Coolant - Change


Clean the cooling system before the recommended maintenance interval if the following conditions
exist:

• The engine overheats frequently.


• Foaming is observed.
• Oil or fuel has entered the cooling system and the coolant is contaminated.

NOTICE

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

Drain the Cooling System

1. Stop the engine and allow the engine to cool. Ensure that the engine will not start
when the cooling system is drained.

2. Loosen the cooling system filler cap slowly in order to relieve any pressure.
Remove the cooling system filler cap.

Note: Vent valves and must be open during engine operation.

3. Ensure that vent valves and are open during this procedure. Open the cooling
system drain valves or drain plugs. Allow the coolant to drain.

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-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

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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).

NOTICE

Improper or incomplete rinsing of the cooling system can result in damage to copper and
other metal components.

To avoid damage to the cooling system, make sure to completely flush the cooling system
with clear water. Continue to flush the system until all signs of the cleaning agent are gone.

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) or remove the cooling system drain
plugs. Allow the water to drain. 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.

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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.

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 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).

NOTICE

Improper or incomplete rinsing of the cooling system can result in damage to copper and
other metal components.

To avoid damage to the cooling system, make sure to completely flush the cooling system
with clear water. Continue to flush the system until all signs of the cleaning agent are gone.

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) or remove the cooling system drain
plugs. Allow the water to drain. 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.

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Fill the Cooling System

NOTICE

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

1. Fill the cooling system with water and SCA. For information about the proper
mixture to use, see this Operation and Maintenance Manual, "Water/Supplemental
Coolant Additive (SCA)". For the capacity of the cooling system, see this Operation
and Maintenance Manual, "Refill Capacities". 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 within 13 mm
(.5 inch) below the bottom of the filler pipe.
4. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler
cap. If the gaskets of the cooling system filler cap are damaged, discard the old
cooling system filler cap and install a new cooling system filler cap. If the gaskets of
the cooling system filler cap are not damaged, use a 9S-8140 Pressurizing Pump in
order to pressure test the cooling system filler cap. The correct pressure is stamped
on the face of the cooling system filler cap. If the cooling system filler cap does not
retain the correct pressure, install a new cooling system filler cap.
5. Start the engine. Inspect the cooling system for leaks and for proper operating
temperature.

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Cooling System Coolant Level - Check

WARNING!

Climbing equipment may be required to access this service point. Refer to the Operation
and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

Engines That Are Equipped With a Sight Gauge

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

Engines That Are Not Equipped With a Sight Gauge

WARNING!

Pressurized System: Hot coolant can cause serious burns. To open the cooling system
filler cap, stop the engine and wait until the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order to relieve the pressure.

Check the coolant level when the engine is stopped and cool. Check the coolant level only after
the engine has been stopped and the cooling system filler cap is cool enough to touch with your
bare hand.

Remove the cooling system filler cap slowly in order to relieve any pressure. Maintain the coolant
within 13 mm (0.5 inch) below the bottom of the filler pipe.

Add Coolant

Note: For the proper coolant mixture to use, see this Operation and Maintenance
Manual, "Refill Capacities and Recommendations" (Maintenance Section).

1. Stop the engine. Allow the engine to cool.


2. Remove the cooling system filler cap slowly in order to relieve any pressure. Pour
the proper coolant mixture into the filler pipe.
3. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler
cap. If the gaskets are damaged, replace the old cooling system filler cap with a
new cooling system filler cap. Install the cooling system filler cap.
4. Start the engine. Inspect the cooling system for leaks.

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Cooling System Coolant Sample (Level 1) - Obtain

NOTICE

Always use a designated pump for oil sampling, and use a separate designated pump for
coolant sampling. Using the same pump for both types of samples may contaminate the
samples that are being drawn. This contaminate may cause a false analysis and an
incorrect interpretation that could lead to concerns by both dealers and customers.

Check the concentration of supplemental coolant additive (SCA) regularly. The concentration of
SCA can be checked with an S·O·S coolant analysis (Level I).

Obtain the sample of the coolant as close as possible to the recommended sampling interval. In
order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In
order to establish a pertinent history of data, perform consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from your Caterpillar dealer.

Use the following guidelines for proper sampling of the coolant:

• Never collect samples from expansion bottles.


• Never collect samples from the drain for a system.
• Keep the unused sampling bottles stored in plastic bags.
• Keep the lids on empty sampling bottles until you are ready to collect the sample.
• Complete the information on the label for the sampling bottle before you begin to
take the samples.
• Obtain coolant samples directly from the coolant sample port. You should not obtain
the samples from any other location.
• Place the sample in the mailing tube immediately after obtaining the sample in
order to avoid contamination.

Submit the sample for Level 1 analysis.

Note: Level 1 results may indicate a need for Level 2 Analysis.

For additional information about coolant analysis, see this Operation and Maintenance Manual,
"S·O·S Coolant Analysis" or consult your Caterpillar dealer.

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Cooling System Coolant Sample (Level 2) - Obtain

NOTICE

Always use a designated pump for oil sampling, and use a separate designated pump for
coolant sampling. Using the same pump for both types of samples may contaminate the
samples that are being drawn. This contaminate may cause a false analysis and an
incorrect interpretation that could lead to concerns by both dealers and customers.

Obtain the sample of the coolant as close as possible to the recommended sampling interval.
Supplies for collecting samples can be obtained from your Caterpillar dealer.

Refer to this Operation and Maintenance Manual, "Cooling System Coolant Sample (Level 1) -
Obtain" (Maintenance Section) for the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.

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

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Cooling System Supplemental Coolant Additive (SCA) Test/Add

WARNING!

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 S·O·S coolant analysis (Level I).

Test the Concentration of the SCA

Water and SCA

NOTICE

Do not exceed the recommended eight percent supplemental coolant additive


concentration.

Test the concentration of the SCA with the 210-2606 Coolant Conditioner Test Kit. Follow the
instructions that are in this Operation and Maintenance Manual, "Water/Supplemental Coolant
Additive (SCA)" topic.

Add the SCA, If Necessary

WARNING!

Pressurized System: Hot coolant can cause serious burns. To open the cooling system
filler cap, stop the engine and wait until the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order to relieve the pressure.

1. Remove the cooling system filler cap slowly.

Note: Always dispose of fluids according to local regulations.

2. If necessary, drain some coolant in order to allow space for the addition of the SCA.

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NOTICE

Excessive supplemental coolant additive concentration can form deposits on the higher
temperature surfaces of the cooling system, reducing the engine's heat transfer
characteristics. Reduced heat transfer could cause cracking of the cylinder head and other
high temperature components.

Excessive supplemental coolant additive concentration could also result in blockage of the
heat exchanger, overheating, and/or accelerated wear of the water pump seal.

Do not exceed the recommended amount of supplemental coolant additive concentration.

3. Add the proper amount of SCA. See this Operation and Maintenance Manual,
"Water/Supplemental Coolant Additive (SCA)" topic.
4. Clean the cooling system filler cap. Install the cooling system filler cap.

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Crankshaft Vibration Damper - Inspect


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 may be the result of excessive friction. This could be due to misalignment.
Use an infrared thermometer to monitor the temperature of the damper during operation. If the
temperature reaches 93 °C (200 °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 and smooth.

If the fluid leak is oil, inspect the crankshaft seals for leaks. If a leak is observed, replace all of the
seals.

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.
• The crankshaft bearings are showing excessive wear.
• There is a large amount of gear train wear that is not caused by a lack of oil.

Dampers With Sampling Ports

Some dampers have ports for fluid samples. If the damper has no external damage, collect a 2 to
5 mL sample of the damper fluid. The fluid should be analyzed in order to check for a loss of
viscosity. Use the results of the analysis to determine if the damper should be rebuilt or replaced.
Kits for fluid samples are available from the address that follows. Return the kits to the same
address for analysis.

Hasse & Wrede GmbH


Mohriner Allee 30-42
D-12347 Berlin
Germany
Phone: 49 30 / 70 181 195
Fax: 49 30 / 70 09 08-11

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Dampers Without Sampling Ports

Some dampers do not have a port for a fluid sample. These dampers must be rebuilt or the
dampers must be replaced when one of the following criteria has been met:

• the damper has reached 20,000 hours of operation.


• the engine is undergoing a major overhaul.

Removal and Installation

Refer to the Service Manual or consult your Caterpillar dealer for information about damper
replacement.

Driven Equipment - Check


To minimize bearing problems and vibration of the engine crankshaft and the driven equipment,
the alignment between the engine and driven equipment must be maintained properly.

Check the alignment according to the commissioning data and refer to the instructions that are
provided by the following manufacturers:

• Caterpillar
• OEM of the coupling
• OEM of the driven equipment
• OEM of the vessel

Note: Caterpillar recommends the use of laser alignment tools in order to check the
alignment of the driven equipment. Refer to the documentation above for
specifications and alignment procedures.

Driven Equipment - Inspect/Replace/Lubricate

Observe the driven equipment during operation. Look for the following items:

• Unusual noise and vibration


• Loose connections
• Damaged parts

Perform any maintenance that is recommended by the OEM of the driven equipment. Refer to the
literature of the OEM of the driven equipment for the following service instructions.

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

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Engine Air Cleaner Element - Replace


Replace the Soot Filter

NOTICE

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

Unfiltered air will drastically accelerate internal engine wear. The air silencer is wrapped in a
disposable soot filter. The soot filter helps prevent airborne dust and debris from entering the air
inlet. As the soot filter becomes dirty, the air restriction increases. Replace the soot filter when the
air restriction reaches 3.75 kPa (15 inches of water).

NOTICE

Never service the air cleaner element with the engine running since this will allow dirt to
enter the engine.

1. Remove the used soot filter from the air silencer. Discard the used soot filter.
2. Inspect the air silencer. Clean the air silencer, if necessary.
3. Install a new soot filter.

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Engine Crankcase Breather - Clean


Clean the crankcase breather elements and replace the O-ring seals at every oil change.

Perform this maintenance when the engine is stopped.

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 may cause
crankshaft seal leakage. Loosen hose clamps. Remove tee.

1. Loosen retaining clamps. Remove breather assemblies and O-ring seals.


2. Wash the breather elements in clean nonflammable solvent. Inspect tee 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. 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.
5. Install the retaining clamps and the hose clamps. See the Service Manual,
"Specifications" module for the proper torque.

Engine Mounts - Check


Check the condition of the isolators. The isolators must be kept clean and dry. Ensure that the
isolators are free of oil and contamination.

Resilient Isolators

Each isolator has four rubber elements. The most usual cause for failure of the isolator is oil
contamination of the rubber elements. Inspect the rubber elements of each isolator for the
following conditions.

• Swelling
• Blistering
• Cracking

Perform the following procedures when deterioration of the rubber elements is initially observed:

• Record the observation in a log.


• Check the alignment of the driven equipment.

After deterioration of the rubber elements is initially observed, the rubber elements must be
carefully inspected. Any further deterioration of the rubber elements must be recorded. The
isolator must be repaired or replaced if rapid deterioration of the rubber elements is observed.

Deterioration of the rubber elements is usually accompanied by settling of the isolator. Settling of
the isolator will result in misalignment between the engine and the driven equipment.

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Ensure that the covers are in the correct position and that the O-rings are in good condition. This
will help prevent water from entering the top of the mount. Water may cause the adjustment screw
and/or the locknut to seize.

Measure the Height of the Isolators

There are two methods of measuring the heights of the isolator:

Acceptable - This method does not take into account deformation of the bed of the engine.
Measure the loaded height of each isolator. Use an inside micrometer and measure dimension
between the top of the soleplate and the bottom of the engine support assembly. All
measurements must be taken at the location that was marked by the manufacturer of the vessel at
the time of the engine commissioning.

Preferred - This is the most accurate method. This method will ensure that each of the mounts
are carrying the same load. Measure each corner of each isolator and record the average height
of the four measurements from each isolator.

Compare the measurement to the height that is stamped on the mounting foot of the engine or
compare the measurement to the specifications from the report from the engine commissioning. If
the measurement has changed ± 1 mm (± 0.04 inch) from the recorded height, the height of the
mounting foot must be adjusted back to the original specifications. See this Operation and
Maintenance Manual, "Engine Mounts-Inspect" for information on adjusting the engine mounts.

Note: It is important to keep accurate records of all of the measurements so that


trends can be developed for the life of the isolators.

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Engine Mounts - Inspect

Inspect the Center Bolt

Inspect the tightness of locknut on the center bolt. Use a minimum torque of 220 N·m (162 lb ft).

If the locknut is loose, perform the following Steps:

1. Tighten the locknut to 220 N·m (162 lb ft).


2. Measure clearance above adjustable assembly.
3. Compare the clearance to the specification from the engine commissioning. The
clearance and the specification from the engine commissioning must be equal.

Any difference in the clearance indicates that the height of the isolator has changed. A change in
the height of the isolator will result in misalignment between the engine and the driven equipment.

Adjusting the Height Of the Engine Support Assembly

Note: When shims are used in order to maintain the height of the engine support
assembly, the alignment of the engine and the driven equipment must be
verified.

1. Loosen setscrews.
2. Raise the engine with jacking screw.
3. Add or remove shims, if necessary. Tighten set screws.

Maintain a record of all of the shims that are added and/or removed from each isolator. When any
of the following conditions occur the isolators must be rebuilt or replaced:

• There is more than 5 mm (0.2 inch) of difference between dimension and the
dimension that is stamped on the mounting foot of the engine.
• Clearance from illustration 1 can not be adjusted to the required height.

For a standard rotation engine, the specification for clearance for the left side isolators is 9.5 mm
(0.4 inch). The specification for clearance for the right side isolators is 4.5 mm (0.2 inch).
For a reverse rotation engine, the specification for clearance for the left side isolators is 4.5 mm
(0.2 inch). The specification for clearance for the right side isolators is 9.5 mm (0.4 inch).

Note: If the isolators are repaired or replaced the engine must be realigned with the
driven equipment. The new heights of the engine mounts must be stamped on
the mounting feet. A copy of the new specifications must be added to the
report from the engine commissioning and/or ship's documents.

For the proper adjustment, refer to the shipyard's installation manual.

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Engine Oil Level - Check


The most accurate check of the oil level is performed when the engine is running at low idle and
the lube oil is warm. Perform this maintenance when the vessel is as stationary as possible.

1. If the engine is not running, start the prelube pump. If the engine is running, reduce
the engine speed to low idle.
2. Remove the oil level gauge. Observe the oil level on the oil level gauge. Maintain
the oil level between the "ADD" mark and the "FULL" mark.

NOTICE

Operating the engine with the oil level above the "FULL" mark could cause the crankshaft
to dip into the oil. The air bubbles that are created by the crankshaft dipping into the oil
reduces the lubricating characteristics of the oil. This could result in the loss of power and
cause damage to the engine. Do not overfill the engine with oil.

3. If necessary, remove oil filler cap 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. Clean the oil filler cap. Install the oil filler
cap.

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Engine Oil Sample - Obtain


In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order to monitor the condition of the engine and the
maintenance requirements of the engine. S·O·S oil analysis provides infrared analysis, which is
required for determining nitration and oxidation levels.

Obtain the Sample and the Analysis

WARNING!

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.

NOTICE

Always use a designated pump for oil sampling, and use a separate designated pump for
coolant sampling.

Using the same pump for both types of samples may contaminate the samples that are
being drawn.

This contaminate may cause a false analysis and an incorrect interpretation that could lead
to concerns by both dealers and customers.

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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 S·O·S program
for your engine.

Engine Oil Temperature Regulator - Replace


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.

Engine Oil and Filter - Change

Oil Change Interval

The oil change interval is primarily determined by the results of oil analysis. Other considerations
include the type of fuel, the lubrication oil, and the engine application. When you establish an
S·O·S oil analysis program, you will be able to evaluate the used oil. The evaluation can be used
to determine if this oil change interval is suitable for your specific engine.

Replace the lubrication oil when oil analysis determines that the oil has reached the condemning
limit.

In the absence of oil analysis, change the oil after every 500 hours of operation.

Drain the Engine Oil

WARNING!

Hot oil and components can cause personal injury.

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.

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.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid
with suitable containers before opening any compartment or disassembling any
component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for
tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

2. Open drain valve (1) in order to drain used oil. After the oil has drained, close drain
valve (1) .

If a suction device is used to drain the oil, ensure that the suction device is clean in
order to prevent dirt from entering the oil pan. Be careful not to strike the engine oil
suction tubes or the piston cooling jets.

Note: After the used oil has been drained and before the new oil is added, clean the
oil suction screen. Replace the engine oil filter elements.

Clean the Oil Suction Screen

WARNING!

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

Clean the oil suction screen at every oil change. Clean the oil suction screen after the oil sump
has been drained.

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 cover is
removed. Catch the oil with a pan. Clean up any spilled oil with absorbent
pillows or towels. DO NOT use absorbent particles to clean up the oil. Remove
the bolts and washers from cover. Remove cover and the O-ring seal. Inspect
the seal for good condition. If the seal is cut, scratched, or cracked, obtain a
new seal for assembly.

1. Slide screen assembly from the tube.


2. Wash screen assembly in clean nonflammable solvent. Allow the screen assembly
to dry before installation.
3. Install screen assembly. Install cover and the O-ring seal. Secure the cover with the
bolts and washers.

Replace the Engine Oil filters

Replace the engine oil filters for any of the following occurrences:

• Every oil change


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

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Service tools are available to aid in the service of oil filters and fuel filters. Consult your Caterpillar
dealer for the part names and the part numbers. Follow the instructions that are supplied with the
service tools. If the service tools are not used, perform the following procedure.

WARNING!

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

Perform the following procedure after the oil sump has been drained.

1. Connect a hose from each drain valve (1) to a suitable container in order to catch
the oil.
2. Open both drain valves (1). Allow the oil to drain.

Note: Some oil will remain in the housing after the oil has been drained. This oil will
pour out of the housing when cover (2) is removed. Catch the oil with a pan.
Clean up any spilled oil with absorbent pillows or towels. DO NOT use
absorbent particles to clean up the oil.

WARNING!

Personal injury can result from parts and/or covers under spring pressure. Spring force will
be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

3. Be alert to the spring force. 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
corners of the cover. Before removing the last two bolts or nuts, pry the cover
loose in order to relieve any spring pressure.
4. Remove cover. Inspect O-ring seals for good condition. If a seal is cut, scratched,
or cracked, obtain a new seal for assembly.
5. Remove spring and retainer.
6. Use a pan to catch the oil that drips when the filters are removed. Remove the four
used filters. Clean up any oil that is spilled.
7. Clean cover, spring, and retainer
8. Inspect four new filters for each housing for good condition. Coat the sealing
surfaces of the new filters with clean engine oil. Install the filters into the housing.
9. Install new O-ring seal in the cover. Install new O-ring seals in the lower tube.
Install the lower tube into the cover. Cover the bores and cover the seals with
clean engine oil. Check the location of O-ring seal during installation of the cover.

Note: The use of 2 guide pins will make installation of the cover easier.

10.Install retainer, spring, and cover. Ensure that the retainer and the spring are seated
properly against the filter and the cover. Secure the cover with the bolts.
11. Make sure that the drain valves on the covers are closed.

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Fill the Engine with Oil

1. Remove the oil filler cap. Fill the crankcase through the oil filler tube only. Clean the
oil filler cap. Install the oil filler cap.

For the correct oil to use, see this Operation and Maintenance Manual, "Engine Oil"
topic (Maintenance Section).

For the amount of oil to use, see this Operation and Maintenance Manual, "Refill
Capacities" topic (Maintenance Section).

2. Operate the prelube pump in order to fill both of the oil filter housings with oil.
Check the oil level while the prelube pump is still running. Maintain the oil level
between the "ADD" and "FULL" marks on the oil level gauge.

3. Shut off the prelube pump. Start the engine. Operate the engine at low idle rpm.
Check the oil level. Check for oil leaks.

Inspect the Used Oil Filters

Cut the used oil filter 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 cast iron parts of the engine.
Nonferrous metals may indicate wear on the aluminum parts, brass parts or bronze parts of the
engine. Parts that may be affected include the following components: main bearings, rod bearings,
turbocharger bearings and cylinder heads.

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.

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Engine Protective Devices - Check

Calibration Check

Alarms and shutoffs must function properly. Alarms provide timely warning to the operator.
Shutoffs help to prevent damage to the engine. It is impossible to determine if the engine
protective devices are in good working order during normal operation. Malfunctions must be
simulated in order to test the engine protective devices.

A calibration check of the engine protective devices will ensure that the alarms and shutoffs
activate at the setpoints. Ensure that the engine protective devices are functioning properly.

NOTICE

During testing, abnormal operating conditions must be simulated.

The tests must be performed correctly in order to prevent possible damage to the engine.

To prevent damage to the engine, only authorized service personnel or your Caterpillar dealer
should perform the tests.

· For the calibration of temperature contactors, see Special Instruction, SEHS9827,


"Calibration of Temperature Contactors".
· For the calibration of pressure contactors, see Special Instruction, SEHS9828,
"Calibration of Pressure Contactors".

Consult your Caterpillar dealer or refer to the Service Manual for more information.

Check the Magnetic Pickups

1. Clean the face of the magnet. Check the condition of the magnetic pickup.

2. Measure the resistance of the magnetic pickup. Resistance should be about 150
ohms.

3. If necessary, remove the magnetic pickup from the flywheel housing.

Note: Some sensors have flat bottoms but other sensors may have small tips. Ensure
that the tip of the sensor contacts the center point (highest point) of the gear
tooth.

4. Install the magnetic pickup in the flywheel housing. Turn the magnetic pickup
clockwise until the magnet contacts a tooth of the flywheel ring gear.

5. Turn the magnetic pickup counterclockwise for 1 1/4 turns (450 degrees). Maintain a
clearance of 1.41 to 1.76 mm (.0555 to .0693 inch) between the magnetic pickup
and the tooth of the flywheel ring gear. Tighten the locknut to 45 ± 7 N·m
(33 ± 5 lb ft).

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Engine Timing, Synchronization, and Valve Lash - Inspect/Adjust


For instructions on the following procedures, see the Service Manual, "Systems Operation/Testing
and Adjusting". Consult your Caterpillar dealer for assistance.

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. The camshafts must be correctly timed with the
crankshaft before the fuel timing is adjusted.

NOTICE

If the camshaft is rotated with the timing pin installed, the timing pin will break. This can
result in further damage. Make sure to remove the timing pin before the camshaft is
rotated.

NOTICE

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

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 continuously for extended periods of time. If,
during repairs, the prelube pump has run continuously for a period of three hours or more,
it will be necessary to remove any oil that may have collected in the cylinders and/or above
the valves.

Prelube of the engine is required before the crankshaft is rotated for normal maintenance. Activate
the prelube pump for rotating the engine crankshaft.

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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.

Fuel Injector Timing (Fuel Timing)

The camshafts must be correctly timed with the crankshaft before the fuel timing is adjusted. The
fuel timing dimension is stamped on the engine Information Plate.

Fuel Injector Clamp

The top surface of the clamp for the fuel injector must be parallel to the top surface of the cylinder
head.

Fuel Injector Synchronization

Synchronize the fuel injectors. When this maintenance procedure is complete, ensure that the
barring device is disengaged from the flywheel and ensure that the handle of the barring device is
secured in the disengaged position.

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 bridge and adjust the valve bridge, if necessary. Perform the procedure for both
valve bridges for each cylinder.

After the valve bridge is satisfactory, check the valve lash.

Engine Valve Lash

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

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.

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Engine Valve Rotators - Inspect

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.

Exhaust Shields - Inspect

WARNING!

Hot engine components can cause injury from burns. Before performing maintenance on
the engine, allow the engine and the components to cool.

NOTICE

The insulation for the exhaust system can be damaged if work is performed on the
insulation or around the insulation.

Do not tear the surface of the insulation. A torn surface will allow the insulation to absorb
flammable liquids and a fire can result from engine heat.

Remove the insulation or protect the insulation before performing work on the insulation or
around the insulation. Handle the insulation carefully.

Ensure that the exhaust manifold is cool. Inspect the insulation for the exhaust system. Replace
any insulation that is damaged. Consult your Caterpillar dealer for assistance.

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Fuel Analysis - Obtain


To ensure optimum performance of the engine, obtain a complete fuel analysis when fuel is
delivered. Obtain the analysis before using the fuel.

1. Ask the supplier of the fuel for the fuel specifications.


2. Obtain samples of the fuel.

Note: If a fuel supply is delivered to the site by trucks, obtain samples from
approximately five percent of the supply tanks.

a. Submit a sample of the fuel immediately to an independent laboratory


for analysis.
b. The fuel analysis must include all of the properties that are listed in
Special Publication, SEBU7003, "3600 Diesel Engine Fluids
Recommendations For Lubricants, Fuels, and Coolants".
c. Retain samples of the fuel in case future analysis is needed.
Label the samples accurately for future identification. The samples may
be needed for future analysis if questions about quality, stability, or
compatibility arise.
3. Compare the supplier's report to the report from the analysis. The reports may
indicate variations within the fuel. If the reports are inconsistent, obtain another
analysis of the fuel. This will eliminate the possibility of testing error.
4. Compare the reports to Special Publication, SEBU7003, "3600 Diesel Engine Fluids
Recommendations For Lubricants, Fuels, and Coolants". If the fuel does not meet
the minimum requirements, deposits and/or corrosion could cause excessive wear
on the fuel system and/or failure of the fuel system.

Clean fuel that meets the fuel recommendations will help ensure rated engine performance and
maximum engine service life.

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Fuel System - Prime

WARNING!

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system
component that will be disconnected. Fit a suitable cover over disconnected fuel system
component.

Prime the fuel system in order to fill dry fuel filters and purge air from the fuel system. Prime the
fuel system after the following occurrences:

• The fuel filter elements are replaced.


• The engine is run dry.
• The fuel lines have been disconnected.
• The engine has been overhauled.
• The engine is removed from storage.

1. Open the vent plugs for the fuel filters.


2. Operate the fuel priming pump of the vessel until fuel appears at the openings of the
vent plugs. Operate the priming pump until the fuel flows free of air bubbles. Clean
up any spilled fuel immediately.
3. Tighten the vent plugs.

Priming the Fuel System After Disconnecting Fuel Lines or After an


Overhaul

1. Loosen the connector that is above the fuel pressure regulator valve. Use a cloth to
catch any fuel and clean up any fuel that overflows.
2. Operate the fuel priming pump of the vessel until fuel appears at the opening of the
connector. Operate the priming pump until the fuel flows free of air bubbles. Clean
up any spilled fuel immediately.
3. Tighten the connector that is above the fuel pressure regulator valve.

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Fuel System Primary Filter/Water Separator - Drain

WARNING!

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

NOTICE

Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel
immediately.

Drain the primary filter/water separator on a daily basis before starting the engine.
For specific instructions for draining the primary filter/water separator, see the service information
that is provided by the OEM of the primary filter/water separator.

NOTICE

The water separator is under suction during normal engine operation. Ensure that the drain
valve is tightened securely to help prevent air from entering the fuel system.

Fuel System Primary Filter/Water Separator Element - Replace

WARNING!

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help
prevent possible injury, turn the start switch off when changing fuel filters or water
separator elements. Clean up fuel spills immediately.

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system
component that will be disconnected. Fit a suitable cover over disconnected fuel system
component.

Replace the element of the primary filter/water separator according to the instructions that are
provided by the OEM of the primary filter/water separator.

Note: It may be necessary to prime the fuel system before the engine will start. See
this Operation and Maintenance Manual, "Fuel System - Prime" topic
(Maintenance Section).

Fuel System Secondary Filter - Replace


Replace the secondary fuel filter elements when either of the following conditions occur:

• The engine is operating at rated speed and at operating temperature and the fuel
filter differential pressure reaches 69 kPa (10 psi).
• The fuel filter elements have been used for 1000 hours of operation.
Service tools are available to aid in the service of oil filters and fuel filters. Consult your Caterpillar
dealer for the part names and the part numbers. Follow the instructions that are supplied with the
service tools. If the service tools are not used, perform the following appropriate procedure.

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Replacing the Secondary Filters With the Engine Stopped

WARNING!

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help
prevent possible injury, turn the start switch off when changing fuel filters or water
separator elements. Clean up fuel spills immediately.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid
with suitable containers before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for
tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of
all fluids according to local regulations and mandates.

1. Stop the engine. Connect one end of a hose to each drain valve. Insert the other end
of the hoses into a suitable container in order to catch the fuel.

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system
component that will be disconnected. Fit a suitable cover over disconnected fuel system
component.

NOTICE

Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel
immediately.

2. Remove both vent plugs. Open both drain valves in order to drain the secondary fuel
filters.

Note: If the fuel filter is installed vertically, then the drain valves are in the bottom.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

WARNING!

Personal injury can result from parts and/or covers under spring pressure.

Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

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Note: Some fuel will remain in the housing after the fuel has been drained. This fuel
will pour out of the housing when cover is removed. Catch the fuel with a pan.
Clean up any spilled fuel with absorbent pillows or towels. DO NOT use
absorbent particles to clean up the fuel.

3. Be alert to the spring force. Gradually loosen but do not remove the last two bolts
or nuts that are located at opposite corners of cover. Before removing the last two
bolts or nuts, pry the cover loose in order to relieve any spring pressure.
4. Remove cover and O-ring seal. Inspect the seal for good condition. If a seal is cut,
scratched, or cracked, obtain a new seal for assembly.
5. Remove spring and retainer.
6. Filters are loaded on wire rack that is inside of the housing. Remove wire racks.
Use a pan to catch the fuel that drips when the rack and filters are removed.
Remove the used filters. Clean up any fuel that is spilled.
7. Clean cover, spring, and retainer. Clean rack and clean the inside of the housing.
8. Inspect 4 new filters for each housing for good condition. Coat the sealing
surfaces of the new filters with clean diesel fuel. Place the filters onto rack. Install
the filters and the rack into the housing.
9. Install retainer, spring, cover and O-ring seal. Ensure that the retainer and the
spring are seated properly against the filter and the cover. Secure the cover with
the bolts.
10. Make sure that the drain valves on the covers are closed. Clean vent plugs. Install
the vent plugs loosely. Prime the fuel system. See this Operation and Maintenance
Manual, "Fuel System - Prime" topic (Maintenance Section).
11. Start the engine and check for fuel leaks.

Replacing the Secondary Filters During Engine Operation

WARNING!

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

WARNING!

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

1. To service the lower secondary fuel filter, turn control valve to the "UPPER RUN"
position.
2. Connect one end of a hose to drain valve. Insert the other end of the hose into a
suitable container in order to catch the fuel.

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NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system
component that will be disconnected. Fit a suitable cover over disconnected fuel system
component.

NOTICE

Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel
immediately.

3. Remove vent plug. Open drain valve in order to drain the secondary fuel filter.
4. Perform Steps 3 through 9 from "Replacing the Secondary Filters With the Engine
Stopped".
5. Close drain valve. Clean vent plug. Install the vent plug loosely. Slowly turn control
valve to the "LOWER FILL" position. After five minutes, turn control valve to the
"BOTH RUN" position. Tighten vent plug.
6. To service the upper secondary fuel filter, turn control valve to the "LOWER RUN"
position. Perform Steps 1 through 5 for the upper secondary fuel filter.
7. After both of the. secondary fuel filters have been serviced, turn control valve (1) to
the "BOTH RUN" position.

Fuel Tank Water and Sediment - Drain

Day Tank

Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel can
cause excessive wear to the fuel system. Condensation occurs during the heating and cooling of
fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to
the day tank. This causes water to accumulate in the day tank. Draining the day tank regularly and
obtaining fuel from reliable sources can help to eliminate water from the fuel.

Day tanks should have a provision for draining water and sediment.

Open the drain valve on the bottom of the day tank in order to drain the water and the sediment.
Close the drain valve.

Drain the water and sediment from the day tank daily. The quality of the fuel or the operating
conditions may require the water and sediment to be drained more often.

Fill the day tank after operating the engine in order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The fuel expands as the fuel gets warm. The tank may
overflow.

Some day tanks use supply pipes that allow water and sediment to settle below the end of the fuel
supply pipe. Some day tanks use supply lines that take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular maintenance of the fuel system filter is important.

Fuel Storage Tanks

Drain the water and the sediment from the fuel storage tank daily. Ensure that the water and
sediment is drained from the fuel storage tank when the tank is refilled. This will help prevent water
and/or sediment from being pumped from the fuel storage tank into the engine fuel tank.

If a bulk storage tank has been refilled or moved recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.

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Governor Actuator Linkage - Check


Check the governor actuator linkage for proper operation. For the procedure to adjust the actuator
linkage, see the Service Manual, "Systems Operation/Testing and Adjusting".

Metal Particle Detector - Inspect


If the metal particle detector causes a shutdown, inspect the detector.

1. Use a 1/2 inch ratchet to remove cover and the O-ring seal from the detector.
2. Remove the grid and the O-ring seal for the grid from the inside of the detector.
3. If metal particles are found, determine the source of the particles. Make repairs, as
needed.

NOTICE

Metal particles in the lube oil may indicate a serious condition that requires immediate
attention.

If metal particles are found in the grid of the detector, do not start the engine until the
source of the particles is found and the condition is corrected. Failure to do so could cause
severe damage to the engine.

4. Clean the inside of the detector and clean the grid with nonflammable solvent.

Note: To replace the O-ring seals and the grid, use the 165-5690 Particle Detector Kit .

5. Inspect the grid and the O-ring seals for good condition. Obtain new parts, if
necessary.
6. Install the clean, dry grid and the O-ring seal for the grid.
7. Install the cover and the O-ring seal for the cover. Torque the cover to 54 N·m
(40 lb ft).

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Oil Mist Detector - Maintain

NOTICE

The engine can be severely damaged by excessive oil mist.

To help ensure proper operation of the oil mist detector, perform the recommended
maintenance on the detector.

Failure to perform the recommended maintenance for the oil mist detector can allow these
possible effects on the operation of the detector:

· Inability to activate an alarm for excessive oil mist


· Activation of faults in the detector
· Activation of false alarms for excessive oil mist

Perform the maintenance procedures for the oil mist detector according to the instructions
in Service Manual, RENR2225, "Oil Mist Detectors".

Note: The intervals for performing the maintenance are provided as guidelines.
Particular installations may require more frequent maintenance intervals.

Maintenance Schedule for the Oil Mist Detector

Interval Maintenance Procedure

When Required Perform all of the following maintenance after the vessel has been in storage:

Daily Maintain the system for the compressed air.

Check the pressure of the vacuum in the measuring head.


Every Month Adjust the pressure, if necessary. (1)

Clean the box for the oil drain (if equipped).

Perform the following maintenance on these items in the


Every 3 Months measuring head: Clean the bores for the filered air.
Replace the sintered bronze filters.
Clean the glass of the infrared filters.

Replace the sintered bronze filter for the pressure regulator.

Every Year Clean the suction lines for sampling the atmosphere from the crankcase.

Clean the oil drain line.

( 1 ) When this procedure is performed after Every Three Months, perform this procedure last.

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Overhaul (Major)
The need for a major overhaul is determined by several factors.

• An increase of oil consumption


• An increase of crankcase blowby
• A decrease and variation of cylinder compression

Other factors must also be considered for determining a major overhaul:

• The total amount of fuel consumption


• The service hours of the engine
• The wear metal analysis of the lube oil
• An increase in the levels of noise and vibration

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

Note: It is possible for oil analysis to indicate a decrease of wear metals in the lube
oil. The cylinder liners may be worn so that polishing of the bore occurs. Also,
the increased use of lube oil will dilute the wear metals.

Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer
about scheduling a major overhaul.

Note: The driven equipment may also require service when the engine is overhauled.
Refer to the literature that is provided by the OEM of the driven equipment.

A major overhaul includes all of the work that is done for top end overhauls. A major overhaul
includes additional parts and labor. Additional parts and labor are required in order to completely
rebuild the engine.

For the major overhaul, all of the bearings, seals, gaskets, and components that wear are
disassembled. The parts are cleaned. The parts are inspected. If necessary, the parts are
replaced. The crankshaft is measured for wear. The crankshaft may require regrinding.
Alternatively, the crankshaft may be replaced with a Caterpillar replacement part.

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

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.

Rebuild - The component is reconditioned in order to comply with reusability guidelines.

Replace - The service life of the part is exhausted. The part may fail before the next maintenance
interval. The part must be replaced with a part that meets functional specifications. The
replacement part may be a new part, a CAT remanufactured part, a rebuilt part, or a used part.
Some worn components may be exchanged with your Caterpillar dealer for a credit on
replacement parts.

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Consult your Caterpillar dealer about repair options for your engine.

If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the
recommendations in Table 1.
Table 1

Recommendations for the Major Overhaul

Service Component

Rebuild Centrifugal oil filters

Cylinder heads

Starting motor

Vibration damper

Replace Accessory group bearings

Camshaft bearings (1)

Connecting rod bearings (2)

Cylinder head valves and valve guides

Cylinder head valve spring guides

Exhaust manifold bellows

Exhaust shields

Front gear train bearings (3)

Fuel injectors

Main bearings (2)

Oil pump bearings

Oil temperature regulators

Turbocharger bearings and bushings

Water pump bearings

Water temperature regulators

Inspect Aftercooler cores

Alarm and shutoff controls

Camshafts (1) (4)

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Crankshaft (2) (4)

Cylinder liners

Cylinder sleeves

Exhaust manifolds

Front gear group (3)

Oil cooler

Oil pump bushings

Oil suction screen

Pistons and piston rings

Priority valve

Rear gear group (3)

Rear gear train bearings (3)

Rocker arm bearings

Thermocouples

Thrust bearings

Valve mechanism group

Replace the gaskets and Air inlet lines


seals of these components.
Camshaft front covers

Camshaft drive gear covers

Central structure covers

Crankcase side covers

Crankshaft (5)

Crankshaft vibration damper

Cylinder heads

Exhaust manifold

Front housing group

Fuel lines

Fuel transfer pump

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Gear inspection group

Oil cooler

Oil lines

Oil temperature regulators

O-ring seals and plugs

Power take-off covers

Priority valve group

Rear gear train

Rear housing group

Rear structure covers

Turbocharger

Valve covers

Water lines

Water pumps

Water temperature regulators

( 1 ) Inspect the camshaft for damage to the journals and the lobes. Inspect the camshaft
bearings and the camshaft followers for signs of wear and/or scuffing.

( 2 ) Inspect the crankshaft for these conditions: deflection, damage to the journals and bearing
material that has seized to the journals. Inspect the profile and the taper of the crankshaft journals.
Compare the crankshaft journals to the wear patterns in the connecting rod bearings and the main
bearings.

( 3 ) Inspect the gears and the bushings of the gear trains for worn gear teeth, unusual fit, and
unusual wear.

( 4 ) If the crankshaft or the camshaft are removed for any reason, use the magnetic particle
inspection process to check for cracks.

( 5 ) Inspect the area around the front seal and the rear seal of the crankshaft. It is not necessary
to replace a crankshaft seal if the seal is not leaking.

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Overhaul (Top End)


The overhaul interval that is listed in this Operation and Maintenance Manual, "Maintenance
Interval Schedule" is expressed in fuel consumption and service hours. The more accurate figure
to use is fuel consumption. Fuel consumption corresponds more accurately to the engine load.

Table 1 lists an average range of fuel consumption for a reasonable load factor before a top end
overhaul. Use the range of fuel consumption only as a guideline.

Table 1

Approximate Fuel Consumption Before A Top End Overhaul

Engine Model Fuel Consumption (1)

3618 12 605 000 to 14 763 000 L


3 330 333 to 3 900 000 US gal

( 1 ) The fuel consumption is based on fuel with a low heat value of 42 780 kJ/kg and density of
838.9 g/L.

A top end overhaul involves the removal, the inspection, and the rework of the cylinder head
components. Some additional components are replaced and serviced.

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

Note: The driven equipment may also require service when the engine is overhauled.
Refer to the literature that is provided by the OEM of the driven equipment.

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.

Rebuild - The component is reconditioned in order to comply with reusability guidelines.

Replace - The service life of the part is exhausted. The part may fail before the next maintenance
interval. The part must be replaced with a part that meets functional specifications. The
replacement part may be a new part, a CAT remanufactured part, a rebuilt part, or a used part.
Some worn components may be exchanged with your Caterpillar dealer for a credit on
replacement parts. Consult your Caterpillar dealer about repair options for your engine.

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If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the
recommendations in Table 2.

Table 2

Recommendations for the Top End Overhaul

Service Component

Inspect Replace Cylinder sleeves

Exhaust shields

Starting motor

Turbocharger bearings, bushings, and seals

Clean Inspect Oil cooler core

Oil suction screen

Rebuild Cylinder heads Exhaust valves (1)

Exhaust valve seat inserts

Inlet valves (1)

Inlet valve seat inserts

Inner valve springs

Outer valve springs

Valve spring guides

Valve spring locks

Valve rotators

Replace Cylinder head gaskets

Exhaust manifold gaskets

Fuel injectors

Fuel transfer pump seals

Oil pump bearings and seals

Oil temperature regulators and seals

O-ring seals and plugs

Seals for the inlet air lines

Water pump bearings and seals

Water temperature regulators and seals

( 1 ) The angles of the valves and the seats are different. If the valves and the seats are not replaced, lap
the valves and the seats. The valve and the outer diameter of the seat must have 360 degrees of contact.
If the valves and the seats require grinding, see the Service Manual, "Specifications" for the angles.

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Overhaul Considerations
Severe Operation

Severe operation is the use of an engine that exceeds current published standards for that engine.
Caterpillar maintains standards for the following engine parameters:

• Horsepower
• Range of rpm
• Fuel consumption
• Fuel quality
• Altitude
• Maintenance intervals
• Selection of oil
• Selection of coolant
• Environmental qualities
• Installation

Refer to the standards for your engine or consult your Caterpillar dealer in order to determine if
your engine is operating within the defined parameters.
Severe operation can accelerate component wear. Engines that are operating under severe
conditions may need more frequent maintenance intervals for the following reasons:

• Maximum reliability
• Retention of full service life

Because of individual applications, it is not possible to identify all of the factors which can
contribute to severe operation. Consult your Caterpillar dealer about the maintenance that is
needed for your specific engine.

The following factors can contribute to severe operation: environment, improper operating
procedures and improper maintenance practices.

Environmental Factors

Extreme Ambient Temperatures

Extended operation in environments that are extremely cold or hot can damage components.
Valve components can be damaged by carbon buildup if the engine is frequently started and
stopped in very cold temperatures. Extremely hot inlet air reduces the performance capabilities of
the engine.

Note: See this Operation and Maintenance Manual, "Cold Weather Operation" topic
(Operation Section), or see Supplement, SEBU5898, "Cold Weather
Recommendations".

Cleanliness

Unless the equipment is cleaned regularly, extended operation in a dirty environment and in a
dusty environment can damage components. Built up mud, dirt, and dust can encase components.
This can make maintenance difficult. The buildup can contain corrosive chemicals. Corrosive
chemicals and salt can damage some components.

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Improper Operating Procedures


• Extended operation at low idle
• Minimum cool down periods after high load factor operation
• Operating the engine beyond the guidelines for the engine rating
• Operating the engine at loads that are greater than the rated load
• Operating the engine at speeds that are greater than the rated speed
• Use of the engine for an application that is not approved

Improper Maintenance Practices


• Extension of maintenance intervals
• Not using recommended fuel, lubricants, and coolant/antifreeze

Overhaul Information
An overhaul is replacing the major worn components of the engine. An overhaul interval 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

Most owners will save money by overhauling the engine at the intervals that are recommended in
this Operation and Maintenance Manual

The higher peaks result from two key factors:

• Delaying an overhaul until a breakdown increases the chance of a catastrophic


failure. This type of failure requires more parts, labor, and cleanup.
• Excessive wear means that fewer components will be reusable. More labor may be
required for salvage or repair of the components.

When all of the costs are considered, "repair-before-failure" is the least expensive alternative for
most components and engines.

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.

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Overhaul Intervals
Some 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

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.

Other factors must also be considered for determining a major overhaul:

• The total amount of fuel consumption


• The service hours of the engine
• An increase of oil consumption
• An increase of crankcase blowby
• The wear metal analysis of the lube oil
• An increase in the levels of noise and vibration

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

Note: It is possible for oil analysis to indicate a decrease of wear metals in the lube
oil. The cylinder liners may be worn so that polishing of the bore occurs. Also,
the increased use of lube oil will dilute the wear metals.

Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.

Note: The driven equipment may also require service when the engine is overhauled.
Refer to the literature that is provided by the OEM of the driven equipment.

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Using Fuel Consumption For Calculating the Overhaul Intervals

Experience has shown that maintenance intervals are most accurately based on fuel consumption.
Fuel consumption corresponds more accurately to the engine load. Tables 1, 2, and 3 list average
ranges of fuel consumption for a load factor of approximately 60 percent.

Table 1
Maintenance Intervals for Overhaul
Fuel Consumption for 3508B Engines and 3508 Engines with the EUI System
High High High
Interval Rated Up To Rated 1301 To Rated 1601 To Performance B Performance D
1300 RPM (1) 1600 RPM (1) 1800 RPM (1) and C Ratings (1) and E Ratings (2)
666,667 L 500,000 L
Top End 1,000,000 L
(176113.4214 (132,085
Overhaul (264,170 US gal)
US gal) US gal)
Second
2,000,000 L
Top End n/a n/a
(528,340 US gal)
Overhaul

Major 3,000,000 L 2,000,000 L 1,500,000 L


Overhaul (792,510 US gal) (792,510 US gal) (396,255 US gal)

(1) Fuel consumption is based on a load factor of approximately 60 percent.


(2) Fuel consumption is based on a load factor of approximately 40 percent.

Table 2
Maintenance Intervals for Overhaul
Fuel Consumption for 3512B Engines and 3512 Engines with the EUI System
High High High
Interval Rated Up To Rated 1301 To Rated 1601 To Performance B Performance D
1300 RPM (1) 1600 RPM (1) 1800 RPM (1) and C Ratings (1) and E Ratings (2)
1,000,000 L 750,000 L
Top End 1,500,000 L
(264,170 (198,127
Overhaul (296,255 US gal)
US gal) US gal)
Second
3,000,000 L
Top End n/a n/a
(792,510 US gal)
Overhaul

Major 4,500,000 L 3,000,000 L 2,250,000 L


Overhaul (1,188,765 US gal) (792,510 US gal) (594,382 US gal)

(1) Fuel consumption is based on a load factor of approximately 60 percent.


(2) Fuel consumption is based on a load factor of approximately 40 percent.

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Table 3
Maintenance Intervals for Overhaul
Fuel Consumption for 3516B Engines and 3516 Engines with the EUI System
Rated Up Rated 1301 Rated 1601 High High High
Interval To 1300 To 1600 To1800 Performance Performance B Performance D
RPM (1) RPM (1) RPM (1) A Ratings (2) and C Ratings (1) and E Ratings (3)

Top End 2,000,000 L 1,000,000 L


Overhaul (528,340 US gal) (264,170 US gal)

Second
4,000,000 L
Top End n/a n/a n/a
(1,056,680 US gal)
Overhaul

Major 6,000,000 L 4,000,000 L 3,000,000 L


Overhaul (1,585,020 US gal) (1,056,680 US gal) (792,510 US gal)

(1) Fuel consumption is based on a load factor of approximately 60 percent.


(2) Fuel consumption is based on a load factor of approximately 80 percent.
(3) Fuel consumption is based on a load factor of approximately 40 percent.

Use the actual records of fuel consumption, when possible. If the actual records are not available,
use the following procedure in order to estimate the fuel consumption.

Table 4
Equation For Calculating Overhaul Intervals
F/R = H
"F" is the estimated total amount of fuel consumption of the engine.
"R" is the rate of fuel consumption in liters per hour or gallons per hour.
"H" is the number of estimated hours until the overhaul interval

1. Estimate the average percent of the load for the operation of the engine.
2. Refer to the fuel consumption data in the Technical Marketing Information (TMI) for
your engine. This will determine the fuel consumption for the percent of the load that
was estimated in Step 1. Use this figure as variable "F" for the equation in Table 4.
For more information about the Technical Marketing Information (TMI) for your
engine, consult your Caterpillar dealer.

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Oil Consumption as an Overhaul Indicator


Oil consumption, fuel consumption, and maintenance information can be used to estimate the total
operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable for the maintenance intervals.

Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of
the engine load is increased, the amount of oil that is consumed per hour also increases.

The oil consumption rate (brake specific oil consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC) depends on the engine load. Consult your
Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine.

When an engine's oil consumption has risen to three times the original oil consumption
rate due to normal wear, an engine overhaul should be scheduled. There may be a
corresponding increase in blowby and a slight increase in fuel consumption.

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.

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. New parts are not necessary if the old parts can be reused, repaired, or salvaged.
Otherwise, the old parts can be replaced or exchanged.

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:

• Cylinder heads
• Oil Pumps
• Turbochargers
• Water pumps

Consult your Caterpillar dealer for details and for a list of the remanufactured parts that are
available.

Your Caterpillar dealer may be offering a variety of overhaul options.

A Flat Rate Overhaul guarantees the maximum price that you will pay for an overhaul. Flat rate
prices on preventive maintenance programs or major repair options are available from many
servicing dealers for all Caterpillar Engines. Consult your Caterpillar dealer in order to schedule a
before failure overhaul.
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Overhaul Recommendation

Caterpillar recommends a scheduled overhaul in order to minimize downtime. A scheduled


overhaul will provide the lowest cost and the greatest value. Schedule an overhaul with your
Caterpillar dealer.

Overhaul programs vary between dealers. To obtain specific information about the types of
overhaul programs and services, consult your Caterpillar dealer.

Starting Motor - Inspect

More frequent inspection and replacement of the starting motor may be required for the following
conditions:

• Operation in harsh environments


• Applications that require frequent stops and starts, such as the operation of a fast
ferry

If the starting motor fails, the engine may not start in an emergency situation. A scheduled
inspection of the starting motor is recommended.

The starter motor pinion and the flywheel ring gear must be in good condition in order for the
engine to start properly. The engine will not start if the starter motor pinion does not engage the
flywheel ring gear. The teeth of the starter motor pinion and the flywheel ring gear can be
damaged because of irregular engagement.

Inspect the starting motor for proper operation. Listen for grinding when the engine is started.
Inspect the teeth of the starter motor pinion and the flywheel ring gear. Look for patterns of wear
on the teeth. Look for teeth that are broken or chipped. If damaged teeth are found, the starter
motor pinion and the flywheel ring gear must be replaced.

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

Remove the air starting motors for inspection. Overhaul the air starting motors. Refer to the
Service Manual or consult your Caterpillar dealer for instructions on removing and on overhauling
the air starting motors.

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Trend Data - Record


Records of engine performance are an important element of a maintenance program. The data on
engine performance can help to predict problems with operation. Also, the data can provide
information that is useful for achieving optimum operation.

Traditionally, data on engine performance might be recorded regularly. However, the data might
not be reviewed until the occurrence of a problem. This method of monitoring engine operation
has several disadvantages:

• The engine may not be providing optimum performance. This may not be noticed
because the engine does not exhibit excessive changes in performance.
• Because a problem occurs, the engine may be in an alarm condition that requires a
quick response.
• Repairs may cause more downtime.
• The cost of downtime is compounded by the cost of parts and labor for repairs.

The absence of an alarm condition does NOT guarantee normal operation. Not all parameters
have alarms and/or shutdowns. Setpoints for alarms are outside of the normal ranges in order to
avoid occasional nuisance warnings. An alarm indicates a serious condition that requires
immediate attention. Service or repair is a reaction to an alarm condition.

A different approach is necessary in order to schedule service before an alarm condition occurs.

Monitor the trends of the engine's performance.

The following benefits can be realized:

• Reduction of engine performance will be noticed sooner.


• Problems can be predicted. This enables prevention of the problems. Service can
be planned before an alarm condition occurs.
• Planning for downtime will also reduce downtime.
• The cost of parts and labor for service that is planned will be less than the cost of
repairs that are not anticipated.

Monitoring the Trends of Engine Performance

For marine applications, the power demand can be difficult to determine. Consider the following
factors for determining the power demand:

• For propulsion with a water jet or a fixed propeller, the theoretical power is
approximately proportional to the cubed engine speed.
• Power demand at a given engine speed is dependent on several factors: loading of
the vessel, weather, design of the hull and other conditions.

To maintain a program for monitoring that is successful, several factors are important:

• Record the data regularly when the engine is operating at similar loads and speeds.
• Obtain accurate data.
• At regular intervals, review the data in a graphic format.
• Perform corrections before damage and/or downtime occurs.

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Accurate data is provided by accurate instruments and proper use of the instruments. The gauges
and the sensing devices must be in good condition. This is especially true for thermocouples.
Establish a program for calibrating the instruments periodically. Avoid using infrared thermometers
for obtaining data. Be sure to read the gauges properly. Accurate recording of the data is also
important.

Use the following Steps to establish a program.

1. Establish a baseline for the engine parameters. The baseline is necessary in order
to know the normal gauge readings. The new data will be compared to the
baseline.

• Use the data from the engine commissioning. The data is recorded for
various loads. The data is recorded before any wear or deterioration
takes place.
• If there is no data from the engine commissioning, use data from the
engine test cell. Understand that the data will not be specific to the site.
• If data is not available from the engine commissioning or the engine test
cell, calculate an average of the existing data.
• Establish a new baseline after an overhaul.
2. Frequently record the new data during engine operation. For an example of a log to
use, see this Operation and Maintenance Manual, "Hourly Performance Log"
(Reference Information Section).

Be aware that the readings of some parameters depend on the engine load.
Record the data when the engine is operating at a high load. This increases the
accuracy of the data. Also, any reduction in performance will be revealed sooner.
A load of 75 to 100 percent is recommended.

• For operations with a consistent load cycle, record the data at the same
time for each day.
• If the load can be controlled, set the load to the same amount for each
reading.

Some parameters that are NOT affected by the load ARE affected by the engine
rpm. Obtain the readings for these parameters when the engine is operating at the
same rpm.

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Some parameters are not affected by either the load or the rpm. See Table 1.
Table 1

Parameters of Engine Operation

Parameters That Depend On the Load

Aftercooler and oil cooler water temperature (outlet)

Cylinder pressure

Crankcase pressure

Exhaust manifold pressure

Exhaust manifold temperature

Exhaust port temperature

Inlet air restriction

Inlet air temperature

Inlet manifold air pressure (boost pressure) (1)

Inlet manifold air temperature (1)

Outlet temperature of the jacket water

Parameters That Depend On the RPM

Fuel filter differential pressure

Fuel pressure

Jacket water pressure

Lube oil pressure

Oil filter differential pressure

Parameters That Are Independent of the Load and RPM

Aftercooler and oil cooler water temperature (inlet)

Inlet temperature of the jacket water

Lube oil temperature

( 1 ) This includes the air before the aftercooling and after the aftercooling.

Note: A gauge reading that is abnormal may indicate a problem with operation or a
problem with the gauge.

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3. Average the data for each day. Use a computer or graph paper in order to produce
a graph of the data. Compare the new data to the baseline. This will help to reveal
the trends of the engine performance.

Illustration 1 shows that the engine oil pressure was near baseline (1). Later, the
operating pressure was approaching setpoint (3). The trend of operating pressure
(2) indicated that the condition required investigation before activation of the alarm.

4. Compare the new data to the data from previous months. This comparison will be
useful for scheduling reconditioning for the engine.

Monitoring the Trends of Oil Consumption

The consumption of lube oil depends on the following factors:

• Engine load
• Hours of operation
• Type of oil

Monitor the engine's oil consumption by calculating the Specific Oil Consumption on a daily basis.
Be aware that the following conditions can produce misleading data on oil consumption:

• Improper operation of the lube oil centrifuge


• Inaccurate measurement of additions of oil
• Leaking of lube oil
• Overfilling of the oil sump

To measure additions of oil accurately, use a meter to monitor additions of oil at the engine. Also,
check the total oil consumption against the delivery of oil.

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Calculating Specific Oil Consumption


Use the equation that is in Table 2 in order to calculate the Specific Oil Consumption.

Table 2
Equation For Calculating the Specific Oil Consumption
OžD
= BSOC
bkW-hr
O is the liters of fuel that have been consumed.
D is the density of the fuel. The density is expressed in grams per liter.
bkW-hr is the kilowatt hours that have been produced during consumption of the oil.
BSOC is the brake specific oil consumption.
This is expressed in grams per kilowatt hour.

To calculate the BSOC, the bkW-hr must be known. Table 3 is an example for calculating the bkW-
hr. The data in the example assumes the following conditions:

• A meter was used to measure the fuel consumption of 1000 liters.


• The density of the fuel sample is 980 grams per liter.
• One kilowatt hour per 200 grams of fuel is the average estimate. This is based on
Brake Specific Fuel Consumption (BSFC) for various engine loads and for various
operating conditions.

Table 3
Example For The Calculation of Kilowatt Hours
1000 L 980 g bkW-hr
ž ž = 9800 bkW
1 L 200 g

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Turbocharger - Inspect
Periodic inspection and cleaning is recommended for the turbocharger compressor housing (inlet
side).

Fouling of the compressor can contribute to loss of engine power, increased black smoke and
overall loss of engine efficiency.

If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the turbocharger compressor wheel could allow parts
from the compressor wheel to enter an engine cylinder. This can cause additional damage to the
pistons, the valves, and the cylinder head.

NOTICE

Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and
exhaust systems. Loss of engine lubricant can result in serious engine damage.

Minor leakage of a turbocharger housing under extended low idle operation should not
cause problems as long as a turbocharger bearing failure has not occurred.

When a turbocharger bearing failure is accompanied by a significant engine performance


loss (exhaust smoke or engine rpm up at no load), do not continue engine operation until
the turbocharger is repaired or replaced.

An inspection of the turbocharger can minimize unscheduled downtime. An inspection of the


turbocharger can also reduce the chance for potential damage to other engine parts.

Note: Turbocharger components require clearances that are precise. The


turbocharger cartridge must be balanced due to high rpm. Severe service
applications can accelerate the wear of the components. Severe service
applications may require more frequent inspections of the turbocharger.

Removal and Installation

For options regarding the removal and installation of the turbocharger, refer to Service Manual,
RENR1335, " 3618 Engine" or consult your Caterpillar dealer. For repair instructions, refer to
Operation and Maintenance Manual, SEBU7642, "TPL 65 Turbocharger" or consult your
Caterpillar dealer.

Cleaning and Inspecting

1. Remove the exhaust outlet piping and remove the air inlet piping from the
turbocharger. Visually inspect the piping for the presence of oil.
2. Turn the compressor wheel and the turbine wheel by hand. The assembly should
turn freely. Inspect the compressor wheel and the turbine wheel for contact with the
turbocharger housing. There should not be any visible signs of contact between the
turbine wheel or compressor wheel and the turbocharger housing. If there is any
indication of contact between the rotating turbine wheel or the turbocharger wheel
and the turbocharger housing, the turbocharger should be reconditioned or
replaced.
3. Check the compressor wheel for cleanliness. If only the blade side of the wheel is
dirty, dirt and/or moisture is passing through the air filtering system. If oil is found
only on the back side of the wheel, there is a possibility of a failed turbocharger oil
seal.
The presence of oil may be the result of extended engine operation at low idle. The
presence of oil may also be the result of a restriction of the line for the inlet air
(plugged air filters), which causes the turbocharger to slobber.
4. Inspect the bore of the turbine housing for corrosion.
5. Clean the turbocharger housing with standard shop solvents and a soft bristle brush.
6. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing.

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Walk-Around Inspection
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 compartment 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 (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.

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 and tight. 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 the removal
of water pumps and the installation of water pumps and/or seals, refer to the Service Manual 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 cover.
• Inspect 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.
• Drain the water and the sediment from fuel tanks on a daily basis in order to ensure
that only clean fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for loose connections and for worn
wires or frayed wires.
• Inspect the ground strap for a good connection 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. Inspect the gaskets and the exhaust bellows
joint. If a leak is found, make repairs.

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Water Pump - Inspect


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.

Water Temperature Regulator - Replace


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

NOTICE

Failure to replace the temperature regulators on a regularly scheduled basis could cause
severe engine damage.

Never operate the engine without the temperature regulators installed.

If the temperature regulator is installed incorrectly, the engine may overheat, causing
cylinder head damage. Ensure that the new temperature regulator is installed in the original
position.

A 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.

NOTICE

A temperature regulator that fails in a partially opened position can cause overheating or
overcooling of the engine.

A 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.

For the procedure to replace the temperature regulators, see the service information that is
provided by the OEM of the temperature regulators.

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Cylinder Overhaul Procedure Index

Single Cylinder Overhaul

Procedure ....................................................................................................................................3-3
Cylinder Head Removal Initial Steps ............................................................................................3-4
Cylinder Head Removal (3600) ....................................................................................................3-5
Cylinder Head Removal (3618) ....................................................................................................3-7
Cylinder Head Disassembly ........................................................................................................3-9
Cylinder Head Assembly ............................................................................................................3-11
Rod and Piston Removal (3600) ................................................................................................3-12
Rod and Piston Removal (3618) ................................................................................................3-13
Rod and Piston Disassembly ....................................................................................................3-14
Cylinder Liner Removal ..............................................................................................................3-15
Camshaft Segment and Journal Removal (3600) ......................................................................3-16
Camshaft Bearing Removal........................................................................................................3-17
Camshaft Bearing Installation ....................................................................................................3-17
Camshaft Segment and Journal Installation ..............................................................................3-18
Cylinder Liner Installation ..........................................................................................................3-20
Piston / Connection Rod Assembly ............................................................................................3-21
Piston & Connection Assembly Installation (3600) ....................................................................3-22
Piston & Connection Assembly Installation (3618) ....................................................................3-24
Cylinder Head Installation (3600) ..............................................................................................3-27
Cylinder Head Installation (3618) ..............................................................................................3-29
Post Installation Of Cylinder Head ............................................................................................3-32
Crankshaft Position for Fuel Injector Timing & Valve Lash Adjustments....................................3-33
Crankshaft Main Bearing Removal & Installation (3600) ..........................................................3-35
Crankshaft Main Bearing Removal & Installation (3618) ..........................................................3-40

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Caterpillar 3600 Diesel Engine Single Cylinder Overhaul Procedure

WARNING!

• During the single cylinder overhaul, major overhaul or maintenance procedures


the PRE-LUBE Pump must be operating while the engine is being rotated to
prevent damage to engine components.
• Personal injury or death can result from the engine starting.
• The engine can start and injure persons working on or near the engine.
• Be sure the engine cannot be started while service work is being performed.
This is very important when the engine is equipped with an Automatic Start
Stop System.
• On engines equipped with an air starting system, close the air supply valve to
the air starting motor before service work is begun.
• Shut off air supply at the air reservoir. Drain the pressurized air from the air
from starting system. The sudden release of pressurized air can cause personal
injury.
• Personal injury can result from oil under high pressure.
• DO NOT allow high-pressure oil to contact skin.
• Wear appropriate protective equipment while working with high-pressure oil
systems.

NOTICE:

During all Assembly Procedures keep all parts clean from contaminants. Contaminants
may cause rapid wear and shortened component life.

Note: The 4C9515 Overhaul Protection Kit can be used to protect 3600 Vee engines
from dust, dirt and heavy moisture entry while the engine is being overhauled.

Note: The 4C9525 Overhaul Protection Kit can be used to protect 3600 In-line engines
from dust, dirt and heavy moisture entry while the engine is being overhauled.

NOTICE:

Care must be taken to ensure that all fluids are contained during performance of
inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collet
the fluid with suitable containers before opening any compartment or disassembling any
component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Products Guide" for tools and
supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids
according to local regulations and mandates.

Tool Group: The 8T2850 Tool Group must be used to overhaul the 3600 engines. If the correct
service tool is not used damage could occur to certain engine components.

Features/Benefits: The 8T2850 Diesel Combination Tool Group consists of 9U5105 Basic Tool
Group and 9U5106 Diesel Tool Group. Both tool groups contain essential tools to test and adjust,
remove and install, and disassemble and assemble components of the 3600 Diesel Engine. The
9U5105 Basic Tool Group can be used on either diesel or spark-ignited engines.

Note: The 8T2850 Tool Group does not contain tools to disassemble or assemble
turbochargers or cylinder heads. A 9U7522 Tool Group, Head Repair is available
to repair heads.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 3

The 8T2850 Diesel Combination Tool Group contains tools to:

- Drain oil filter housing & remove filter elements.


- Tension cylinder head studs & main bearing studs.
- Drain fuel filter housing to remove filter elements.
- Protect crankshaft rod journal & align connecting rod assembly onto crankshaft during
removal & installation of piston & rod assembly.
- Test, check, & adjust fuel timing & injector synchronization.
- Support piston & connecting rod assembly while removing & installing rod bearing.
- Rotate crankshaft.
- Disassemble centrifugal oil filter.
- Remove & Install the following:
- Idler gears - Wrist pin - Water pump seal
- Main bearings - Camshaft segments - MUI
- Camshaft journals - Camshaft bearings - Flywheel
- Cylinder head - Piston ring - Cylinder liner
- Vibration damper - Piston & Connecting
rod assembly

3-3 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 4

Cylinder Head Removal (Initial Steps)

Q -- DENOTES CRITICAL STEP


Procedures required for the initial removal of the Cylinder Head.
Step Procedure

1 Steam clean engine to remove foreign material from Valve Cover are.
2 Disconnect starting system.
3 Drain oil.
Q 4 Remove and inspect Oil Filters for foreign material
5 Drain coolant.
6 Shut off fuel supply.
7 Drain fuel from Fuel Manifold.
8 Remove Exhaust Manifold Blanket (if equipped).
9 Remove, clean & Cap Exhaust Manifold.
10 Remove, clean & Cap coolant Manifold.
11 Remove, clean & Cap Crankcase Breather (if equipped).
12 Remove, clean & Valve Cover.
13 Remove, clean & Valve Cover Base.
14 Remove Rocker Arm assembly.(put location identification marks).
Q 15 Clean & inspect Rocker Arm Shaft hold down Bolts.
16 Remove Pushrods. (put loc. Id. marks)
17 Remove Valve Bridges. (put loc. Id. marks)
Q 18 Clean & inspect Valve Bridge bore for roughness or wear.
Q 19 Clean & check lubrication passage for restriction.
Q 20 Clean & inspect Valve Bridge Dowel for roughness or wear.
21 Disassemble Rocker Arm assembly.
Q 22 Clean & inspect Rocker Arms.
Q 23 Remove, Clean & inspect Rocker Arm Buttons.
24 Remove Valve Lifter Cover.
25 Remove, clean & Cap Oil supply Tube.
26 Remove Valve Lifter Assembly (put loc. Id. marks).
Q 27 Clean & inspect Valve Lifter Assembly. Inspect roller for wear or damage and
looseness on shaft.
NOTICE: Valve lifter guide springs may be installed on valve lifters only once. If valve lifter guide springs is
removed from a valve lifter, the guide spring must be replayed with a new guide spring. If the lifter guide springs is
not remove from a valve lifter after the lifter is remove from a valve lifter guide, the valve lifter can be installed in
original location without having to replace the valve lifter guide spring.

Q Check Valve Lifter Assembly Bore> Inspect Valve Lifter Diameter


28
for roughness. > Inspect for roughness.
> Valve: 42.000 ± 0.002 mm > Valve: 41.910 ± 0.010 mm
(1.6535 ± 0.0001 in) (1.650 ± 0.0004 in)
> MUI: 56.00 ± 0.02 mm > MUI: 55.900 ± 0.0102 mm
(2.205 ± 0.001 in) (2.201 ± 0.0004 in)
29 Check Lubrication passages in lifter body for obstructions..
30 Remove O-ring & Insert from the upper end of the Valve Lifter & inspect .
31 Remove, clean & Cap Fuel supply Lines & Fittings.
32 Disconnect Fuel Control Rod from Control Lever.
33 Use 8T3268 Unit injector Removal Bolts (2) & remove MUI.
NOTICE: Do not use pry bar to remove MUI
34 Clean & inspect MUI & install new O-rings.

3-4 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 5

Cylinder Head Removal


The following are tools from the 207-5034 Stud Tensioner Tool Group.
This group was the first tool group used on 3600 Engines only.

Part No. Qty. Tool and Part Name


8T0820 1 Hydraulic Pressure Group
3S6224 1 Electric Hydraulic Pump (115V-50/60 Cycle)
8S8033 Electric Hydraulic Pump (230V- 50/60 Cycle)
191-5347 Hydraulic Pump, Pneumatic
156-7167 Hydraulic Pump, Manual
8T-0895 4 Hydraulic Cylinder Groups
8T-3035 1 Lines Group
(5) 6D-7726 - Hoses
(1) 3J-5390 - Plug
(1) 8T-5206 - Manifold
(5) 1P-2375 - Coupler Assembly (male)
(8) 1P-2376 - Coupler Assembly (female)
8T0891 4 Threaded Collar (head stud)
8T0889 2 Threaded Collar (used on front head studs on # 1 cylinder to
clear fuel filters)
8T-0897 4 Pedestal (head stud)
8T-0898 2 Pedestal (used on front head studs on # 1 cylinder to clear fuel
filters)
4C-6987 1 Socket
9U-5141 2 Nut turning Handle
126-6918 1 Lifting Bracket (Vee)
126-6919 Lifting Bracket (In-line)
126-6920 1 Tiller Handle
5D-1972 2 Bolt 3/4 -10 NC X 11 3/4 (29.9 cm) long

Q - DENOTES CRITICAL STEP


Procedures required for the removal of the Cylinder Head Using the 207-5034 Tool Group.
Step Procedure
Q 1 Remove and Clean Cylinder Head Stud Protectors.
Q 2 Clean Stud threads.
3 Install (4) 8T0897 Protectors on Cylinder Head Studs
4 Install (4) 8T0897 Hydraulic (Hyd.) Tensioners
5 Install (4) 8T0897 threaded Collars
6 Install (4) 6T7726 (Hose) 1P2376 (Coupler) Hyd. Hoses to Hyd. Tensioners
7 Install Hyd. Hoses to 8T5206 (1-Manifold) 1P2375 (5-Coupler) 3J5390 (1-Plug)
8 Install Hyd. Hoses to Hyd. Pump
9 Place Hyd. Pump in bypass
10 Tighten (CW) all Collars (this bleeds all oil from Hyd Tensioners)
11 Loosen (CCW) all Collars 11/2 turn loose
CAUTION: Before operation pump, be sure all connections are secure. Be sure all hoses are in
good condition. Oil escaping under high pressure can cause personal injury. Wear safety glasses.
Q 12 Operate Hyd pump to 40,000 ± 1500 kPa (5,800 ± 220 psi)
WARNING: While pressurizing or loosing the Cylinder Head Stud Nuts, make sure you have no
body parts above hydraulic tensioning equipment. If Head Stud should break personal injury could
occur.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 6

13 Using the 9U5141 Handle loose all Cylinder Head Nuts 11/2 turns or 12 holes.
14 Slowly release Hydraulic Oil Pump pressure.
15 Remove all tooling.
Q 16 Remove and Inspect Nuts and Washers.
17 Install (4) 126-6919 (in-line) 126-6918 (vee) 126-6920 (handle) Head Lifting Tool.
18 Remove Cylinder Head. 204kg (450 lbs)
CAUTION: Care should be taken not to damage Head Studs
Q 19 Remove, Clean & Inspect Combustion Gasket.
Q 20 Remove & Clean Water Seal Adapters.
Q 21 Remove & Clean Water Seal Plates.
22 Install 4C9515 Overhaul Protection Kit part as needs to protect all opening from for-
eign material.
See pages in this book for Combustion Seal Gasket specification and part number, Cyliner
Liner part numbers on pistons and piston rings.

3-6 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 7

The following are tools from the 191-5320 Stud Tensioner Tool Group
This is the second tool group used on 3600 Series Engines and with some modification the tools
can be used on the 3618 engine.
Part No. Qty. Tool and Part Name
227-6724 1 Hydraulic Pump, Electric, 120V
227-8834 Hydraulic Pump, Electric, 240V
191-5347 Hydraulic Pump, Pneumatic
156-7167 Hydraulic Pump, Manual
229-9453 1 Pump Accessory Group (required)
178-9312 (4) - Hose Assembly
178-9313 (1) - Distribution Coupler (manifold)
185-0683 (1) - Comparison Gauge
191-5320 1 Stud Tensioner Tool Group (required)
191-5322 (4) - Stud Tensioner Cylinder Group for 3606, 3608, 3612, 3616
Cylinder Heads
191-5333 (4) - Stud Tensioner Cylinder Support for Cylinder Head
(replacement for damage support) 3606, 3608, 3612, 3616
191-5324 (4) - Stud Tensioner Cylinder Bushing for Cylinder Head
(replacement for damage support) 3606, 3608, 3612, 3616
179-9051 (4) - Replacement Bushing for modification of Stud Tensioner
Group for 3618 Cylinder Head.
178-9053 (4) - Replacement Support for modification of Stud Tensioner
Group for 3618 Cylinder Head.
191-5341 1 Optional Gear Drive Group (permits faster rotation of nut onto stud)
191-5343 (4) Turning Sleeve (for 191-5322 Stud Tensioner Cylinder Groups)
191-5342 (4) Gear Drive Assembly
(2) Swivel Head Ratchet (1/2 inch square drive)
229-9457 1 Auxiliary Group
225-5637 (2) Support (used in place of the 191-5333 Support when used on
front head studs on # 1 cylinder to clear fuel filters.)
225-5636 (2) Bushing(used in place of the 191-5324 Bushing when used on
front head studs on # 1 cylinder to clear fuel filters.)
126-6918 1 Lifting Bracket (Vee)
126-6919 Lifting Bracket (In-line)
126-6920 1 Tiller Handle
5D1972 2 Bolt 3/4 -10 NC x 11 3/4 (29.9 cm) long

3-7 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 8

Q - DENOTES CRITICAL STEP


Procedures required for the removal of the Cylinder Head Using the 191-5320 Tool Group.
Step Procedure
Q 1 Remove and Clean Cylinder Head Stud Protectors.
Q 2 Clean Stud threads.
NOTE: The 191-5322 Tensioner Cylinder (4), 191-5333 Support (4), 191-5324 Bushing (4) tools
must be assembled together to form a Stud Tensioner Cylinder Groups. Four of the groups
are required.
NOTE: The 191-5333Support (4), 191-5324 Bushing (4), may be changed out with 178-0051
Bushing (4)., 178-9053 Support (4) to complete the 3618 Cylinder Head.
are required.
NOTE: An optional 191-5341 Gear Drive Group may be added to each Stud Tensioner Cylinder
Groups to aid in th turning of the cylinder head stud nut during removal and installation.

3 Install (4) the Stud Tensioner Groups on Cylinder Head Studs


4 Install (1) 178-9313 (Manifold) to the Hydraulic Pump of choice
5 Install (4) 178-9312 Hydraulic Hose As. to the (4) 191-5322 Stud Tensioner
Groups
6 Install the (4) Hose AS. to the 178-9313 Coupler
7 Open the shutoff valve
8 Tighten (CW) all Bushings (this bleeds all oil from Hyd Tensioners)
9 Loosen (CCW) all Bushings 1 1/2 turn loose
WARNING: Before operation pump, be sure all connections are secure. Be sure all hoses are in
good condition. Oil escaping under high pressure can cause personal injury. Wear safety glasses.
10 Pressure-Regulate-Valve to the low position
11 Shut-Off-Valve to the close position
12 While operating pump turn the Pressure-Regulate_Valve towards the high
position
NOTE: This must be done slowly to prevent a too high pressure. If the pressure should rise
above the specification, damage can occur to studs, nuts or cylinder head.
Q 13 3600 Series Engine Operate Pump to 123 ± 15 mPa (17,660 ± 200 psi)
3618 Series Engine Operate Pump to 125 ± 15 mPa (18,140 ± 200 psi)
WARNING: While pressurizing or loosing the Cylinder Head Nuts, make sure you have no body
parts above hydraulic tensioning equipment. If Head Stud should break personal injury could
occur.
NOTE: If the 9U5141 Handle is used perform step 14. If the 191-5341 Gear Drive Group is used
perform step 15.
14 Using the 9U5141 Handle loosen all Cylinder Head Nuts 12 holes. (1 1/2 turns)
15 Use the 1/2 drive ratchet and turn the gear 2 complete revolutions.
16 Slowly open the Shut-Off-Valve to release Hydraulic Oil Pump pressure.

NOTE: Do not move the Pressure-Regulate-Valve to change the pressure of the pump. When you
have the pressure set by using the Pressure-Regulate-Valve teh same setting can be used by
all other heads for both removal and install.

17 Remove all tooling.


Q 18 Remove and Inspect Nuts and Washers.
19 Install 126-6919 (in-line) , 126-6918 (vee) 126-6920 (handle) Head Lifting Tool.
20 Remove Cylinder Head 204kg (450 lbs)
CAUTION: Care should be taken not to damage Head Studs.
Q 21 Remove Clean & Inspect Combustion Jacket.
Q 22 Remove and Clean Water Seal Adapters.

Q 23 Remove and Clean Water Seal Plates.


24 Install 4C9515 Overhaul Protection Kit part as needs to protect all openings
from foreign material.

See pages in this book for Combustion Seal Gasket specifications and part numbers. Cylinder Liner
part numbers on pistons and piston rings.

3-8 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 9

Cylinder Head Disassembly, Assembly & Repair


Part No. Qty. Tool and Part Name
1U9352 1 Engine Stand
8T2826 1 Head Adapter
3S6224 1 Hydraulic Pump, Electric, 120V (1,3,4)
8S8033 Hydraulic Pump, Electric, 240V (1,3,4)
191-5347 Hydraulic Pump, Pneumatic (1,3,4)
156-7167 Hydraulic Pump, Manual (1,3,4)
6V7047 1 Cylinder (20 ton) (1)
8T3109 1 Retaining Plate (1)
8T3108 1 Compression Plate (1)
8T2679 1 Rod (1)
1D4720 2 Nuts (5/8 - 11 NC) (1)
8T3035 1 Hydraulic Lines (1)
8T0820 1 Hydraulic Pressure Gauge (1)
8T2660 1 Valve Spring Compressor (2)
8F6350 1 Bolt 3/8 -16 NC X 8 in (203 mm) (2)
5B2638 1 Bolt 3/8 -16 NC X 5 1/4 in (133 mm) (2)
4B5271 1 Washer - 3/8 in (2)
9S8752 1 Nut
9U5096 1 Bridge
6V7047 1 Hydraulic Puller (3)
9U5098 1 Thread Insert (3)
1F7958 1 Full Nut (4)
7Y2292 1 Washer (4)
1U9570 1 Dowel Puller Gp. (Slide Hammer Puller)
4C8731 1 Dowel Puller Rod (4)
5P5247 1 Hydraulic Puller
8T2674 1 Valve Seat Driver
8T2676 1 Valve Guide Driver
8T2672 1 Bridge Dowel and Plug Driver
130-2534 1 Bridge Dowel Gauge
9U7522 1 Head Repair Tool Group
4C8540 ( 1 ) - Dowel and Plug Driver
4C8731 ( 1 ) - Dowel Pulling Rod (4)
4C9839 ( 1 ) - Safety Retainer Gp. with ( 2 ) 2M5139 Machine Screws (4)
8T2673 ( 1 ) - Stop sleeve
8T2674 ( 1 ) - Valve Seat Drive
8T2676 ( 1 ) - Valve Guide Driver As.
8T2679 ( 1 ) - Puller Rod As.
8T2681 ( 1 ) - Cylinder Support Pedestal (4)
9U6399 ( 1 ) - Valve Guide Gauge
9U6401 ( 1 ) - Valve Guide Gauge
130-1449 ( 1 ) - Valve Seat Puller) (3)
8T2660 ( 1 ) - Compressor Group
4C8769 1 Valve Seat Driver (used for water cooled exhaust valve seats)
147-2285 1 Valve Seat Gp.
4C2980 1 Valve Projection Group
8S2263 1 Valve Spring Tester
9U6068 1 Vacuum Pump
FT1741 1 Vacuum Test Adapter
( 1 ) Tool used to compress all 4 valve springs at same time.
( 2 ) Tool used to compress 1 single valve springs at a time.
( 3 ) Tool used to hydraulic pull valve seat, used in conjunction with the 130-1449 Valve Seat Puller time.
( 4 ) Tool used to hydraulic pull valve guide.
3-9 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 10

Q - DENOTES CRITICAL STEP


Procedures required for the disassembly of the Cylinder Head
Step Procedure
1 Install 8T2826 Head adapter on Cylinder Head
2 Install Cylinder Head & 8T2826 adapter on 1U9352 Stand

NOTE: If this is a production type of shop area the service tools in the tool list for all four
valve may be used in place of the 8T2660 Valve Spring Compressor Tool.

3 1 Install the 8T2660 Valve Spring Compressor Tool ( same tool used on all
4 Valves).
4 Compress Valve Spring. ( on all 4 Valves).
WARNING: Do not remove or install the spring locks with your fingers. If the spring should
move, personal injury may result.
5 Release Pressure slowly.

6 Remove tooling.
Q 7 Remove Rotocoil and inspect ( on all 4 Valves).

Q 8 Remove outer Valve Spring and inspect ( on all 4 Valves).

Q 9 Free length 114.0 mm ( 4.488 in ).

Q 10 Using the 8S2263 Valve Spring Tester Compress Spring to 84.87 mm


( 3.340 in ). Force required 682 to 834 N (153 to 188 lb.)

Q 11 Remove inner Valve Spring and inspect.

Q 12 Free length 107.0 mm ( 4.213 in ).

13 Using the 8S2263 Valve Spring Tester Compress Spring to 79.25 mm


( 3.120 in ). Force required 325 to 297 N (73 to 89 lb.)
14 Remove Valve (on all 4 Valves). (put loc. ld. marks )

Q 15 Inspect Valves for damage. ( on all 4 Valves)


Q 16 Remove & Inspect Valve Seat. (on all 4 Valves)

17 Use 130-1449 Valve Seat Removal Tool and Valve Seat (if necessary)

Q 18 Use 9U6399 and 9U6401 gauges and measure Valve Guide bore.

Q 19 Use 130-2534 Bridge Dowel Gauges and Inspect/Check straightness and


height.
20 Use 8T2676 Valve Guide Removal Tool and Removal Valve Guide (if
necessary)
Q 21 Thoroughly clean and inspect Cylinder Head.

Q 22 Inspect water jacket of Cylinder Head.

23 If cleaning is necessary, remove all plugs before using hot tank process for
cleaning.

3 - 10 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 11

Q - DENOTES CRITICAL STEP


Procedure required for the assembly of the Cylinder Head
Step Procedure
1 Install new O-rings on all plugs. By using the Service Manual and the correct
lubricant install all Plug and O-ring assemblies in their proper location with the
correct torque.
2 Put clean engineoil on the outside of the valve guide.
3 Use 8T2876 Valve Gude Driver & install valve guide.
NOTICE: Be careful not to damage the cylinder head with hammer.
Q 4 Height of valve guide from top of cyliner head is:
20.0 ±2.0 mm (0.79 ± 0.08 in.)
Q 5 Inside diameter of valve guide (new) 16.031 ± 0.011o in.).
6 Use 4C8540 Dowel Driver & Install Bridge Dowels
Q 7 Height of Bridge Dowel from top of cylinder head is:
105.0 ± 2.0 mm (4.1 ± 0.08 in.)
NOTE: The 130-2534 Bridge Dowel Gauge may be used to check height of Bridge Dowel
8 Use a Dowel Driver and install Rocker Arm Support Dowels.
Q 9 Height of Rocker Arm Support Dowels from top of cylinder head is:
8.0 ± 1.0 mm (0.314 ± 0.039 in.)
Q 10 Check diameter of Insert 97.195 ± 0.015 mm (3.8266 ± 0.0006 in.).
11 Use 8T2874 Valve Seat Driver and Install Valve Seat Inserts:
Standard Inserts: Room temperature - Apply a light coat of clean engine oil
on outside diameter and radius area.
Water Cooled Exhaust Inserts: Room temperature - Apply 4C9500 Quick
Cure Primer & 4C9507 Retaining Compound over Primer. Only install with
Hydraulic Press.
12 Inspect the valve. If necessary, grind enough to restore the valve face.
NOTE: Be sure to use a fine stone that is properly dressed and has the correct diameter for
grinding the valve.
13 Install valve in the original position
Q 14 Use a straight edge and a thickness gauge to determine the amount of
material that will be removed from the valve seat.
Measure the projection. Place a straight edge acroos the valve head. Measue
the distance between the straight edge and the bottom deck of the cylinder
head. Dimension must be +0.5 to -2.0 mm (+0.02 to - 0.079 in.)
15 Use an orbital valve seat grinder with a fine stone that has the correct
Q diameter in order to polish the valve seat insert.
16 Put a light coat of Prussian Blue on the valve seat of each valve. Install each
valve in the original location

Q 17 Check the correct pattern on the valve face. A continuous line that is 3.0 mm
(0.12 in.) around the valve face indicates a good fit.
18 If a continuous line is not obtained, use a light-lapping compound on the
valve face area.
NOTE: Be sure the lapping compound is completely removed from all parts.
19 Clean, Lubricate Valve Stems with 8T2998 and install all valves in
proper location.
20 Install Valve Spring Guides (all 4 valves)
21 Install Inner Valve Springs (all 4 valves)
22 Install Outer Valve Springs (all 4 valves)
23 Install Robo-coils (all 4 valves)
24 Install the 8T2660 Valve Spring Compressor Tool. (all 4 valves)
25 Compress Valve Spring (all 4 valves)
26 Install retaining Locks. (all 4 valves)
WARNING: The valve keepers can be thrown from the valve when the valve spring compressor
is released. Ensure that the valve keepers are properly installed on the valve stem. To help
prevent personal injury, keep away from the front of the valve keepers and valve springs during
the installation of the valves.
27 Remove Valve Spring Compressor & lightly hit the end of each valve stem
with a soft face hammer.
28 Use 9U6485 Vacuum Pump & FT1741 Vacuum Tester to check leak down
rate. Apply a vacuumof 25 in. hg. (minimum). The maximum allowable leak
down rate is 5 in. hg. in 10 seconds.
3 - 11 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 12

Rod and Piston Removal for 3600 Series Engine


Part No. Qty. Tool and Part Name
8T-3022 1 Rod Guide Group (In-Line)
4C-6357 1 Rod Guide Group (Vee)
8T-2859 4 Aluminum Nuts
4C-9039 1 Bracket Assembly
FT-2252 1 Assembly Fixture
136-1452 1 Internal Tip Pliers
9U-5981 1 Snap Ring Retainer
8T-3033 1 Ring Expander Group
1U-8692 1 Piston Pin Guide
4C-9522 1 Protective Cover
4C-3654 1 Gauge - Ring Groove (Top & 2nd Ring)
1U-9030 1 Gauge - Ring Groove (3rd Ring)
1U-9029 1 Gauge - Ring Groove (Oil Ring)
4C-9515 1 Overhaul Protection Kit (provides covers for one cylinder)
145-5190 1 Piston Support Group (if jut the rod bearing is to be removed this tool
may be used to hold piston and rod in position while changing
rod bearing.)

Q - DENOTES CRITICAL STEP


Procedures required for removal of the Piston/Rod Assembly
Step Procedure
1 Remove Crankcase Side Cover (1 each side)
2 Remove Piston Cooling Jet.
NOTICE: Special care must be taken not to bend the Piston Cooling Jet because they are
precision aligned with a cooling passage in the piston.
Q 3 Inspect Cooling Jet for cracks or evidence of contact with other components.
4 Tap Cooling Jet lightly to remove debris from the screen.
Q 5 Check diameter of orifice
3.98 to 4.02 mm (.157 to .158 in)
NOTICE: Do not enlarge orifice.

NOTICE: If this is at TOP END OVERHAUL for 145-5190 Piston/Rod Support Group may
be install where the outside piston cooling jet was removed. This tool will support the
Piston/Rod Assembly in-place while the crankshaft is being rotated to remove and install
new rod bearings
NOTICE: Remove carbon accumulation from the cylinder before removing piston.
6 Turn Crankshaft until Nuts that hold Connecting Rod Cap can be removed.
7 Loosen all Nuts and remove 3 of the 4 Nuts that hold the Connecting Rod Cap.
8 Place a 51 x 102 mm (2x4 in) x 1200 mm (48 in.) long board from side to side
to support cap.
9 Turn engine (TDC) until there is enough clearance for Connecting Rod Cap to
come off the bolts.
10 Raise board to support Cap and remove the 4th Nut.
NOTICE: DO NOT re-sue Connecting Rod Nuts. Connecting Rod Bolts may be reused if the bolt
meets all of the reusability guidelines (SEBF8063) and if the free length is 329.00 mm (12.953 Inches)
or less. The free length is measured from the underside of the bolt head to the end of the bolt
threads.
11 Carefully lower the Connecting Rod Cap down and let board support the cap.
16 kg (35 lb)
12 Using board, slide Connecting Rod Cap to the outside and remove.
13 Mark the lower Connect Rod Bearing for position.
14 Install 8T3022 Connecting Rod Guide Group (In-line)
Install 4C6357 Connecting Rod Guide Group (Vee)
15 Install 6T2859 Aluminum Nuts ( 4) on rod bolts.
NOTICE: Use round aluminum nuts provided. Using Standard Connect Rod Nuts can cause
damage to Cylinder Liner wall.
16 Use a 1/2 - 13 NC Bottom Tap to clean carbon from the holes that are
provided for 4C9039 Lifting Bracket.
17 Using 1/2 - 13 NC Bolts (2) install 4C9039 Lifting Bracket to Piston.
18 Use overhead lifting device and remove Piston/Connecting Rod assembly.
102 kg (225 lb)
19 When removing Piston/Connecting Rod assembly the engine may be turned
to prevent interference.
3 - 12 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 13

Piston/ Connection Rod Removal for D3618 Engine


Part No. Qty. Tool and Part Name
178-5083 1 Pin Guide
235-0612 1 Bracket Assembly
0V-0375 2 Bolt
4C-9515 1 Overhaul Protection Kit (provides covers for one cylinder)
156-7160 1 Piston Support Group (if just the rod bearing is to be removed
rod bearing.)

Q - DENOTES CRITICAL STEP


Procedures required for the removal of the Piston/Rod Assembly
Step Procedure
1 Remove Crankcase Side Cover. (1 each side)
2 Remove Piston Cooling Jets (2/Cylinder)
NOTICE: Special care must be taken not to bend the Piston Cooling Jets because they are
precision aligned with a cooling passage in the piston.
Q 3 Inspect Cooling Jets for cracks or evidence of contact with other components.
4 Tap Cooling Jet lightly to remove debris from the screen.
Q 5 Check diameter of orifice.
3.50 mm (.14 in.)

NOTICE: Do not enlarge orifice.


NOTICE: If this is at TOP END OVERHAUL for 145-5190 Piston/Rod Support Group may be
installed where the outside piston cooling jet was removed. This tool will support the Piston/Rod
Assembly in-place while the crankshaft is being rotated to remove and install new rod bearings
NOTICE: Remove carbon accumulation from the cylinder before removing piston.
6 Turn crankshaft until Locks and Bolts that hold Connect Rod Cap can be
removed.
7 Loosen all Nuts and remove 3 of the 4 Nuts that hold the Connecting Rod
Cap.
8 Remove the bolt lokcs (2).
9 Remove two bolts and install 178-5083 Guides (2).
10 Remove the last two bolts.
11 Tap rod cap lightly with plastic dead blow hammer.
12 Carefully remove rod cap 16 kg (35 lb) and guides.
13 Put location marks on rod cap.
14 Turn crankshaft until piston is at TDC for piston to be removed.
15 Use a 1/2 - 13 NC Bottom Tap to clean carbon from the holes that are
provided for 4C9039 Lifting Bracket.
16 Using 1/2 - 13 NC Bolts (2) install 4C9039 Lifting Bracket to Piston.
17 Place a clean rag between connect rod and cylinder liner to prevent
damage to liner.
18 Use overhead lifting device and remove Piston/Connecting Rod assembly
123 kg (271 lb)
19 When removing Piston/Connecting Rod assembly the engine may be
turned to prevent interference.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 14

Rod and Piston Disassembly


Part No. Qty. Tool and Part Name
8T-3022 1 Rod Guide Group (In-Line)
4C-6357 1 Rod Guide Group (Vee)
8T-2859 4 Aluminum Nuts
4C-9039 1 Bracket Assembly
FT-2252 1 Assembly Fixture
136-1452 1 Internal Tip Pliers
9U-5981 1 Snap Ring Retainer
8T-3033 1 Ring Expander Guide
1U-8692 1 Piston Pin Guide
4C-9522 1 Protective Cover
4C-3654 1 Gauge - Ring Groove (Top & 2nd Ring)
1U-9030 1 Gauge - Ring Groove (3rd Ring)
1U-9029 1 Gauge - Ring Groove (Oil Ring)
4C-9515 1 Overhaul Protection Kit (provides covers for one cylinder)

Q - DENOTES CRITICAL STEP


Procedures required for disassembly of the Piston/Rod Assembly
Step Procedure
1 Remove Connecting Rod Guide Group
2 Remove Upper Connecting Rod Bearing. (Put ID mark on upper Bearing)
NOTICE: Connecting Rod Nuts are not reusable. Connecting Rod Bolts may be reused if the bolt
meets all of the reusability guidelines (SEBF8063) and if the free length is 329.00 mm (12.953 inch)
or less. The free length is measured from the under side of the bolt head to the end of the
threads.
NOTICE: Because the 3618 uses a different type of rod, the Piston/Rod Assembly must be
3 Lower Piston/Connecting Rod assembly down on a solid surface (do not lay
assembly flat)
NOTICE: Do not scratch the machined surface for the Connecting Rod Cap.
4 Install 9U5981 Wrist Pin Snap Ring Retainer Tool in hole of Wrist Pin.
WARNING: Failure to use 9U5981 Wrist Pin Snap Ring Retainer could cause personal injury if
snap ring should come off pliers.
5 Use 5P4758 Internal Snap Ring Pliers and remove both Wrist Pin Snap Ring
Retainers.
CAUTION: When Wrist Pin Snap Rings are removed the Wrist Pin may slide out.
WARNING: Hold the connecting rod to prevent it from falling as the piston is removed.
50 kg (110 lb)
6 Install 1U8692 Piston Pin Guide into Wrist Pin.
CAUTION: Check the 1U8692 Service tool to make sure it is free of damage. Clean and
lubricate with engine oil.
7 Carefully slide the Service Tool and Wrist Pin out. 30 kg (63 lb.)
8 Place Piston on workbench. 38 kg (82 lb.)
9 Use 8T3033 Piston Ring Expander and remove Piston Rings.
Q 10 Clean and inspect Piston using Reusability Guidelines.
Q 11 Use 4C3854, 1U9030 & 1U9029 Ring Groove Gauge to determine Piston
Ring Groove Wear.
See pages in this book for wear limit specifications on pistons and piston rings.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 15

Cylinder Liner Removal for 3600 Series Engine


Part No. Qty. Tool and Part Name
3S-6224 1 Electric Hydraulic Pump (115V-50/50 Cycle)
8S-8033 Electric Hydraulic Pump (230V-50/60 Cycle)
191-5347 Hydraulic Pump, Pneumatic
156-7167 Hydraulic Pump, Manual
6V-7073 1 Liner Puller Group
8T-3035 2 Hydraulic Line
8T-0820 1 Hydraulic Pressure Group
4C-9041 1 Cylinder Installation Tool Group

Q - DENOTES CRITICAL STEP


Procedures required for the installation of the Cylinder Liner
Step Procedure
1 Install 4C9515 Overhaul Protection Kit part as needed to protect all
openings from foreign material.
2 Install 6V7073 Cylinder Liner Puller into Cylinder Liner.
3 Install (2) 6D7726 (Hose) 1P2376 (Coupler) Hyd Hoses to Cylinder Liner
Puller
4 Install Hyd. Hoses to 8T5206 (1-manifold) 1P2375 (5-Coupler) 3J5390
(1- plug)
5 Install Hyd. Hose to Hyd. Pump.
CAUTION: Before operating pump, be sure all connections are secure. Be sure all hoses are in
good condition. Oil escaping under high pressure can cause personal injury. Wear safety glasses.
6 Operate Hydraulic Pump until Cylinder Liner O-rings are free of Cylinder
Block.
7 Use overhead lifting device to remove Cylinder Liner Puller and Cylinder Liner
as one. 160 kg (360 lb.)
8 Remove O-rings from Cylinder Liner.
Q 9 Clean and inspect Cylinder Liner as per Reusability Guidelines.
128 kg (282 lb.)
10 Install 4C9515 Overhaul Protection Kit part as needs to protect all openings
from foreign material.
11 Remove sealing plates and O-rings.
Q 12 Clean and inspect Sealing Plates and Install new O-rings.
See pages in this book for wear limit specifications on cylinder liners.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 16

Camshaft Segment and Journal Removal for 3600 Series Engine


Part No. Qty. Tool and Part Name
8T3029 1 Camshaft Segment Support
1U6311 1 Adapter, Camshaft Support extension for Vee
9U5932 1 Camshaft Torque Extension for 5/8 in. bolts (for engines newer than 6/90)
1P2382 1 Camshaft Torque Extension for 1/2 in. bolts (for engines older than 6/90)

Q - DENOTES CRITICAL STEP


Procedures required for the removal of the Camshaft Segments & Bearing Journals.
Step Procedure
1 Remove Camshaft Access Cover
Q 2 Check Camshaft End Play 0.20 ± 0.10 (.008 ± 0.04)
3 Rotate engine until Camshaft Locating Dowel is at top or bottom. This will
aid in removal of Camshaft.
NOTICE: If the rocker arms are not removed on the one you are working on and everything
forward of the one you are working on, damage can happen between the camshaft follower roller
and the cam lobe as you slide the camshaft forward (see step 11)
4 Use 1P2382 Extension for 1/2 bolts (early) or 9U5922 Extension for 5/8 bolts
(later)
5 Remove 1/2 of the Bolts that hold Camshaft Segment to Camshaft Journal
NOTICE: If a Camshaft Journal is going to be removed, remove 1/2 of the bolts of the Camshaft
Journal to be removed.
6 Rotate engine until the remaining bolts can be removed.
7 Remove all bolts except one on each end of Camshaft.
WARNING: If the Valve Train is in place. Rotating engine after a Camshaft segment is
removed can cuse damage to valve train forward of the one removed.
8 Install 8T3029 Camshaft Segment Support Service Tool under Camshaft
Segment to be removed.
NOTICE: A 1U6311 Adapter must be bolted on the 8T3029 if a Camshaft Segment is going to
be removed on a Vee Engine.

9 Adjust the Service tool to support Camshaft Segment.


10 Remove the remaining 2 bolts.
11 Carefully move the front section of Camshaft toward to front of the engine
to disengage location dowels.
NOTICE: Newer thick-flanged Camshaft Segments may have threaded hole that may be
used for forcing bolts.
NOTICE: By moving the camshaft segment to far forward could cause damage to the small
Oil Metering Pump mounted at the front of the engine.
12 Carefully move Camshaft Segments to be removed forward to disengage rear
dowel.
13 Carefully roll Camshaft Segment out of the Cylinder Block onto Camshaft
Support.
14 Fasten hoist to Camshaft Segment and remove 28 kg (62 lb.)
15 Mark proper ID location for Camshaft Segment.
16 Thin flange Camshafts Segments with 1/2" Bolts will have spacer that must
also be removed.
17 Remove all Camshaft Service Tooling.
18 Place protection (shop towel) in the bottom of camshaft cavity to protect
Camshaft Journal removal.
19 Slide Camshaft Jouranl towards where Camshaft Segment was removed.
(20 kg 44 lb.)
20 Thin flange Camshafts Segments with 1/2" Bolts will have spacer that must
also be removed.
Q 21 Clean and Inspect Camshaft Segment as per Reusuability Guidelines
28 kg (62 lb.)
Q 22 Clean and Inspect Camshaft Journal as per Reusuability Guidelines
20 kg (44 lb.)
Q 23 Clean and Inspect Camshaft Journal Bearing as per Reusuability Guidelines.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 17

Camshaft Bearing Removal for 3600 Series Engine


Part No. Qty. Tool and Part Name
8T-0970 1 Camshaft Bearing Tool
6V-7047 1 Single Acting Cylinder
8T-3035 1 Hydraulic Line
8T-0820 1 Hydraulic Pressure Gauge
3S-6224 1 Electric Hydraulic Pump (115V-50/60 Cycle)
8S-8033 Electric Hydraulic Pump (230V-50/60 Cycle)
191-5347 Hydraulic Pump, Pneumatic
158-7167 Hydraulic Pump, Manual

Q - DENOTES CRITICAL STEP


Procedures required for the removal of the Camshaft Bearing.
Step Procedure
1 Carefully remove Camshaft Segments and Journal
2 Install 8T0972 Pilot, 8T0971 Plate & OL1143 Bolt on bearing to be removed.
3 Install 8T0968 Bridge into Cam Bearing bore ahead or to rear of bearing to be
removed. NOTE: You must choose the right diametr of the 8T0958 Bridge to
fit into either the bore of the block or bearing.
4 Install 6V7047 Cylinder and 8T0869 Adjustment Rod in position. The nut on
the Adjust rod must be adjusted to the correct length.
5 To keep the 6V7047 Cylinder and 8T0869 Adjustment Rod in position, the
Nut on the adjust rod must be adjusted to the correct length.
Press the camshaft bearing out of the block. Hold 8T0972 Pilot, 8T0971 Plate
6
and old bearing from dropping.
7 Repeat procedure for other camshaft bearings to be removed.

Camshaft Bearing Installation


Q - DENOTES CRITICAL STEP
Procedures required for the installation of the Camshaft Bearing.
Step Procedure
1 Remove the plug from the Bearing oil supply hole.
2 Install new Bearing between the 8T0972 Pilot, 8T0971 Plage & )L1143 Bolt.
Q 3 Clean and lubricate the outside of the tool and bearing assembly with engine
oil.
Q 4 Place the 8T0972 Pilot of the tool and bearing assembly into the bore with
the Bearing Joint at the top Camshaft Bearing Bore.
NOTE: The joint of the new Bearing must be at the top of the Camshaft Bearing Bore.
5 Install new Bearing between the 8T0972 Pilot, 8T0971 Plate & 0L1143 Bolt.
Q 6 Press bearing into bore until the groove in the back of the bearing aligns with
the oil supply hole.
WARNING: The groove on the back of the bearing must be in alignment with the oil supply hole
of the block. If not oil delivery to the bearing will be shut off.
Q 7 On the rear Camshaft Bering the timing pin hole must be in alignment with
the oil hole of the bearing. This will enable the Timing Pin to be installed
during pin timing the engine.
8 Install the Camshaft Bearing Journals & Camshaft Segments.

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Camshaft Segment and Bearing Journal Installation for


3600 Series Engine
Part No. Qty. Tool and Part Name
8T3029 1 Camshaft Segment Support
1U6311 1 Adapter, Camshaft Support extension for Vee
9U5932 1 Camshaft Torque Extension for 5/8 in. bolts (for engines newer than 6/90)
1P2382 1 Camshaft Torque Extension for 1/2 in. bolts (for engines older than 6/90)

Q - DENOTES CRITICAL STEP


Procedures required for the removal of the Camshaft Segments & Bearing Journals.
Step Procedure
1 Choose engine configuration. (1)
Q 2 Choose Engine Direction of rotation (2)
3 Choose journal “annular groove” direction (3)
4 Choose segment “annular groove” direction (4)
5 Install journal per alpha character starting at rear of engine (5)
NOTICE: Be sure to install the camshaft segments i the correct side of the engine. The
camshaft segments are different on each side.
WARNING: Correct Camshaft Journal / Segments relationship (timing) must be observed
at assembly. If the Camshaft Segments are out of time, serious engine damage will occur.
NOTICE: Each journal has several dowel holes on the non-annular grooved end and one
dowel hole one the annular grooved end. The letter designation of each journal gives the
location of that journal.
NOTE: Standard Engine Rotation is CCW. On Vee engines (3612/3616) the alpha
character is the same on both sides of the engine.
NOTICE: Install Camshaft Journal with annular groove toward the front of the engine for both
CCW and CW rotation.
(1) (2) (3) (4) REAR (5) FRONT
Configuration Rotation Journal Segment
3606 CCW FRONT REAR B•B•A•C•C
3606 CW FRONT FRONT B•B•A•C•C
3608 CCW FRONT REAR E•G•E•A•D•F•D
3608 CW FRONT FRONT E•G•E•A•D•F•D
3612 CCW FRONT FRONT C•C•A•B•B
3612 CW FRONT REAR C•C•A•B•B
3616 CCW FRONT FRONT D•L•E•A•D•H•E
3616 CW FRONT REAR D•L•E•A•D•H•E
3618 CCW FRONT FRONT Q•Q•R•P•P•R•Q•Q
3618 CW FRONT REAR Q•Q•R•P•P•R•Q•Q
Q 6 Check Location Dowel height 15.0 ± 0.5 mm (.59 ± .02 in.)
7 Thin flange Camshaft Segments with 1/2" Bolts will have spacer that must
be installed.
NOTICE: Install Camshaft Journal with annular groove toward the front of the engine for both
CCW and CW rotation.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 19

8 Place protection (shop towel) inthe bottom of camshaft cavity to protect


Camshaft Journal installation.
9 Lubricate Camshaft Journal & Camshaft Journal Bearing with engine oil.
10 Slide Camshaft Journal into Camshaft Journal bore 20 kg (44 lb)
11 Place Camshaft Journal Location Dowel into Camshaft Segment Locating Hole.
12 Install a bolt to hold Camshaft Segment to Camshaft Journal.
13 Thin flange Camshaft Segments with 1/2" Bolts will have spacer that must be
installed.
14 Install Camshaft Segment Support Service Tooling.
15 Fasten hoist to Camshaft Segment and place Camshaft onto Service Tool
28 kg (62 lb.)
NOTICE: See chart above for installation of Camshaft Journal & Camshaft Segment.
16 Carefully roll Camshaft Segment into Cylinder Block.
17 Carefully place location dowels in Camshaft Journals into locating hole of
Camshaft Segments.
18 Install 1/2 of Camshaft Bolts
Q 19 Torque 1/2" Bolts to 135 ± 20 N•m (100 ± 15 ft lbs.) or
Torque 5/8" Bolts to 270 ± 40 N•m (200 ± 30 ft. lbs).
20 Remove all tooling.
21 Install side covers and torque bolts to 47 ± 9 Nm (35 ±7 ft. lbs.)

3 - 19 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 20

Cylinder Liner Install for 3600 Series Engine


Part No. Qty. Tool and Part Name
235-0632 1 Cylinder Installation Tool Group
1F7958 (2) Nut
9S1366 (2) Bolt
5P1076 (6) Washer
1U7819 (2) Spacer
0V0375 (2) Bolt
4C9040 (2) Bracket
235-0612 (1) Bracket Assembly
4C6987 1 Socket Cylinder Head Stud Nuts
191-1135 2 Cylinder Liner Spacer Assembly
4C9041 1 Cylinder Installation Tool Group

Q - DENOTES CRITICAL STEP


Procedures required for the installation of the Cylinder Liner
Step Procedure

1 Remove 4C9515 Overhaul Protection Kit part as needed to install cylinder


liner.
2 Install new O-ring on top of Cylinder Liner
3 Install new O-ring on bottom of Cylinder Liner
Q 4 Clean Cylinder Block Bore
5 Install (2) 4C9040 Brackets on Cylinder Liner.
6 Install (2) 1U7619 Spacer with (2) 9S1366 Bolt with (2) 5P1076 Washer with
(2) 1F7958 Nuts
7 Insert 4C9041 Cylinder Liner Installation Tool on Cylinder Liner.
8 Fasten a hoist to Cylinder Liner Installation Tool.
9 Coat O-rings with a water & liquid soap solution
WARNING: After coating O-rings with a water & Liquid Soap Solution do not wait. Install
Cylinder Liner immediately.
10 Coat Cylinder Block Bore with a water & liquid solution
NOTICE: Do not install the cylinder liner with the seal plates in position.
NOTE: Place the Cylinder Liner int othe cylinder block bore making sure any liner pitting that may
have occurred is not in the same position where it was removed.
11 Carefully lower Cylinder Liner into Cylinder Block until lower liner O-rings sets
on the block. (282 lb.)
12 Remove all service tools.
13 Install 191-1135 (2) Cylinder Linder Press.
Use 4C8987 Socket and Cylinder Head Nuts (2) to press Cylinder Liner
14
into the Block.
15 Remove all Service Tooling.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 21

Piston / Connection Rod Assembly


Part No. Qty. Tool and Part Name
136-1452 1 Internal Tip Pliers
8T3033 1 Ring Expander Group
1U8692 1 Piston Pin Guide
9U5981 1 Snap Ring Retainer
235-0612 1 Lifting Bracket
0V0375 2 Bolt

Q - DENOTES CRITICAL STEP


Procedures required for the assembly of the Piston & Connecting Rod
Step Procedure
1 Use 8T3033 Ring Expander to install all piston Rings. (Do not intall rings
without using Service Tool)
Install new Expander & Oil Ring on Piston. (Ends of ring expander 180° apart
Q 2
from Oil Control Ring gap)
Install new #3 Piston Ring. (Install ring with the side marked “UP-3" towards
Q 3 the top of the piston)
Install new #2 Piston Ring. (Install ring with the side marked “UP-2" towards
Q 4 the top of the piston)
Install new #1 Piston Ring. (Install ring with the side marked “UP-1" towards
Q 5 the top of the piston)
NOTICE: All rings should be spaced equally around piston. Ring gaps should not be aligned over
wrist pin bore.
6 Install 4C9039 Lifting Braket on piston using 1/ -13 NC bolts (2)
7 Fasten a hoist to 4C9039 Lifting Bracket & Piston. 38 kg (82 lb)
8 Align wrist pin bore of piston with pin bore of connecting rod.
WARNING: When installing Piston on Connecting Rod make sure “V” mark or Dimple“ is in
alignment with “Tab Slot” of the Connecting Rod Bearing.
WARNING: Hold the connecting rod to prevent it from falling as the piston is installed. 50 kg
(110 lb)
9 Install 1U8692 Piston Pin Guide into Wrist Pin
CAUTION: Check the 1U8692 Service Tool to make sure it is free of damage. Clean and lubricate
with clean engine oil.
10 Slide Wrist Pin and Service Tool into pin bore. 30 kg (63 lb)
11 Remove Service Tool.
CAUTION: When Wrist Pin Snap Rings are not installed the Wrist Pin may slide out.
12 Install 9U5981 Wrist Pin Snap Ring Retainer Tool in hole of Wrist Pin.
WARNING: Failure to use 9U5981 Wrist Pin Snap Ring Retainer could cause persona injury if
snap ring should come off pliers.
13 Use 5P4758 Internal Snap Ring Pliers and install both Wrist Pin Snap Ring
Retainers. (Marked OUT)
Q 14 After assembly clearance between wrist pin and snap ring. 0.05mm (.002 in)

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 22

Piston / Connection Rod Installation Assembly for D3600 Series Engines


Part No. Qty. Tool and Part Name
8T3022 1 Rod Guide Group (In-line)
4C6357 1 Rod Guide Group (Vee)
8T2859 4 Nut (aluminum)
235-0612 1 Bracket Assembly
0V0375 2 Bolt
FT2252 1 Assembly Fixture
4C5719 1 Piton Ring Compressor (Cuffed or Non-cuffed Liner)
8T3037 1 Piston Ring Compressor (Non-cuffed Liner only)

Q - DENOTES CRITICAL STEP


Procedures required for the assembly of the Piston & Connecting Rod Assembly
Step Procedure
1 Lubricate Piston Rings and internal diameter of the 4C5719 or 8T3037 Piston
Ring Compressor with clean engine oil.
Install 4C-5719 or 8T3037 Piston Ring Compressor over the piston and
2
carefully close compressor.
CAUTION: Damage to Piston Rings can occur if piston rings are not compressed carefully.

3 Install upper half of Connect Rod Bearing. Ensure tabs on bearing


match-up with connecting rod tab slots.
4 Install 8T3022 (inline) or 4C6357 (vee) Connecting Rod Guide Group with
8T2859 (4) Nut.
NOTICE: Use round aluminum nuts provided. Using standard Connecting Rod Nuts can
cause damage to Cylinder Liner wall.
5 Remove any protective covers.
6 Place Piston / Connecting rod assembly in position over the Cylinder Liner.
7 Rotate Crankshaft for that cylinder to true top dead center.
8 Place the "V" or "Dimple" on the piston in alignment with the "V" mark on the
block deck surface.
NOTICE: If alignment is not correct the piston will make contact with the Piston Cooling Jet.
9 Lubricate the cylinder wall with a large amount of clean engine oil
10 Lower the piston / connecting rod assembly into the Cylinder Liner.
NOTICE: Do not use excessive force in order to move the piston into the cylinder liner. Piston ring
breakage may occur.
NOTICE: Once you have started to lower the assembly into the cylinder liner do not raise the
assembly up. If you raise the piston / rod assembly up the (bottom) oil control ring could expand
out into the Cuff bore and could be damaged as you lower the piston /rod assembly back down.
NOTICE: If the piston assembly will not slide in the cylinder bore, carefully loosen the tensioning
screw on the ring compressor. If the piston still does not slide in the cylinder liner, remove the piston
assembly and inspect.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 23

11 Align the connect rod with the crankshaft.


12 Lower the piston assembly until the rod bearing is seated on the crankshaft.
13 Remove the 8T3022 (inline) or 4C6357 (vee) Connecting Rod Group.
Coat the Connecting Rod Bolt threads and seat area of the Connect Rod
14
Nuts with 6V4876 Lubaricant (Dow Corning Molykote GN Lubricant)
15 Place a 51 x 102 mm (2 x 4 in) x 1200 mm (48 in) long board from side to
side to support cap.
16 Install lower Connecting Rod Bearing and lubricate bearing face with clean
engine oil.
NOTE: Do not lubricate back of bearing.
Slide the Connecting Rod Cap into position. Make sure the Connecting Rod
17 Cap Bearing Tab slots align with the Bearing Tab slots on the Connecting
Rod . 16 kg (35 lbs)
18 Carefully turn the engine so the connecting rod cap can be installed easily.
Carefully raise the Connecting Rod Cap up onto the Connecting Rod
19
Bolts and install a Connecting Rod Bolt Nut.
NOTE: This one single nut will hold the cap in place until the other 3 nuts
can be installed.
20 Remove long board.
21 Install the other 3 Connecting Rod Bolt Nuts

3 1

4 2
Bearing Tab Slot.

Note: The No. 1 & 2 Rod Bolts are always on the Bearing tab slot side of the
Connecting Rod Cap.

Q 22 Torque nut #1 to 105±20 N•m (75±15 lb ft)


Q 23 Torque nut #2 to 105±20 N•m (75±15 lb ft)
Q 24 Torque nut #3 to 105±20 N•m (75±15 lb ft)
Q 25 Torque nut #4 to 105±20 N•m (75±15 lb ft)
Q 26 Torque nut #1 to 340±15 N•m (250±10 lb ft)
Q 27 Torque nut #4 to 340±15 N•m (250±10 lb ft)
Q 28 Torque nut #2 to 340±15 N•m (250±10 lb ft)
Q 29 Torque nut #3 to 340±15 N•m (250±10 lb ft)
Q 30 Torque nut #1 to 340±15 N•m (250±10 lb ft)
Q 31 Torque nut #4 to 340±15 N•m (250±10 lb ft)
Q 32 Torque nut #2 to 340±15 N•m (250±10 lb ft)
Q 33 Torque nut #3 to 340±15 N•m (250±10 lb ft)
Q 34 Loosen #1 nut and then re-torque nut to 80±10 N•m (59±7 ft lb)
Q 35 Place an index mark on nut and rotate an additional 360±5 degrees.
Q 36 Loosen #4 nut and then re-torque nut to 80±10 N•m (59±7 ft lb).
Q 37 Place an index mark on nut and rotate additional 360±5 degrees.
Q 38 Loosen #2 nut and then re-torque nut to 80±10 N•m (59±7 ft lb).
Q 39 Place an index mark on nut and rotate additional 360±5 degrees.
Q 40 Loosen #3 nut and then re-torque nut to 80±10 N•m (59±7 ft lb).
Q 41 Place an index mark on nut and rotate additional 360±5 degrees.
Q 42 Connecting Rod side clearance should be 0.33 to 0.68 mm (0.0130 to 0.268).
Q 43 Install Piston Cooling Jet. Torque bolts to 47±9 N•m (35±7 ft lb).
NOTICE: Special care must be taken not to bend the Piston Cooling Jet because they are
precision aligned with a cooling passage in the piston.
44 Install crankcase Inspection Covers and torque bolts to 47±9 N•m (35±7 ft lb.)

3 - 23 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 24

Piston / Connecting Rod Assembly Installation for D3618 Engine


Part No. Qty. Tool and Part Name
136-1452 1 Internal Tip Pliers
8T3033 1 Ring Expander Group
178-5063 1 Pin Guide
9U5981 1 Snap Ring Retainer
235-0612 1 Lifting Bracket
0V0375 2 Bolt
4C5719 1 Ring Compressor
8T5096 1 Dial Indicator Group

Q - DENOTES CRITICAL STEP


Procedures required for the installation of the Piston & Connecting Rod Assembly
Step Procedure
NOTE: After the assembly of the piston and connecting rod together, carefully lay the piston rod
assembly on its side. If possible, without rings.
WARNING: The piston rings may be damaged during the lifting and turning process.

1 Attach the 235-0612 Lifting Bracket to the top of the piston with 0V0375
Bolts (1/2-13 NC Bolts)
With a suitable lifting device attached to the 235-0612 Bracket carefully lift
2
the piston assembly into the vertical position. 123 kg (271 lb)
3 Carefully install rings and space rings 120° apart.

4 Lubricate Piston Rings and Cylinder Liner bore with clean engine oil.

Install 4C-5719 Piston Ring Compressor over the piston and carefully close
5 compressor.
CAUTION: Damage to Piston Rings can occur if piston rings are not compressed carefully.

6 Wrap the connecting rod with a cushion of towels.

NOTE: By doing this will help prevent the connecting rod from rubbing the cylinder liner.
7 Remove the protective cover from the cylinder liner.
8 Rotate the crankshaft until the connecting rod bearing journal for the opposite
cylinder is at the TDC position
9 Make sure the dimple or (X) on top of the piston is towards the center of the
engine.
10 Carefully lower the connecting rod & piston into the cylinder liner.
NOTICE: Do not use excessive force in order to move the piston into the cylinder.
Piston ring breakage may occur.
11 Allow enough clearance for installation of the connecting rod bearing.
12 Clean the inside diameter of the rod bearing and outside diameter of the
crankshafts connecting rod bearing journal.
Use a liberal coat of clean engine oil on the inside diameter of both rod
13 bearings and outside diameter of the crankshafts connecting rod bearing
journal.
14 Install new bearing clips (2) into the oval shaped opening on both ends one
of the bearings.
CAUTION: The clips must be installed correctly or damage will occur. The clips must have the
opening or proud towards the outside of the bearing.
15 Slide the bearing with the clips onto the crankshaft.
NOTE: The bearing must be installed in the correct direction as shown on the back of the
bearing.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 25

Attach the other half of the connecting rod bearing by putting the small clips
16
into the oval shaped opening to hold in place.

17 Remove the protective wrap for the connecting rod.


Coat the outside diameter of the rod bearing with a light coat of clean engine
18 oil
Make sure the connecting rod bearing locating dowel is in alignment with the
19 locating slot of the connecting rod.
NOTICE: It is very important that the dowel in the connecting rod bearing is inserted into the
locating slot of the connecting rod. If the dowel is not inserted into the slot, damage to the
engine will occur.

20 Carefully lower the connecting rod down until it lightly touches the rod
bearing.
Rotate the connecting rod bearing until the dowel in the bearing is inserted
21 into the slot of the connect rod.
Q 22 Make sure the dowel touches the back of the slot.
Q 23 Now move the dowel away from the back of the slot .5 mm (0.02 in)
24 Rotate the engine in order to install the connecting rod cap.
25 Coat the contact surfaces with 6V4876 or 186-1531 lubricant.
26 Install 178-5063 (2) Guides into opposite hole of the connecting rod.
Locate and install the correct connecting rod cap with the correct connecting
27
rod.
NOTE: The connecting rod and connecting rod cap will have the same serial number.
28 Install connecting rod cap over the guides so the serial numbers are aligned
on the same side with each other
29 Install two bolts with retainers on each side into the two empty holes.

30 Remove the two guides and install the other two bolts through the retainer
and into the connecting rod.
Before you fully tighten the bolts, make sure the bolt heads are centered in
31
the counterbore of the retainer, and hand tighten.
NOTE: In the illustration below, the bolts (2) and (4) are at the rod thrust side and bolts (1) and
(3) are to the crankshaft side of the rod.
NOTE: Special care must be taken when bolts (1) and (4) are tightened in order to make sure
that the retainer plates do not move.
NOTE: Always use a master to calibrate torque tools before use in order to insure accuracy.
NOTE: Always complete the following torque sequence on the connecting rod that has been
installed prior to any further rotation of the crankshaft. Rotation without completing the torque
sequence can result in bearing rotation and subsequent bearing damage.

2 4

1 3

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 26

Q 32 Torque nut #1 to 60±10 N•m (44±7.4 lb ft)


Q 33 Torque nut #4 to 60±10 N•m (44±7.4 lb ft)
Q 34 Torque nut #2 to 60±10 N•m (44±7.4 lb ft)
Q 35 Torque nut #3 to 60±10 N•m (44±7.4 lb ft)
Q 36 Torque nut #1 to 300±20 N•m (222±14.8 lb ft)
Q 37 Torque nut #4 to 300±20 N•m (222±14.8 lb ft)
Q 38 Torque nut #2 to 300±20 N•m (222±14.8 lb ft)
Q 39 Torque nut #3 to 300±20 N•m (222±14.8 lb ft)
Q 40 Torque nut #1 to 600±30 N•m (440±22 lb ft)
Q 41 Torque nut #4 to 600±30 N•m (440±22 lb ft)
Q 42 Torque nut #2 to 600±30 N•m (440±22 lb ft)
Q 43 Torque nut #3 to 600±30 N•m (440±22 lb ft)
Q 44 Torque nut #1 to 600±30 N•m (440±22 lb ft)
Q 45 Torque nut #4 to 600±30 N•m (440±22 lb ft)
Q 46 Torque nut #2 to 600±30 N•m (440±22 lb ft)
Q 47 Torque nut #3 to 600±30 N•m (440±22 lb ft)
Q 48 Loosen #1 nut and then re-torque nut to 15±3 N•m (132±24 lb in or (11±2 lb ft)
NOTE: 132 is inch pounds not foot pounds.
Q 49 Place an index mark on nut and rotate additional 150±5 degrees.
Q 50 Loosen #4 nut and then re-torque nut to 15±3 N•m (132±24 lb in or (11±2 lb ft)
NOTE: 132 is inch pounds not foot pounds.)
Q 51 Place an index mark on nut and rotate additional 150±5 degrees.
Q 52 Loosen #2 nut and then re-torque nut to 15±3 N•m (132±24 lb in) or (11±2 lb ft)
NOTE: 132 is inch pounds not foot pounds.)
Q 53 Place an index mark on nut and rotate additional 150±5 degrees.
Q 54 Loosen #3 nut and then re-torque nut to 15±3 N•m (132±24 lb in or (11±2 lb ft)
NOTE: 132 is inch pounds not foot pounds.)
Q 55 Place an index mark on nut and rotate additional 150±5 degrees.
56 Verify that all bolts have been torqued to a minimum of 600 N•m (440 lb ft) in
Q
order to verify the tension of the bolt.
57 Install the 8T5096 Dial Indicator Group to measure the clearance at the sides
Q
of the connecting rod and the counterweight.
58 Carefully move Connecting Rod to the right zero the dial indicator. Then move
the connecting rod to the left and the measurement should be between
0.33 to .68 mm (.013 to .027 in)
If the clearance is not correct, make sure the right connecting rod cap is on the right connecting
rod. If it is correct, remove the cap and complete the procedure again. Inspect the components
for wear and/or damage.
59 Install the retainer lock rings, retainer plates and bolts (2).
Q 60 Tighten bolts to 12±3 N•m (108±24 lb in or 9 ± 2 lb ft)
NOTE: Do NOT reuse retainer plates.
61 Bend the tabs on the retainer plates to retain bolts into position
62 Install the piston cooling jets.

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Cylinder Head Installation


The following are tools from the 207-5034 Stud Tensioner Tool Group.
This group was the first tool group used on 3600 Engines only.
Part No. Qty. Tool and Part Name
8T-0820 1 Hydraulic Pressure Group
3S-6224 1 Electric Hydraulic Pump (115V-50/60 Cycle)
8S-8033 Electric Hydraulic Pump (230V- 50/60 Cycle)
191-5347 Hydraulic Pump, Pneumatic
156-7167 Hydraulic Pump, Manual
8T-0895 4 Hydraulic Cylinder Groups
8T-3035 1 Lines Group
(5) 6D-7726 - Hoses
(1) 3J-5390 - Plug
(1) 8T-5206 - Manifold
(5) 1P-2375 - Couplder Assembly (male)
(8) 1P-2376 - Coupler Assembly (female)
8T-0891 4 Threaded Collar (head stud)
8T-0889 2 Threaded Collar (used on front head studs on # 1 cylinder to
clear fuel filters)
8T-0897 4 Pedestal (head stud)
8T-0898 2 Pedestal (used on front head studs on # 1 cylinder to clear fuel
filters)
4C-6987 1 Socket
9U-5141 2 Nut turning Handle
126-6918 1 Lifting Bracket (Vee)
126-6919 Lifting Bracket (In-line)
126-6920 1 Tiller Handle
5D-1972 2 Bolt 3/4 -10 NC X 11 3/4 (29.9 cm) long

Q - DENOTES CRITICAL STEP


Procedures required for the removal of the Cylinder Head Using the 207-5034 Tool Group.
Step Procedure
NOTE: If a stud(s) was removed:
a. Coat the lower half of the cylinder head stud with 4C-4774 Water & Temperature Resistant Grease.
b. Apply an extra bead of grease around the stud at the area where the stud exits the tip of the block.
c. Clean the top of the block.
d. Install the studs in the block and tighten to a torque 100 ± 20 N•m (75 ±15 lb ft).
e. Coat the entire length of stud and pack the area where the stud enters the block with 4C-4774
Water & Temperature Resistant Grease. This will prevent water from entering and causing
corrosion between the stud and block.
1 Install (4) new O-ring on the Cylinder Head Studs

NOTE: Always install liner before Seal Plates to prevent the liner from cutting the seal plate.
NOTE: If a water-cooled flange liner is used, place O-rings on top of liner before Seal Plate is
installed. Lubricate O-rings with Petroleum Jelly.
2 Remove 4C-9515 Overhaul Protection Kit.
3 Clean and Install (2) Seal Plates with new O-rings.
4 Clean and Install Water (4) Seal Adapters with new (8) O-rings.
5 Clean and Install Combustion Gasket.
6 Clean and Install Cylinder Head. Carefully not to to damage Head Studs.
204kg (450 lbs)
7 Clean Washers & Nuts. Lubricate Washer faces and Stud threads with 4C-4774
Water & Temperature Resistant Grease, Install Washers and Nuts.

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CAUTION: Care should be taken not to damage Head Studs.


8 Install 126-6919 (In-line) 126-6918 (vee) 126-6920 (handle) Head Lifting Tool
9 Install Cylinder Head. 204kg (450 lbs)
10 Clean and Install Washers & Nuts
11 Remove all tooling.
12 Use 4C-6987 Socket and 1/2" drive ratchet and lightly tighten nuts equally.
NOTE: A torque wrench and the 4C-6987 Socket can be used to torque the Cylinder Head Nuts to
a torque of 185 N•m (250 lb ft). By doing this step the technician will be able to feel whether or not
a spacer plate O-ring is sticking our of position. If the torque wrench has a good sharp click
chances are the O-rings are on the spacer plate correctly, however if the click is a soft mushy feel
the odds are an O-ring is out of position.
13 Install (4) 8T-0897 Pedestals on Cylinder Head Studs.
14 Install (4) the Stud Tensioner Groups o Cylinder Head Studs.
15 Install (4) 8T-0891 Threaded Collars
16 Install (4) 6D-7726 (Hose) 1P2376 (Coupler) Hyd. Hoses to Hyd Tensioners
17 Install Hyd Hoses to 8-T3206 (1-Manifold) 1P2375 (5-Coupler) 3J-5390 (1-Plug)
18 Install Hyd. Hose to Hydraulic Pump
19 Place Hydraulic Pump in bypass.
20 Tighten all Collars (This bleeds all oil from Hydraulic Tensioners)
21 Loosen all Collars 1/4 turn loose.
Q 22 Operate Hyd Pump to 40,000 ± 1500 kPa (5,800 ±220 psi).
CAUTION: Before operation pump, be sure all connections are secure. Be sure all hoses are in
good condition. Oil escaping under high pressure can cause personal injury. Wear safety glasses.
CAUTION: When tightening the Cylinder Head Stud Nuts, make sure you have no body parts
above hydraulic tensioning equipment. If Head Stud should break personal injury could occur.
23 Using the 9U5141 Handle tighten all Cylinder Head Nuts.
24 Slowly release Hydraulic Oil Pump pressure.
25 Place Hydraulic Pump in bypass.
26 Tighten all collars (this bleeds all oil from Hyd Tensioners).
27 Loosen all Collars 1/4 turn loose.
Q 28 Operate Hydraulic Pump to 40,000 ± 1500 kPa (5,800 ±220 psi)
CAUTION: Before operation pump, be sure all connections are secure. Be sure all hoses are in
good condition. Oil escaping under high pressure can cause personal injury. Wear safety glasses.

CAUTION: When tightening the Cylinder Head Stud Nuts, make sure you have no body parts
above hydraulic tensioning equipment. If Head Stud should break personal injury could occur.
29 Using the 9U5141 Handle tighten all Cylinder Head Nuts.
30 Slowly release Hydraulic Oil Pump pressure.
31 Remove all tooling.
32 Install Cylinder Head Stud Protectors.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 29

The following are tools from the 191-5320 Stud Tensioner Tool Group
This is the second tool group used on 3600 Series Engines and with some
modification the tools can be used on the 3618 engine.

Part No. Qty. Tool and Part Name


227-6724 1 Hydraulic Pump, Electric, 120V
227-8834 Hydraulic Pump, Electric, 240V
191-5347 Hydraulic Pump, Pneumatic
156-7167 Hydraulic Pump, Manual
229-9453 1 Pump Accessory Group (required)
178-9312 (4) - Hose Assembly
178-9313 (1) - Distribution Coupler (manifold)
185-0683 (1) - Comparison Gauge
191-5320 1 Stud Tensioner Tool Group (required)
191-5322 (4) - Stud Tensioner Cylinder Group for 3606, 3608, 3612, 3616
Cylinder Heads
191-5333 (4) - Stud Tensioner Cylinder Support for Cylinder Head
(replacement for damage support) 3606, 3608, 3612, 3616
191-5324 (4) - Stud Tensioner Cylinder Bushing for Cylinder Head
(replacement for damage support) 3606, 3608, 3612, 3616
179-9051 (4) - Replacement Bushing for modification of Stud Tensioner
Group for 3618 Cylinder Head.
178-9053 (4) - Replacement Support for modification of Stud Tensioner
Group for 3618 Cylinder Head.
191-5341 1 Optional Gear Drive Group (permits faster rotation of nut onto stud)
191-5343 (4) Turning Sleeve (for 191-5322 Stud Tensioner Cylinder Groups)
191-5342 (4) Gear Drive Assembly
(2) Swivel Head Ratchet (1/2 inch square drive)
229-9457 1 Auxiliary Group
225-5637 (2) Support (used in place of the 191-5333 Support when used on
front head studs on # 1 cylinder to clear fuel filters.)
225-5636 (2) Bushing(used in place of the 191-5324 Bushing when used on
front head studs on # 1 cylinder to clear fuel filters.)
126-6918 1 Lifting Bracket (Vee)
126-6919 Lifting Bracket (In-line)
126-6920 1 Tiller Handle
5D1972 2 Bolt 3/4 -10 NC x 11 3/4 (29.9 cm) long

3 - 29 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 30

Q - DENOTES CRITICAL STEP


Procedures required for the installation of the Cylinder Head Using the 191-5320 Tool Group.
Step Procedure
NOTE: If a stud(s) was removed:
a. Coat the lower half of the cylinder head stud with 4C-4774 Water & Temperature Resistant Grease.
b. Apply an extra bead of grease around the stud at the area where the stud exits the tip of the block.
c. Clean the top of the block.
d. Install the studs in the block and tighten to a torque 100 ± 20 N•m (75 ±15 lb ft).
e. Coat the entire length of stud and pack the area where the stud enters the block with 4C-4774
Water & Temperature Resistant Grease. This will prevent water from entering and causing
corrosion between the stud and block.
1 Install (4) new O-ring on the Cylinder Head Studs

NOTE: Always install liner before Seal Plates to prevent the liner from cutting the seal plate.
NOTE: If a water-cooled flange liner is used, place O-rings on top of liner before Seal Plate is
installed. Lubricate O-rings with Petroleum Jelly.
2 Remove 4C-9515 Overhaul Protection Kit.
3 Clean and Install (2) Seal Plates with new O-rings.
4 Clean and Install Water (4) Seal Adapters with new (8) O-rings.
5 Clean and Install Combustion Gasket.
6 Clean and Install Cylinder Head
Clean Washers & Nuts. Lubricate Washer faces and Stud threads with 4C-4774
7
Water & Temperature Resistant Grease, Install Washers and Nuts.
8 Install 126-6919 (In-line) 126-6918 (vee) 126-6920 (handle) Head Lifting Tool.
9 Install Cylinder Head. 204kg (450 lbs)

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CAUTION: Care should be taken not to damage Head Studs.


10 Install Washers and Nuts
11 Use 4C6987 Socket and 1/2" drive ratchet and lightly tighten nuts equally.
NOTE: A torque wrench and the 4C6987 Socket can be used to torque the Cylinder Head Nuts to a
torque of (185N•m (250 ft lb.). By doing this step the techncian will be able to feel whether or not a
spacer plate O-ring is sticking out of position. If the torque wrench has a good sharp click chances
are the O-rings are on the spacer plate correctly, however if the click is a soft mushy feel the
odds are an O-ring is out of position.
12 Install (4) the Stud Tensioner Groups on Cylinder Head Studs.
13 Install (1) 178-9313 (Manifold) to the Hydraulic Pump of choice.
14 Install (41) 178-9312 Hydraulic Hose As. to the (4) 191-5322 Stud Tensioner
Groups.
15 Install the (4) Hose As. to the 178-9313 Coupler.
16 Open the shutoff valve.
17 Tighten (CW) all Bushings (this bleeds all oil from Hyd Tensioners)
Q 18 Loosen (CCW) all Bushings 1/4 turn loose.
WARNING: Before operation pump, be sure all connections are secure. Be sure all hoses are in
good condition. Oil escaping under high pressure can cause personal injury. Wear safety glasses.
19 Close the Shut-Off Valve on pump.
20 Operate pump.
WARNING: This must be done slowly to prevent a too high pressure. If the pressure should rise
above the specification, damage can occur to studs, nuts or cylinder head.
Q 21 3600 Series Engine Operate Pump to 123 ± 15 mPa (17,660 ± 200 psi)
3618 Series Engine Operate Pump to 125 ± 15 mPa (18,140 ± 200 psi)
WARNING: While pressurizing or tightening the Cylinder Head Stud Nuts, make sure you have
no body parts above hydraulic tensioning equipment. If Had Stud should break personal injury
could occur.
NOTE: If the 9U5141 Handle is used perform step 22. If the 191-5341 Gear Drive Group is used
perform step 23.
22 Using the 9U5141 Handle tighten Cylinder Head Nuts.
23 Use the 1/2 drive ratchet and turn the gear until nuts are tight.
24 Slowly release Hydraulic Oil Pump pressure by opening the shutoff valve.
25 Tighten (CW) all Bushings (This bleeds all oil from Hyd Tensioners).
Q 26 Loosen (CCW) all Bushings 1/4 turn loose.
WARNING: Before operation pump, be sure all connections are secure. Be sure all hoses are in
good condition. Oil escaping under high pressure can cause personal injury. Wear safety glasses.
27 Close the shutoff valve on pump.
28 Operate pump.
Q 29 3600 Series Engine Operate Pump to 123 ± 15 mPa (17,660 ± 200 psi)
3618 Series Engine Operate Pump to 125 ± 15 mPa (18,140 ± 200 psi)
WARNING: While pressurizing or tightening the Cylinder Head Stud Nuts, make sure you have
no body parts above hydraulic tensioning equipment. If Had Stud should break personal injury
could occur.
NOTE: If the 9U5141 Handle is used perform step 30. If the 191-5341 Gear Drive Group is used
perform step 31.
30 Using the 9U5141 Handle tighten Cylinder Head Nuts.
31 Use the 1/2 drive ratchet and turn the gear until nuts are tight.
32 Slowly release Hydraulic Oil Pump pressure by opening the shutoff valve.
33 Remove all tooling.
34 Install Cylinder Head Stud Protectors.

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Post Installation Of Cylinder Head


Q - DENOTES CRITICAL STEP
Procedure required for the assembly of the Cylinder Head
Step Procedure
1 Clean and Inspect MUI & Install new O-rings
2 Connect Fuel Control Rod from Control Lever
3 Clean & Install Fuel Supply Lines & Fittings
4 Clean & Install Oil Supply Tube
5 Clean, Install new O-ring & Install Valve Lifter Cover
6 Clean, Install new O-ring & Install Rocker Arm Buttons
7 Clean and Assemble Rocker Arm assembly
8 Install Valve Bridges (proper location)
9 Install new springs on Valve Lifter Body
10 Install the Insert in the upper end of the valve and MUI lifter and install new O-
ring in to hold.
11 Immerse lifter assemblies in clean engine oil & install lifter assemblies in the
original position of the Valve Lifter body
Q 12 Push the lifter assembly into the Valve Lifter Body until the dimension from
the end of the roller to the bottom of the Lifter Body is 118.0 ± 2.0mm (4.65
± .08)
13 Install Valve Lifter Assembly (proper location)
14 Install Oil Supply Tube & new O-rings
15 Install Pushrods (proper location)
16 Install Rocker Arm assembly in proper location
17 Adjust Bridges (see chart below for sequence)
18 Adjust Valves (see chart below for sequence)
19 Clean and Install Valve Cover Base with new O-ring
20 Clean and Install Valve Cover with new O-ring
21 Clean and Install Crankcase Breather ( if required)
22 Clean and Install Water Manifolds with new O-rings
23 Clean and Install Exhaust Manifolds with new Gaskets
24 Install Exhaust Manifolds Blanket (if equipped)
25 Shut on fuel supply and Prime System
26 Install new Oil Filters
27 Fill Engine with proper new Oil
28 Fill Engine with proper new Coolant
29 Connect starting system
30 Clean and paint repair area

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Crankshaft Position for Fuel Injector Timing & Valve Lash Adjustments
Check and Adjust with Piston on the following stroke. (1)
3606 Top Center Top Center
Compression Stroke Exhaust Stroke
SAE Standard Rotation Engine - CCW (2)
Firing Order 1-5-3-6-2-4
Inlet Valves 1-2-4 3-5-6
Exhaust Valves 1-3-5 2-4-6
Fuel Injectors 1-5-6 1-2-4
SAE Reverse Rotation Engine - CW (3)
Firing Order 6-3-5-1-4-2
Inlet Valves 1-3-5 2-4-6
Exhaust Valves 1-2-4 3-5-6
Fuel Injectors 2-4-6 1-3-5

Check and Adjust with Piston on the following stroke. (1)


3608 Top Center Top Center
Compression Stroke Exhaust Stroke
SAE Standard Rotation Engine - CCW (2)
Firing Order 1-6-2-5-8-3-7-4
Inlet Valves 1-7-4-6 3-5-2-8
Exhaust Valves 1-2-4-6 3 - 5 - 7 -8
Fuel Injectors 3-5-2-8 1-7-4-6
SAE Reverse Rotation Engine - CW (3)
Firing Order 1-4-7-3-8-5-2-6
Inlet Valves 1-2-4-6 3-5-7-8
Exhaust Valves 1-7-4-6 3-5-2-8
Fuel Injectors 3-5-7-8 1-2-4-6

Check and Adjust with Piston on the following stroke. (1)


3612 Top Center Top Center
Compression Stroke Exhaust Stroke
SAE Standard Rotation Engine - CCW (2)
1 - 12 - 9 - 4 - 5 - 8
Firing Order 11 - 2 - 3 - 10 - 7 - 6
1-3-7 5 - 9 - 11
Inlet Valves
6 - 10 - 12 2-4-8

Exhaust Valves 1-5-9 3 - 7 - 11


4 - 6 - 12 2 - 8 - 10

Fuel Injectors 5 - 9 - 11 1-3-7


2-4-8 6 - 10 - 12

SAE Reverse Rotation Engine - CW (3)


1 - 6 - 7 - 10 - 3 - 2
Firing Order 11 - 8 - 5 - 4 - 9 - 12
1-5-9 3 - 7 - 11
Inlet Valves
4 - 6 - 12 2 - 8 - 10
1-3-7 5 - 9 - 11
Exhaust Valves
6 - 10 - 12 2-4-8
3 - 7 - 11 1-5-9
Fuel Injectors
2 - 8 - 10 4 - 6 - 12

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 34

Check and Adjust with Piston on the following stroke. (1)


3616 Top Center Top Center
Compression Stroke Exhaust Stroke
SAE Standard Rotation Engine - CCW (2)
1 - 2 - 5 - 6 - 3 - 4 - 9 - 10
Firing Order
15 - 16 - 11 - 12 - 13 - 14 - 7 - 8

Inlet Valves 1 - 5 - 7 - 13 3 - 9 - 11 - 15
2 - 8 - 12 - 14 4 - 6 - 10 - 16

Exhaust Valves 1-3-5-7 9 - 11 - 13 - 15


2-4-6-8 10 - 12 - 14 - 16
3 - 9 - 11 - 15 1 - 5 - 7 - 13
Fuel Injectors
4 - 6 - 10 - 16 2 - 8 - 12 - 14

SAE Reverse Rotation Engine -CW (3)


1 - 8 - 7 - 14 - 13 - 12 - 11
Firing Order 16 - 15 - 10 - 9 - 4 - 3 - 6 - 5 - 2
1-3-5-7 9 - 11 - 13 - 15
Inlet Valves
2-4-6-8 10 - 12 - 14 - 16
1 - 5 - 7 - 13 3 - 9 - 11 - 15
Exhaust Valves
2 - 8 - 12 - 14 4 - 6 - 10 - 16
9 - 11 - 13 - 15 1-3-5-7
Fuel Injectors
10 - 12 - 14 - 16 2-4-6-8

Check and Adjust with Piston on the following stroke. (1)


3618 Top Center Top Center
Compression Stroke Exhaust Stroke
SAE Standard Rotation Engine - CCW (2)
1 - 2 - 9 - 10 - 17 - 18 - 5 - 6 - 11 - 12
Firing Order 15 - 16 - 3 - 4 - 7 - 8 - 13 - 14
1 - 3 - 7 - 9 - 13 5 - 11 - 15 - 17
Inlet Valves
2 - 4 - 8 - 14 6 - 10 - 12 - 16 - 18
1 - 5 - 9 - 17 3 - 7 - 11 - 13 - 15
Exhaust Valves
2 - 10 - 14 - 18 4 - 6 - 8 - 12 -16
5 - 11 - 15 - 17 1 - 3 - 7 - 9 - 13
Fuel Injectors
6 - 10 - 12 - 18 2 - 4 - 8 - 14 - 16

SAE Reverse Rotation Engine CW (3)


1 - 14 - 13 - 8 - 7 - 4 - 3 - 16 - 15
Firing Order
12 - 11 - 6 - 5 - 18 - 17 - 10 - 9 - 2

Inlet Valves 1 - 5 - 9 - 13 - 17 3 - 7 - 11 - 15
2 - 10 - 14 - 18 4 - 6 - 8 - 12 - 16
Exhaust Valves 1 - 3 - 7 - 9 - 13 5 - 11 - 15 - 17
2 - 4 - 8 - 14 - 16 6 - 10 - 12 - 18
3 - 7 - 11 - 15 1 - 5 - 9 - 13 - 17
Fuel Injectors 4 - 6 - 8 - 12 - 16 2 - 10 - 14 - 18
(1) SAE Standard Rotation Engines turn in the COUNTERCLOCKWISE (CCW) direction when the
engines are viewed from the flywheel end.

(2) Put the No. 1 piston at the top dead center position (TDC) and identify the correct stroke. After the top dead center
position for a particular stroke is found and the adjustments are made to th correct cylinder, remove th timing pin.
Turn the flywheel for 360 degrees in the direction of normal engine rotation. This will put th No. 1 piston at the top
center position on the other stroke. Install the timing pin in the crankshaft and complete the adjustments for the cylinders
that remain.
(3) SAE Opposite Rotation Engines turn in the CLOCKWISE (CW) direction when the
engines are viewed from the flywheel end.
77 3/17/2003

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 35

CRANKSHAFT MAIN BEARING REMOVAL & INSTALLATION


The following are tools from the 207-5034 Stud Tensioner Tool Group
This group was the first tool group used on 3600 Series Engines only.

Part No. Qty. Tool and Part Name


207-5034 1 Stud Tensioner Tool Group
(2) 207-4607 Threaded Collar
(2) 8T-0896 Bearing Pedestal
(2) 9U-5141 Nut Turning Handle
(8) 1B-0581 Bolt
(4) 0L-1351 Bolt
(2) 4C-5816 Collar Plate
(2) 8T-0895 Cylinder Group
8T-3035 1 Lines Group
(5) 6D-7726 Hoses
(1) 3J-5390 Plug
(1) 8T-5206 Manifold
(5) 1P-2375 Coupler Assembly (Male)
(8) 1P-2376 Coupler Assembly (Female)
8T-0960 1 Handling Group (Part of 9U-5105 Group)
(2) 8T-0916 Pin
(2) 8T-0959 Hitch
(2) 8T-0955 Tensioner Lift Tube Group
(2) 8T-0948 Lift Lever Group
(1) 8T-0872 Stud Tensioner Tray
(2) 8T-0961 Rail Retainer Bushing
(2) 4C-8357 Tray Support Rail
(2) 4K-0367 Full Nut
(2) 8T-0947 Tee Handle
(2) 1B-4430 Jam Nut
(2) 8T-0946 Tensioner Lift Stud
(2) 8T-0963 Shaft
(4) 5P-0370 Lock Pin
(4) 8T-0956 Bracket Group
3S-6224 1 Electric Hydraulic Pump (115V-50/60 Cycle)
8S-8033 Electric Hydraulic Pump (230V-50/60 Cycle)
191-5347 Hydraulic Pump, Pneumatic
156-7167 Hydraulic Pump, Manual
8T-0820 1 Hydraulic Pressure Gauge
134-0932 1 Main Bearing Driver
3P-1529 1 Level
4C-9818 1 Hex Adapter
4C-9819 1 Universal Joint
1U-7515 1 Socket

3 - 35 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 36

Q - DENOTES CRITICAL STEP


Procedures required for the removal of the Crankshaft Main Bearing
Step Procedure
NOTE: The inspection or replacement of the main bearing can be done with the crankshaft in
place. Due to the weight of the crankshaft no more than 2 mains should be removed at any one
time. The crankshaft will sag or bend damaging the crank.
NOTE: Anytime crankshaft is rotated the pre-lube pump must operation.

1 Remove the crankshaft access covers, oil filter, oil level gauge and the crank-
case explosion relief valves and any other engine parts that may be in the way.
Refer to Special Instructions, SEHS9156, installation and Use of the 4C-5818 Collar and Retainer
Group.
2 Loose the saddle bolts. Remove one and allow the other to remain screwed
in 5 or 6 turns.
3 Move the crankshaft to a position out of the way of the connecting rod and
crankshaft journal weight.
4 Put the 4C8357 Tray Support Rail (2) and 8T0872 Stud Tensioner Support
Tray (1) in position under the main bearing cap being removed.
5 Put the assembled Tensioner (2) on the tool tray. (8T0895 cylinder (1),
4C5817 Collar (1), 4C5816 Retainer (1), 1B0581 Bolts (4), 0L1351 Bolts (2),
8T0947 Tee Handle (2) with 1B4430 Jam Nut (2) & 8T0946 Tension Lift Stud
(1). )

6 Place the 8T0896 Pedestal (2) onto the main beading stud. Place the 9U5141
Dowel Handle into one of the Main Bearing Nut holes. This will keep the
Pedestal into position.
7 Bolt the 8T-0956 Bracket Groups (2) in the openings of the crankcase access
covers on each side of the engine.
8 Slide the 8T0955 Tube Group (2) onto the shaft of the 8T0948 Lever Group
(2). Install the 8T0959 Pin through the hole of the 8T0955 Tube Group.
NOTICE: The distance is adjustable and may adjusted later.
9 Slide the 8T0948 Lever Group onto the 8T0963 Shaft.
10 Use 5P0370 Pin Locks (2) to hold the 8T0936 Shaft in position.
11 Place the 8T0955 Tube Group onto the 8T0946 Stud mounted on the side of
the 8T0895 Tensioner and use the 5P0370 Pin to hold in position.
12 Install the handle on the end of the 8T0948 Lever Group and use the
8T0959 Pin to hold in position.
13 By pressing down on the Handle Group, lift the Tensioning cylinder and onto
the stud. A level can be use to level cylinders, by using the adjusting screws
on the handles, before trying to tighten the adapter nut.
14 Use a ratchet wrench and thread the 4C5817 Collar onto the end of main
bearing stud.
15 Attach the hoses, hydraulic cylinders and hydraulic pump together.

16 With the pump in bypass, tighten the Collars to bleed any fluid out of the
cylinders.
17 Loosen the nuts 11/2 turns.
WARNING: Run the pump to a pressure of 1000 psi and check all connection and the hoses
to insure all are in proper working order before proceeding
WARNING: While pressurizing. DO NOT have any part of your body inside the engines
Crankcase or around the Tensioning Cylinders. Safety Glasses MUST be worn. Visually
CHECK all tooling for damage or leaks.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 37

Q 18 Run the pump to a pressure of 65,000 2,400 kPa (9,425 350 psi)
19 Check and make sure both nuts are loose.
20 Place 9U5141 dowel handle through 8T0896 pedestal slot intonut dowel hole
and loosen both nuts 1 1/2 turns or 12 dowel holes.
21 Slowly release hydraulic pressure.
22 Disconnect the hoses and lower the hydraulic tooling.
NOTE: Leave the tensioners on the Tool Tray.
NOTE: The bearings can be changed without removing the bearing caps.
23 Attach the hoses, hydraulic cylinders and hydraulic pump together.
24 With the pump in bypass, tighten the Collars to bleed any fluid out of the
cylinders.
25 Loosen the nuts 1 1/2 turns.
26 Remove the remaining Saddle bolt from the cap. Using the handling group
lower the cap on to the hydraulic cylinders.
NOTE: The bearing cap does not have to be removed from the inside of the engine if you are
only changing one bearing at a time. Lower the main cap down on top of the Hydraulic Tensioners.
27 Remove the lower main bearing from the cap by using a rubber mallet.
28 Install the 134-0932 Bearing Driver in the lubrication hole in the main bearing
journal of the crankshaft.
NOTE: The bearings have a locating tab. When the bearing is viewed from the flywheel,
clockwise rotation is required in order to remove the upper half of the bearing.
NOTE: On a D3606 & D3612 Engine the number 4 main, and on a D3608 & D3615 Engine, the
number 5 main bearing journals do not have oil holes in the crankshaft. The 134-0932 Bearing
Driver Tool cannot be used to roll the upper main bearing half out. In order to remove these
bearings, protect the crankshaft and rap on the side of the bearing without the tab with a narrow tool.
NOTE: It may be necessary to remove the load on the bearing by loosening the bearing caps
before it and after the one being removed. If this does not allow removal of the bearing, a plastic
wedge may be driven between the bearing and the bearing saddle.
29 Rotate the crankshaft clockwise until the bearing comes out and tool can be
removed.

3 - 37 10/2005
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Q - DENOTES CRITICAL STEP


Procedures required for the installation of the Crankshaft Main Bearing
Step Procedure
Q 1 Use a clean cloth to wipe clean the upper half of the main bearing and
Crankshaft surface. Put clean engine oil on the bearing surface and use
134-0932 Bearing Driver Tool to roll the upper half of the main bearing into the
cylinder block. Make sure there is no oil on the back side of the bearing
CAUTION: The bearing should be lined up and installed by hand approximately half the length of
the bearing before using the Bearing Driver to push, the main bearing into the block.
WARNING: The 134-0932 Bearing Driver may slide between the bearing and crankshaft and
cause damage to the bearing.
Q 2 Use a clean cloth in order to wipe the lower half of the Main Bearing and the
bore in the main bearing cap.
Q 3 Ensure there is no thread lubricant on the lower half of the main bearing or on
the main bearing cap. Install the lower half of the main bearing in the main
bearing cap. Ensure that the tab on the back of the bearing is engaged with
the slot in the cap.
Q 4 Put clean engine oil on the lower half of the main bearing. Be sure no oil is
put on the backside of the bearing.
Q 5 Check the length of the dowel on the Main Bearing Cap. 10.0 ± 0.5 mm
(.39 ± .02 in)
6 Use the 8T0960 Handling Tool Group to raise the main bearing cap on the
studs.
7 Ensure that the dowel engages with the hole in the cylinder block.
8 Install one of the Saddle Bolts to hold the Main Bearing Cap in place.
9 Install the washers and nuts in order to hold the main bearing cap. Tighten the
nuts by hand, then remove Tool B from the main bearing.
10 Remove the 8T0916 Pins from the cap.
Q 11 Put 4C5593 Thread Lubricant on the face of the washer and the threads of
each saddle bolt.

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03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 39

12 Install saddle bolts and hand tighten.


Q 13 Tighten the saddle bolt on to the right side of the engine to a torque
215 ± 40 N•m (160 ± 30 ft Ib)
Use the handing group and raise the hydraulic cylinders off the trays. Use
14 the adjusting screws to level the cylinders.
Lift the hydraulic cylinders to the studs and start the threaded collars. Hand
15
tighten the on the main bearing cap bolts.
16 Attach the hoses from the pump to the hydraulic cylinders.
17 Place hydraulic pump in the bypass.
18 Tighten all threaded collars with a 1/2 inch ratchet.
19 Loosen all threaded collars with a 1/4 turn.
WARNING: Run the pump to a pressure of 1000 psi and check all connection
and hoses to insure all is in proper working order before proceeding.
Q 20 Run the pump to 65,000 ± 2400 kPa (94250 ± 350 psi) on the gauge.
21 Tighten the nuts using the dowel handle.

22 Slowly release the hydraulic pressure.

23 Repeat steps 17 through step 22.


24 Remove all Tooling.
25 After installation of the main bearing, check that the crankshaft can turn.
Q 26 Tighten the saddle bolt on to the left side of the engine to a torque
215 ± 40 N•m (160 ± 30 ft Ib)

Q 27 Tighten the saddle bolt on to the right side of the engine to a torque
1825 ± 175 N•m (1350 ± 130 ft Ib)

Q 28 Tighten the saddle bolt on to the left side of the engine to a torque
1825 ± 175 N•m (1350 ± 130 ft Ib)

29 Reinstall remaining parts; crankcase explosion relief valves, centrifugal oil


filters, oil filler, oil level gauge, crankcase access covers.

3 - 39 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 40

CRANKSHAFT MAIN BEARING REMOVAL &


INSTALLATION
The following are tools from the 191-5320 Stud Tensioner Tool Group
This group was the second tool group used on 3600 Series Engines and could
be modified to work on 3618 engines.
Part No. Qty. Tool and Part Name
229-9453 1 Pump Accessory Group
(4) 178-9312 Hose Assembly
(1) 178-9313 Distribution Coupler (manifold)
(1) 185-0683 Comparison Gauge
191-5320 1 Stud Tensioner Tool Group (required)
191-5323 (2) Stud Tensioner Cylinder Group for 3618 Main Bearings
191-5335
(2) Stud Tensioner Cylinder Support for Main Bearing (replacement
for damage support)
175-0185 (2) - 3618 Stud Tensioner Cylinder Sleeve for Cylinder Head
(modification or replacement for damage support.
191-5326 (2) - 3618 Stud Tensioner Cylinder Bushing for Main Bearing
(replacement for damage bushing)
191-5341 4 Optional Gear Drive Group (permits faster rotation of nut onto stud)
191-5343 (2) - Turning Sleeve (for 191-5322 Stud Tensioner Cylinder Groups)
191-5342 (2) - Gear Drive Assembly
(2) - Swivel Head Ratchet (1/2 inch square drive)
191-5320 1 Stud Tensioner Tool Group
(2) - 9U-5141 Nut Turning Handle
8T-0960 1 Handling Group (Part of 9U-5105 Group)
(2) 8T-0916 Pin
(2) 8T-0959 Hitch
(2) 8T-0955 Tensioner Lift Tube Group
(2) 8T-0948 Lift Lever Group
(2) 8T-0872 Stud Tensioner Tray
(2) 8T-0961 Rail Retainer Bushing
(2) 4C-8357 Tray Support Rail
(2) 4K-0367 Full Nut
(2) 8T-0947 Tee Handle
(2) 1B-4430 Jam Nut
(2) 8T-0946 Tension Lift Stud
(2) 8T-0963 Shaft
(4) 5P-0370 Lock Pin
(4) 8T-0956 Bracket Group
227-6724 1 Electric Hydraulic Pump (115V-50/60 Cycle)
227-8834 Electric Hydraulic Pump (230V-50/60 Cycle)
191-5347 Hydraulic Pump, Pneumatic
156-7167 Hydraulic Pump, Manual
8T-0820 1 Hydraulic Pressure Gauge
134-0932 1 Main Bearing Driver
3P-1529 1 Level
4C-9818 1 Hex Adapter
4C-9819 1 Universal Joint
1U-7515 1 Socket

3 - 40 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 41

Part No. Qty. Tool and Part Name


227-6724 1 Hydraulic Pump, Electric 120V
227-8834 Hydraulic Pump, Electric 240V
191-5347 Hydraulic Pump, Pneumatic
156-7167 Hydraulic Pump, Manual
229-9453 1 Pump Accessory Group
178-9312 (4) - Hose Assembly
178-9313 (1) - Distribution Coupler (manifold
185-0683 (1) - Comparison Gauge
191-5320 1 Stud Tensioner Tool Group (required)
191-5322 (4) - Stud Tensioner Cylinder Group for 3606, 3608, 3612,
3616 Cylinder Heads
191-5333 (4) - 3606, 3608, 3612, 1616 Stud Tensioner Cylinder Support for
Cylinder Head (replacement for damage support)
(4) - 3618 Stud Cylinder Support for Cylinder Head (Modification or
178-9053
replacement for damage support
191-5324 (4) - 3606, 3608, 3612, 1616 Stud Tensioner Cylinder Bushing for
Cylinder Head (replacement for damage support)
178-9051 (4) - Stud Tensioner Cylinder Bushing for Cylinder Head
(Modification or replacement for damage support
178-9053 (4) - Replacement support for modification of Stud Tensioner Group
for 3618 Cylinder Head
191-5341 4 Optional Gear Drive Group (permits faster rotation of nut onto stud.)
191-5343 (4) - Turning sleeve (for 191-5322 Stud Tensioner Cylinder Groups)
191-5342 (4) - Gear Drive Assembly
(2) - Swivel Head Ratchet (1/2 inch square drive)
229-9457 1 Auxiliary Group
225-5637 (2) - Support (used in place of the 191-5333 Support when used on
front head studs on # 1 cylinder to clear fuel filters.)
225-5636 (2) - Bushing used in place of the 191-5324 Bushing when used on
front head studs on # 1 cylinder to clear fuel filters.)
126-6918 1 Lifting Bracket (Vee)
126-6919 Lifting Bracket (In-line)
126-6920 1 Tiller Handle
5D-1972 2 Bolt 3/4 - 10 NC x 11 3/4 (29.9 cm) long

3 - 41 10/2005
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Q - DENOTES CRITICAL STEP


Procedures required for the removal of the Crankshaft Main Bearing
Step Procedure
NOTE: The inspection or replacement of the main bearing can be done with the crankshaft in place.
Due to the weight of the crankshaft no more than 2 mains should be removed at any one time. The
crankshaft will sag or bend damaging the crank.
NOTE: Anytime crankshaft is rotated the pre-lube pump must operation.
1 Remove the crankcase access covers, oil filter, oil level gauge and the crankcase
explosion relief valves and any other engine parts that may be in the way.
Refer to Special Instructions, SEHS9156, installation and Use of the 4C-5818 Collar and Retainer
Group.
2 Loose the saddle bolts. Remove one and allow the other to remain screwed
in 5 or 6 turns.
3 Move the crankshaft to a piston out of the way of the connecting rod and
crankshaft journal weight.
4 Put the 4C8357 Tray Support Rail (2) and 8T0872 Stud Tensioner Support
Tray (1) in position under the main bearing cap being removed.
5 Place the assembled Tensioner (2) on the tool tray.

5 Put the assembled Tensioner (2) on the tool tray. (8T0895 cylinder (1),
4C5817 Collar (1), 4C5816 Retainer (1), 1B0581 Bolts (4), 0L1351 Bolts (2),
8T0947 Tee Handle (2) with 1B4430 Jam Nut (2) & 8T0946 Tension Lift Stud
(1).
6 Place the 8T0896 Pedestal (2) onto the main beading stud. Place the 9U5141
Dowel Handle into one of the Main Bearing Nut holes. This will keep the
Pedestal into position.
7 Bolt the 8T-0956 Bracket Groups (2) in the openings of the crankcase access
covers on each side of the engine.
8 Slide the 8T0955 Tube Groups (2) onto the shaft of the 8T0948 Lever Group
(2). Install the 8T0959 Pin through the hole of the 8T0955 Tube Group.
NOTICE: The distance is adjustable and may adjusted later.
9 Slide the 8T0948 Lever Group onto the 8T0963 Shaft.
10 Use 5P0370 Pin Locks (2) to hold the 8T0936 Shaft in position.
11 Place the 8T0955 Tube Group onto the 8T0946 Stud mounted on the side of
the 8T0895 Tensioner and use the 5P0370 Pin to hold in position.
12 Install the handle on the end of the 8T0948 Lever Group and use the
8T0959 Pin to hold in position.
13 By pressing down on the Handle Group, lift the Tensioning cylinder and onto
the stud. A level can be use to level cylinders, by using the adjusting screws
on the handles, before trying to tighten the adapter nut.
14 Use a ratchet wrench and thread the 4C5817 Collar onto the end of the main
bearing stud.
15 Attach the hoses, hydraulic cylinders and hydraulic pump together.

16 With the pump in bypass, tighten the Collars to bleed any fluid out of the
cylinders.
17 Loosen the nuts 11/2 turns.

WARNING: Run the pump to a pressure of 1000 psi and check all connection and the hoses
to insure all are in proper working order before proceeding
WARNING: While pressurizing. DO NOT have any part of your body inside the engines
Crankcase or around the Tensioning Cylinders. Safety Glasses MUST be worn. Visually
CHECK all tooling for damage or leaks.

3 - 42 10/2005
03 Maint-Serv_SingCylinOverhaul.qxd 2/20/2006 9:38 AM Page 43

Q 18 Run the pump to a pressure of 65,000 ± 2,4000 kPa (9,425 ± 350 psi)
19 Check and make sure both nuts are loose.
20 Place 9U5141 dowl handle through 8T0896 pedestal slot into nut dowel hole
and loosen both nuts 1 1/2 turns or 12 dowel holes.
21 Slowly release hydraulic pressure.
22 Disconnect the hoses and lower the hydraulic tooling.
NOTE: Leave the Tensioners on the Tool Tray.
NOTE: The bearings can be changed without removing the bearing caps.
23 Remove and inspect the 2 nuts and washers. Use the handling group to lower
the hydraulic cylinders and sit them on the tray.
24 Install the 8T0916 Pin (2) into the Main Bearing Cap.
25 Disconnect the handling group from the cylinders and reconnect to the
bearing cap
26 Remove the remaining Saddle bolt from the cap. Using the handling
group, lower the cap on the the hydraulic cylinders.
NOTE: The bearing cap does not have to be removed from the inside of the engine if you are
only changing one bearing at a time. Lower the main cap down on top of the Hydraulic
Tensioners.
27 Remove the lower main bearing from the cap by using a rubber mallet.
28 Install the 134-0932 Bearing Driver in the lubrication hole in the main bearing
journal of the crankshaft.
NOTE: The bearings have a locating tab. When the bearing is viewed from the flywheel,
clockwise rotation is required in order to remove the upper half of the bearing.
NOTE: On a D3606 & D3612 Engine the number 4 main, and on a D3608 & D3616 Engine, the
number 5 main bearing journals do not have oil holes in the crankshaft. The 134-0932 Bearing
Driver Tool cannot be used to roll the upper main bearing half out. In order to remove these
bearings, protect the crankshaft and rap on the side of the bearing without the tab with a narrow
tool.
NOTE: It may be necessary to remove the load on the bearing by loosening the bearing caps
before it and after the one being removed. If this does not allow removal of the bearing, a plastic
wedge may be driven between the bearing and the bearing saddle.
clockwise rotation is required in order to remove the upper half of the bearing.
29 Rotate the crankshaft clockwise until the bearing comes out and the tool
can be removed.

3 - 43 10/2005
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3 - 44 10/2005
04 Maint-Serv_PartNumber.qxd 2/24/2006 2:04 PM Page 1

Common Parts

Index

Common Seals, Gaskets & O-Rings ............................................................................................4-2


3600 Combustion Seal Gasket ....................................................................................................4-5
3600 Combustion Seal Gasket ....................................................................................................4-6
Remanufactured Part Number......................................................................................................4-7
Spare Parts List for 3606 & 3608 Marine ....................................................................................4-9

4-1
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04 Maint-Serv_PartNumber.qxd 2/24/2006 2:04 PM Page 2

Common Filter Elements Part Numbers


Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179-1502
Oil Suction Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Y3307
Centrifugal Oil Filter Paper Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7C8390*
Air Filter (primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105-9741
Silencer **
Fuel Filter
(All Distillate & Duplex Filters)(8 Reqd.) . . . . . . . . . . . . . . . . . . .1R0725
(4W5421 Primary Filter Gp) (2 Reqd.) . . . . . . . . . . . . . . . . . . . .4W2609
(Filter Kit includes (2) 4W2609 Filters) . . . . . . . . . . . . . . . . . . . .9Y6898
Soot Filter
(Primary Filter 22 in. ID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4W7103
(Silencer 25 in. ID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137-9974
(Engine Room Air Inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125-7774
(Marine Only 27.8)
* If you double the paper liners (1 on top of the other), it makes cleaning
easier.
** The former 159-4507 Air Cleaner Group is canceled and replaced by the 246-
3237 Screen As. and the 246-3236 Silencer Shell must also be replaced. The
new air silencer is adaptable to all of the 3600 Engines that are listed in the
December 2003, Engine News Article, SEBD9328.

Former Part Former Part


159-4507 Air Cleaner Group 159-4507 Air Cleaner Group
116-5048 Felt Segment 116-5048 Felt Segment
159-7433 Silencer Screen 159-7433 Silencer Screen
159-7434 Silencer Shell 159-7434 Silencer Shell

Common Seals, Gaskets & O-Rings Part Numbers


NOTE: The following chart is only a reference. Call your local Caterpillar
Dealership for the current part required.

Name of Part Part Number # reqd.

A/C Core Seals (high performance 12 cyl.) front 130-1300 2


rear 135-9951 2
A/C Core Seals (high performance 16 cyl.) front 130-1300 2
rear 130-1300 2
A/C Core Seal (inline)
A/C Core Seal (standard core 12 cyl) front 2W-8320 1
rear 4W-7563 1
A/C Core Seal (standard core 16 cyl) front 2W-4054 1
rear 2W-4054 1
Air Plenum Cover Gasket (inline) 9Y-7083
Air Plenum Cover Gasket (vee) 121-3874

Bearings - Connect Standard 142-8615 & 246-7542 replaced by


Rod 227-2902 current
142-8615 non-current
101-4181 non-current
227-2902 effective with
3606 - 8RB077 - up
3608 - 6MC0619 - up
3612 - 9RC0319 - up
9FR0021 - up
2NZ0176 - up
3616 - 1PD0364 - up
1FN015 - up
.5 mm (.02) usid 7E2615
1.0 mm (.04) usid 7E2614

4-2
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04 Maint-Serv_PartNumber.qxd 2/24/2006 2:05 PM Page 3

Bearings – Main Standard 111-3378 replaced by 129-4054


129-4054 current
.25 mm (.01) usid 127-1916 current
.50 mm (.02) usid & 127-1921 current
1.00 mm (.04) osod
.50 mm (.02) usid 127-1917 replaced by 143-6219
143-6219 current
1.00 mm (.04) usid 127-1918 replaced by 143-6221
143-6221 current
1.00 mm (.04) osod 127-1919 replaced by 143-6222
143-6222 current
2.00 mm (.08) osod 127-1920 replaced by 143-6224
143-6224 current
Camshaft Cover O-ring 8T0098
Camshaft Follower Cover 9X7688
Combustion Seal (diesel fuel) 145-7230
Combustion Seal (residual fuel) See chart
Combustion Seal (wet liner) See chart
Crankcase Inspection Cover O-ring 6I4545
Crankshaft Seal & Wear Sleeve CW 9Y7624 replaced by 190-2462
190-2462 current
CCW 9Y7625 replaced by 190-2463
190-2463 current
Wear Sleeve 121-3352 replaced by 160-8173**
Connecting Rod Bolt 1W0098
Connecting Rod Bolt Re-use guide Do not reuse a Connecting Rod Bolt
if the dimension from the underside
of the bolt head to end of bolt is
more than 329.00 mm (12.953 in.)
Connecting Rod Bolt Nut 6V9801 replaced by 205-0604
205-0604 current
8RB0871 – up
6MC0667 – up
9RC0386 – up
1PD0395 – up
Connecting Rod Bolt Nut Re-use guide DO NOT REUSE
Connecting Rod Retainer 4W8344
Cylinder Head Stud Nuts 1W2361
Cylinder Head Stud 7E8400 replaced by 187-0450
187-0450 current
Cylinder Head Stud Reuse guide 20 Tensions
Cylinder Head Stud Thread Standard 2-12 1W0121
st
Repair Kit 1 os 2 1/8-12 121-2764
nd
2 os 2 1/4-12 122-0286
Cylinder Head Stud Nut 1W2361
Cylinder Head Stud Protectors 7W1342 replaced by 185-3545
185-3545 current
Cylinder Head Stud Washer 1W2362
Cylinder Liner distillate 111-1561 replaced by 116-1042
116-1042 replaced by 179-3167
179-3167 current
HFO 7E8268 replaced by 116-1042
116-1042 replaced by 179-3167
179-3167 current
Cylinder Liner Cuff Ring 115-0682 replaced by 141-4857
141-4857 current
Fuel Connector O-ring 8L2786
Fuel Line O-ring 033-6033
Main Bearing Stud 1W0121
Main Bearing Stud Nut 1W0123
Main Bearing Stud Washer 1W1022
MUI (injector) distillate 224-9050 or 1OR1252 (new)
3606, 3608, 3612, 3616 184-2527 or OR8575 (old)
HFO 224-9089 or 1OR1253 (new)
168-3554 or OR3650 (old)
MUI (injector) distillate 184-2528 or OR7470
3618
MUI (injector) O-rings (diesel) top 6V1179 2
bottom 061-9455 1
MUI (injector) O-ring (HFO) top 6V1179 2
middle 4W3182 1
bottom 061-9455 1

4-3
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04 Maint-Serv_PartNumber.qxd 2/24/2006 2:05 PM Page 4

4-4
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3600 Combustion Seal Gasket


Thickness

Cross-Sectional Shape
Per 25.0 (1.0) length
Gasket In Production

Minimum for Reuse


Gasket Part No.

Roundness
Parallelism
Note:

Flatness
4.00 ± 0.10 3.50 .03 ±.03 ±.3
1W0496 N 1
(.157 ± .004) (.154) (.001) (.001) (.012)
A

4.20 ± 0.10 4.15 .03 ±.03 ±.3


123-0247 N 2
(.165 ± .004) (.163) (.001) (.001) (.012)
A

4.20 ± 0.10 4.15 .03 ±.03 ±.3


145-7230 Y
(.165 ± .004) (.163) (.001) (.001) (.012)
B

4.20 ± 0.10 4.15 .03 ±.03 ±.3


142-2826 Y
(.165 ± .004) (.163) (.001) (.001) (.012)
C

4.20 ± 0.10 4.15 .03 ±.03 ±.3


173-2669 Y
(.165 ± .004) (.163) (.001) (.001) (.012)
A

4.20 ± 0.10 4.15 .03 ±.03 ±.3


126-5966 N 3
(.165 ± .004) (.163) (.001) (.001) (.012)
A

4.20 ± 0.10 4.15 .03 ±.03 ±.3


166-7083 Y
(.165 ± .004) (.163) (.001) (.001) (.012)
B

4.20 ± 0.10 4.15 .03 ±.03 ±.3


173-2670 Y
(.165 ± .004) (.163) (.001) (.001) (.012)
A

4.20 ± 0.10 4.15 .03 ±.03 ±.3


179-4382 Y
(.165 ± .004) (.163) (.001) (.001) (.012)
C

1. 1W0498 Gasket was CRB 123-0247 for diesel (distillate) fuel, and 126-5986 for HFO.
2. 123-0247 Gasket CRB 145-7230.
3. 145-7230 Gasket CRB 142-2826
4. 126-5986 Gasket CRB 156-7083.
- Cleaning: Before measurement, the gasket should be cleaned by using a Scotch-Bright pad.
- Surface Finish: The surface finish must be 1.6 micrometer (63 microinches), or smoother. No nicks
or gouges.

- Corrosion: Some corrosion on the sealing surface is allowed, but it is limited to 5.) mm (.20 in.) across the gasket.
- Older liners such as the 116-1042 have only a radius at the gasket seat inner edge. New and old Liners may be
used in same engine, however if both liners are being used in the same engine the 145-7230 combustion gasket
should be used.
- For 3606 - 3608 HarborTugs & Anchor Handling Marine Vessels 8RB825 & UP, 6MC8481 & Up use a
179-3108 Bimetallic Liner.
- Current 179-3167 and discontinued liners may be used in the same engine, but if so, either the 145-7230 or
65-7083 Gasket should be used on all liners.
- When installing 166-7083 or 145-7230 Gaskets on older liners, be sur the side of the gasket with the chamfer
stamped “bottom” next to the part number) is facing the liner.

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3600 Combustion Seal Gasket

Liners, by type, gasket can be used with

Fuel Type Used

non-cuffed,

non-cuffed,

cuffed, dry

cuffed, dry
wet flange
dry flange

flange, bi-
Gasket P/N

metallic
flange
0R9731*
1W7900* 7E4981*
diesel & 116-1042* 179-3168
1W0498 7E8268* 7E8298*
HFO 178-0462* 195-3507
111-1561 111-1656
179-3167
0R9731*
1W7900* 7E4981*
116-1042* 179-3168
123-0247 diesel 7E8268* 7E8298*
178-0462* 195-3507
111-1561 111-1656
179-3167
0R9731*
1W7900* 7E4981*
116-1042* 179-3168
145-7230 diesel 7E8268* 7E8298*
178-0462* 195-3507
111-1561 111-1656
179-3167
179-3168
142-2826 diesel 179-3167