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SEBU7563-09

April 2010

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

SAFETY.CAT.COM
i03684547

Important Safety Information


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

The meaning of this safety alert symbol is as follows:


Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this


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

Failure to heed this warning can lead to prema-


ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7563-09 3
Table of Contents

Table of Contents Maintenance Interval Schedule (G3600 Engines That


Use Natural Gas and Have a Compression Ratio of
10.5:1 or 11:1) ..................................................... 62
Foreword ................................................................. 4
Maintenance Interval Schedule (G3600 Engines That
use Bio-Gas) ....................................................... 64
Safety Section
Safety Messages .................................................... 6 Reference Information Section

Additional Messages ............................................. 10 Customer Service ............................................... 125

General Hazard Information ................................. 12 Reference Materials ............................................ 127

Burn Prevention .................................................... 14 Index Section


Fire Prevention and Explosion Prevention ............ 14 Index ................................................................... 133

Crushing Prevention and Cutting Prevention ........ 16

Mounting and Dismounting ................................... 16

Ignition Systems ................................................... 16

Before Starting Engine .......................................... 17

Engine Starting ..................................................... 17

Engine Stopping ................................................... 17

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

Product Information Section


Model Views and Specifications ........................... 19

Product Identification Information ........................ 28

Operation Section
Lifting and Storage ................................................ 30

Features and Controls .......................................... 32

Engine Diagnostics ............................................... 44

Engine Starting ..................................................... 45

Engine Operation .................................................. 50

Engine Stopping ................................................... 52

Maintenance Section
Refill Capacities .................................................... 54

Maintenance Recommendations .......................... 58

Maintenance Interval Schedule (G3600 Engines


That Use Wellhead or Natural Gas and Have a
Compression Ratio of 9.2:1) ............................... 60
4 SEBU7563-09
Foreword

Foreword Use service hours to determine intervals. Calendar


intervals shown (daily, annually, etc) may be used
instead of service meter intervals if they provide more
Literature Information convenient schedules and approximate the indicated
service meter reading.
This manual contains safety, operation instructions,
lubrication and maintenance information. This Recommended service should always be
manual should be stored in or near the engine area performed at the service hour interval. The actual
in a literature holder or literature storage area. Read, operating environment of the engine also governs
study and keep it with the literature and engine the maintenance schedule. Therefore, under
information. extremely severe, dusty, wet or freezing cold
operating conditions, more frequent lubrication and
English is the primary language for all Caterpillar maintenance than is specified in the maintenance
publications. The English used facilitates translation schedule may be necessary.
and consistency in electronic media delivery.
The maintenance schedule items are organized for
Some photographs or illustrations in this manual a preventive maintenance management program. If
show details or attachments that may be different the preventive maintenance program is followed, a
from your engine. Guards and covers may have periodic tune-up is not required. The implementation
been removed for illustrative purposes. Continuing of a preventive maintenance management program
improvement and advancement of product design should minimize operating costs through cost
may have caused changes to your engine which are avoidances resulting from reductions in unscheduled
not included in this manual. Whenever a question downtime and failures.
arises regarding your engine, or this manual, please
consult with your Caterpillar dealer for the latest
available information. Maintenance Intervals
Perform maintenance on items at multiples of the
Safety original requirement. Each level and/or individual
items in each level should be shifted ahead or back
This safety section lists basic safety precautions. depending upon your specific maintenance practices,
In addition, this section identifies hazardous, operation and application. We recommend that
warning situations. Read and understand the basic the maintenance schedules be reproduced and
precautions listed in the safety section before displayed near the engine as a convenient reminder.
operating or performing lubrication, maintenance and We also recommend that a maintenance record be
repair on this product. maintained as part of the engine's permanent record.

Operation See the section in the Operation and Maintenance


Manual, “Maintenance Records” for information
Operating techniques outlined in this manual are regarding documents that are generally accepted
basic. They assist with developing the skills and as proof of maintenance or repair. Your authorized
techniques required to operate the engine more Caterpillar dealer can assist you in adjusting your
efficiently and economically. Skill and techniques maintenance schedule to meet the needs of your
develop as the operator gains knowledge of the operating environment.
engine and its capabilities.

The operation section is a reference for operators.


California Proposition 65 Warning
Photographs and illustrations guide the operator Battery posts, terminals and related accessories
through procedures of inspecting, starting, operating contain lead and lead compounds. Wash hands after
and stopping the engine. This section also includes a handling.
discussion of electronic diagnostic information.

Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
SEBU7563-09 5
Foreword

Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
programs. If you experience a major engine failure,
there are also numerous after failure overhaul options
available from your Caterpillar dealer. Consult with
your dealer for information regarding these options.
6 SEBU7563-09
Safety Section
Safety Messages

Safety Section
i02602825

Safety Messages
SMCS Code: 1000; 7405

g01048357
Illustration 1
Right side view
SEBU7563-09 7
Safety Section
Safety Messages

g01048362
Illustration 2
Left side view

There may be several specific safety messages


on the engine. The exact location of the hazards
and the description of the hazards are reviewed in Do not operate or work on this engine unless you
this section. Please become familiar with all safety have read and understand the instructions and
messages. warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the
Ensure that all of the safety messages are legible. warnings could result in injury or death. Contact
Clean the safety messages or replace the safety any Caterpillar dealer for replacement manuals.
messages if the words cannot be read or if the Proper care is your responsibility.
pictures are not visible. When the safety messages
are cleaned, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean The safety messages that may be attached on the
the safety messages. Solvents, gasoline, or harsh engine are illustrated and described below.
chemicals could loosen the adhesive that secures
the safety messages. The safety messages that are
loosened could drop off of the engine.

Replace any damaged safety messages or missing


safety messages. If a safety message is attached
to a part of the package that is replaced, install a
new safety message on the replacement part. Any
Caterpillar dealer can provide new safety messages.
8 SEBU7563-09
Safety Section
Safety Messages

(1) Pinch Point (Linkage) (3) Engine Lifting (Label On the


The safety messages for the pinch point (linkage) are
Number Three Camshaft Cover
located on the covers of the fuel control actuator, the and On the Number Four Camshaft
air choke actuator, and the bracket of the exhaust Cover)
bypass actuator .
Safety messages for engine lifting are located on the
camshaft cover of the number three cylinder and on
the camshaft cover of the number four cylinder.

g00123168

During operation, the linkage of the electrohy-


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

g00299841
(2) Crankcase Covers
The safety message for the crankcase covers is
located on the rearmost crankcase covers.
Improper lift rigging can allow unit to tumble caus-
ing injury and damage.

(1) Use a proper spreader bar, as shown.

(2) Attach two properly rated cables to the spreader


bar from the engine lift shackles.

g00123185

Flash fire may result in personal injury, if


crankcase covers are removed within fifteen min-
utes after emergency shut down. Do not restart
engine until cause for shutdown has been cor-
rected.
SEBU7563-09 9
Safety Section
Safety Messages

(4) Engine Lifting (Label On the


Number One Camshaft Cover and
On the Number Two Camshaft
Cover)
Safety messages for engine lifting are located on the
camshaft cover of the number one cylinder and on
the camshaft cover of the number two cylinder.

g00299818

Improper lift rigging can allow unit to tumble caus-


ing injury and damage.

(1) Use a proper spreader bar, as shown.

(2) Attach two properly rated cables to the spreader


bar from the engine lift shackles.
10 SEBU7563-09
Safety Section
Additional Messages

i02040045

Additional Messages
SMCS Code: 1000; 7405

g01049170
Illustration 3
Right side view
SEBU7563-09 11
Safety Section
Additional Messages

g01049171
Illustration 4
Left side view

There may be several specific messages on the (1) Removal of the Prechamber
engine. The exact location of the messages and the Assembly
description of the messages are reviewed in this
section. Please become familiar with all messages.
The notices for the removal of the prechamber
assemblies are located on each valve cover.
Ensure that all of the messages are legible. Clean
the messages or replace the messages if the words
cannot be read or if the pictures are not visible. When
the messages are cleaned, use a cloth, water, and
soap. Do not use solvent, gasoline, or other harsh
chemicals to clean the messages. Solvents, gasoline,
or harsh chemicals could loosen the adhesive that
secures the messages. The messages that are
loosened could drop off of the engine. g00902999

Replace any damaged messages or missing Before the prechamber assembly is removed, drain
messages. If a message is attached to a part of the the coolant and remove the spark plugs in order to
package that is replaced, install a new message prevent damage. Tighten the nuts that are located
on the replacement part. Any Caterpillar dealer can on the wire assembly for the combustion sensor to
provide new messages. 9.5 ± .5 N·m (85 ± 5 lb in). Do not overtighten the
nuts.
12 SEBU7563-09
Safety Section
General Hazard Information

i02602865

General Hazard Information


SMCS Code: 1000; 4450; 7405

g00702020
Illustration 6

• Wear a hard hat, protective glasses, and other


protective equipment, as required.
g00104545
Illustration 5 • When work is performed around an engine that is
operating, wear protective devices for ears in order
Attach a “Do Not Operate” warning tag or a similar to help prevent damage to hearing.
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is • Do not wear loose clothing or jewelry that can snag
repaired. These warning tags (Special Instruction, on controls or on other parts of the engine.
SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine and to • Ensure that all protective guards and all covers are
each operator control station. When it is appropriate, secured in place on the engine.
disconnect the starting controls.
• Never put maintenance fluids into glass containers.
Do not allow unauthorized personnel on the engine, Glass containers can break.
or around the engine when the engine is being
serviced. • Use all cleaning solutions with care.
Engine exhaust contains products of combustion • Report all necessary repairs.
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated Unless other instructions are provided, perform
area. If the engine is in an enclosed area, vent the the maintenance under the following conditions:
engine exhaust to the outside.
• The engine is stopped. Ensure that the engine
Cautiously remove the following parts. To help cannot be started.
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed. • Disconnect the batteries when maintenance
is performed or when the electrical system is
• Filler caps serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• Grease fittings
• Do not attempt any repairs that are not understood.
• Pressure taps Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
• Breathers
California Proposition 65 Warning
• Drain plugs
Some engine exhaust constituents are known to the
Use caution when cover plates are removed. State of California to cause cancer, birth defects, and
Gradually loosen, but do not remove the last two other reproductive harm.
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
SEBU7563-09 13
Safety Section
General Hazard Information

Pressurized Air and Water Asbestos Information


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

When pressurized air and/or pressurized water is


used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.

The maximum air pressure for cleaning purposes


must be below 205 kPa (30 psi) when the air nozzle
is deadheaded. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
g00702022
Illustration 8
Fluid Penetration
Caterpillar equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be


generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
Illustration 7
g00687600 bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
Always use a board or cardboard when you check contains asbestos is generated.
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause If dust that may contain asbestos is present, there
serious injury and possible death. A pin hole leak can are several guidelines that should be followed:
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment • Never use compressed air for cleaning.
from a doctor that is familiar with this type of injury.
• Avoid brushing materials that contain asbestos.
Containing Fluid Spillage • Avoid grinding materials that contain asbestos.
Care must be taken in order to ensure that fluids • Use a wet method in order to clean up asbestos
are contained during performance of inspection, materials.
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable • A vacuum cleaner that is equipped with a high
containers before opening any compartment or efficiency particulate air filter (HEPA) can also be
disassembling any component that contains fluids. used.

Refer to Special Publication, NENG2500, “Caterpillar • Use exhaust ventilation on permanent machining
Dealer Service Tools Catalog” for the following items: jobs.

• Tools that are suitable for collecting fluids and • Wear an approved respirator if there is no other
equipment that is suitable for collecting fluids way to control the dust.

• Tools that are suitable for containing fluids and


equipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.


14 SEBU7563-09
Safety Section
Burn Prevention

• Comply with applicable rules and regulations Any contact with hot coolant or with steam can cause
for the work place. In the United States, use severe burns. Allow cooling system components to
Occupational Safety and Health Administration cool before the cooling system is drained.
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”. Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
• Obey environmental regulations for the disposal
of asbestos. Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
• Stay away from areas that might have asbestos with a bare hand. Remove the filler cap slowly in
particles in the air. order to relieve pressure.

Dispose of Waste Properly Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.

Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.

Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
g00706404 the eyes. Always wear protective glasses for servicing
Illustration 9
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations. i01372262

Always use leakproof containers when you drain Fire Prevention and Explosion
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
Prevention
SMCS Code: 1000; 4450; 7405
i01480768

Burn Prevention
SMCS Code: 1000; 4450; 7405

Do not touch any part of an operating engine.


Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.

Coolant Illustration 10
g00704000

When the engine is at operating temperature, the All fuels, most lubricants, and some coolant mixtures
engine coolant is hot. The coolant is also under are flammable.
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
SEBU7563-09 15
Safety Section
Fire Prevention and Explosion Prevention

Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause deterioration. The hoses must be properly routed.
a fire. Fire may cause personal injury and property The lines and hoses must have adequate support
damage. and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after Oil filters and fuel filters must be properly installed.
an emergency shutdown. The filter housings must be tightened to the proper
torque.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.

If the application involves the presence of combustible


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

Remove all flammable materials such as fuel, oil, and


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

Store fuels and lubricants in properly marked


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

Do not expose the engine to any flame.


g00704135
Illustration 11
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
Gases from a battery can explode. Keep any open
a hose, or a seal failure. Exhaust shields must be
flames or sparks away from the top of a battery. Do
installed correctly.
not smoke in battery charging areas.
Do not weld on lines or tanks that contain flammable
Never check the battery charge by placing a metal
fluids. Do not flame cut lines that contain flammable
object across the terminal posts. Use a voltmeter or
fluid. Clean any such lines thoroughly with a
a hydrometer.
nonflammable solvent prior to welding or flame
cutting.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
Wiring must be kept in good condition. All electrical
the Operation Section of this manual for specific
wires must be properly routed and securely attached.
instructions.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
Do not charge a frozen battery. This may cause an
engine. Clean all electrical connections and tighten
explosion.
all electrical connections.
The batteries must be kept clean. The covers
Eliminate all wiring that is unattached or unnecessary.
(if equipped) must be kept on the cells. Use the
Do not use any wires or cables that are smaller than
recommended cables, connections, and battery box
the recommended gauge. Do not bypass any fuses
covers when the engine is operated.
and/or circuit breakers.

Arcing or sparking could cause a fire. Secure Fire Extinguisher


connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing Make sure that a fire extinguisher is available. Be
or sparking. familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
16 SEBU7563-09
Safety Section
Crushing Prevention and Cutting Prevention

Lines, Tubes and Hoses Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
Do not bend high pressure lines. Do not strike high one will be injured by flying debris.
pressure lines. Do not install any lines that are bent
or damaged.
i01372247

Repair any lines that are loose or damaged. Leaks


can cause fires. Consult your Caterpillar dealer for
Mounting and Dismounting
repair or for replacement parts. SMCS Code: 1000; 4450; 7405
Check lines, tubes and hoses carefully. Do not use Inspect the steps, the handholds, and the work area
your bare hand to check for leaks. Use a board or before mounting the engine. Keep these items clean
cardboard to check for leaks. Tighten all connections and keep these items in good repair.
to the recommended torque.
Mount the engine and dismount the engine only at
Replace the parts if any of the following conditions locations that have steps and/or handholds. Do not
are present: climb on the engine, and do not jump off the engine.
• End fittings are damaged or leaking. Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
• Outer coverings are chafed or cut. with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
• Wires are exposed. controls as handholds.
• Outer coverings are ballooning. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
• Flexible part of the hoses are kinked. platform. Secure the climbing equipment so that the
equipment will not move.
• Outer covers have embedded armoring.
Do not carry tools or supplies when you mount the
• End fittings are displaced. engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other i01519141
parts, and excessive heat.
Ignition Systems
i01359666 SMCS Code: 1550
Crushing Prevention and Ignition systems can cause electrical shocks. Avoid
Cutting Prevention contacting the ignition system components and
wiring.
SMCS Code: 1000; 4450; 7405
Do not inspect the valve mechanism or the
Support the component properly when work beneath transformers while the engine is operating. Personal
the component is performed. injury or death may result.

Unless other maintenance instructions are provided, If the mode control switch is in the AUTOMATIC or
never attempt adjustments while the engine is START position and the wiring harness is connected,
running. the ignition system may discharge and a spark plug
will ignite. The spark plug will ignite any gas that has
Stay clear of all rotating parts and of all moving accumulated in that cylinder. The crankshaft and the
parts. Leave the guards in place until maintenance driven equipment can move. Personal injury may
is performed. After the maintenance is performed, result. The driven equipment could be damaged. Gas
reinstall the guards. that has accumulated in the exhaust system can also
be ignited.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.

When objects are struck, wear protective glasses in


order to avoid injury to the eyes.
SEBU7563-09 17
Safety Section
Before Starting Engine

Turn the mode control switch to the STOP or If there is a possibility that unburned gas remains in
OFF/RESET position before connecting the wiring the exhaust system, refer to the purge procedure in
harness. When the mode control switch is in the this Operation and Maintenance Manual, “Engine
STOP or OFF/RESET position, the ignition system Starting” topic in the Operation Section.
is disabled.
Start the engine from the operator's compartment or
from the engine start switch.
i00659904

Before Starting Engine Always start the engine according to the procedure
that is described in the Operation and Maintenance
SMCS Code: 1000 Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
Inspect the engine for potential hazards. prevent major damage to the engine components.
Knowing the procedure will also help to prevent
Before starting the engine, ensure that no one is on, personal injury.
underneath, or close to the engine. Ensure that the
area is free of personnel. To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Ensure that the engine is equipped with a lighting properly, check the water temperature and the oil
system that is suitable for the conditions. Ensure that temperature during heater operation.
all lights work properly.
Engine exhaust contains products of combustion
All protective guards and all protective covers must which can be harmful to your health. Always start the
be installed if the engine must be started in order engine and operate the engine in a well ventilated
to perform service procedures. To help prevent an area. If the engine is started in an enclosed area,
accident that is caused by parts in rotation, work vent the engine exhaust to the outside.
around the parts carefully.
i00659907
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are Engine Stopping
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent SMCS Code: 1000
engine damage.
To avoid overheating of the engine and accelerated
On the initial start-up of a new engine or an engine wear of the engine components, stop the engine
that has been serviced, be prepared to stop the according to the instructions in this Operation and
engine if an overspeed condition occurs. This may Maintenance Manual, “Engine Stopping” topic
be accomplished by shutting off the fuel supply to the (Operation Section).
engine, or shutting off the ignition system.
Use the Emergency Stop Button (if equipped) ONLY
See the Service Manual for repairs and for in an emergency situation. Do not use the Emergency
adjustments. Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
i02136012
corrected.
Engine Starting On the initial start-up of a new engine or an engine
SMCS Code: 1000 that has been serviced, make provisions to stop
the engine if an overspeed occurs. This may be
If a warning tag is attached to the engine start switch accomplished by shutting off the fuel supply to the
or to the controls, DO NOT start the engine or move engine, or shutting off the ignition system.
the controls. Consult with the person that attached
the warning tag before the engine is started.

All protective guards and all protective covers must


be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
18 SEBU7563-09
Safety Section
Electrical System

i01032810

Electrical System
SMCS Code: 1000; 1400

Never disconnect any charging unit circuit or battery


circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.

Check the electrical wires daily for wires that are


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

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

Uncontrolled electrical circuit paths can result in


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

Ensure that all grounds are secure and free of


corrosion.

The engine alternator must be grounded to the


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

For the starting motor, do not attach the battery


negative terminal to the engine block.

Ground the engine block with a ground strap that is


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

Use a separate ground strap to ground the battery


negative terminal for the control system to the ground
plane.

If rubber couplings connect the steel piping of the


cooling system and the radiator, the piping and the
radiator can be electrically isolated. Ensure that the
piping and the radiator are continuously grounded
to the engine. Use ground straps that bypass the
rubber couplings.
SEBU7563-09 19
Product Information Section
Model Views and Specifications

Product Information
Section

Model Views and


Specifications
i01744053

Model View Illustrations


SMCS Code: 1000; 4450

The illustrations show various typical features of


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

g00892828
Illustration 12
Right hand view (in-line engine)
(1) Gas shutoff valve (4) Integrated Combustion Sensing Module (7) Crankcase pressure sensor
(2) Fuel actuator (ICSM) (8) Engine oil level gauge
(3) Ignition transformer (5) Engine oil filter (9) Engine oil filler
(6) Junction box
20 SEBU7563-09
Product Information Section
Model Views and Specifications

g00892830
Illustration 13
Left hand view (in-line engine)
(1) Exhaust bypass actuator (3) Hydraulic oil tank (5) Hydraulic oil filter
(2) Air choke actuator (4) Hydraulic oil pump

g00893222
Illustration 14
Right hand view (vee engine)
(1) Gas shutoff valve (5) Engine oil filter (10) Engine oil filler
(2) Exhaust bypass actuator (6) Junction box
(3) Fuel actuator (7) Ignition rail
(4) Integrated Combustion Sensing Module (8) Crankcase pressure sensor
(ICSM) (9) Engine oil level gauge
SEBU7563-09 21
Product Information Section
Model Views and Specifications

g00893223
Illustration 15
Left hand view (vee engine)
(1) Ignition transformer (3) Air choke actuator (6) Hydraulic oil pump
(2) Integrated Combustion Sensing Module (4) Ignition rail (7) Hydraulic oil filter
(ICSM) (5) Hydraulic oil tank

i02062100 The ECM monitors the actual engine speed. The


ECM calculates the difference between the actual
Product Description engine speed and the desired engine speed. The
ECM controls the fuel actuator in order to maintain
SMCS Code: 1000; 4450 the desired engine speed.
The G3600 Family of Engines is designed to provide The fuel, the inlet air, and the exhaust bypass are
power for the following applications: regulated by the ECM through control of three
electrohydraulic actuators. The actuators are
• Electrical power generation electronically controlled and hydraulically actuated.
The hydraulic oil is in a circuit that is separate from
• Gas compression the engine oil. The hydraulic oil is circulated by a
gear-driven pump.
• Industrial air compression
The ECM operates the fuel actuator in order to
• Petroleum allow fuel to enter the gas manifold. Fuel flows from
the manifold through an orifice. Some of the gas is
The engines incorporate advanced technology that routed through an adjustable needle valve and into a
is essential for obtaining high output, low emissions, precombustion chamber. The rest of the gas is routed
and thermal efficiency. through a gas admission valve that is actuated by
the camshaft. This allows fuel to enter the inlet port
Precise control of the engine parameters enable in the cylinder head.
optimum engine performance. The engines are
capable of using a variety of fuels in various ambient Air for combustion flows from the turbocharger to
conditions. an air inlet choke. The ECM operates the air choke
actuator in order to allow air to enter the inlet air
The Engine Control Module (ECM) controls most manifold. The air flows through the aftercooler to the
of the functions of the engine. The module is an air plenum and into the cylinder head inlet port. The
environmentally sealed unit that is mounted in a air is mixed with gas in the cylinder head. The rich
junction box on the engine. The ECM monitors fuel in the precombustion chamber is ignited by the
various inputs from sensors in order to activate spark plug. This provides the ignition for the air/fuel
relays, solenoids, etc at the appropriate levels. mixture in the cylinder.
22 SEBU7563-09
Product Information Section
Model Views and Specifications

The inlet manifold air pressure is controlled by the For more detailed information on the control system,
air inlet choke and the exhaust bypass valve. The refer to Systems Operation, “Electronic Control
ECM determines the air pressure that is required to System Operation”.
maintain the correct air/fuel ratio.
The engine has two cooling circuits: a jacket water
Each cylinder has an ignition transformer. To circuit and a separate circuit for the aftercooler and
initiate combustion, the ECM sends a pulse of engine oil cooler. Water temperature regulators
approximately 108 volts to the primary coil of each are used in both circuits in order to maintain the
ignition transformer at the appropriate time and for correct operating temperatures. Water temperature
the appropriate duration. The transformer increases regulators can be installed in order to regulate the
the voltage which creates a spark across the spark inlet or outlet temperature of the water.
plug electrode.
A gear-driven centrifugal pump circulates the jacket
The electronic control system controls the ignition water coolant from an external source. The coolant
timing. The control system monitors changes in is circulated through the water jacket to the cylinder
the load. The control system modifies the timing heads. The coolant flows through water manifolds to
in response to the change in the load. The timing the outlet. The coolant flows through a remote water
can also be modified in order to compensate for temperature regulator and to a heat exchanger. The
detonation that is detected. coolant is returned to the engine.

The fuel flow is the main factor in the calculation of The engine oil and the combustion air are cooled in a
the engine load. Zero fuel flow is zero load. A fuel separate circuit. A gear-driven pump pulls the coolant
flow that is greater than zero is used to calculate a from the heat exchanger. Some of the coolant goes
percentage of the indicated load. to the engine oil cooler. Most of the coolant goes
to the aftercooler. The coolant returns to the heat
At loads that are less than 40 percent, the air/fuel exchanger.
ratio is controlled by the air choke actuator which is
trimmed by the exhaust port temperatures. A gear-driven pump pumps the engine oil. The
temperature of the engine oil is regulated. The engine
The engine has an Integrated Combustion Sensing oil is filtered prior to circulation in the cylinder block.
Module (ICSM) for each bank of cylinders. Each
cylinder exhaust port has a thermocouple that is
monitored by an ICSM. The ICSM monitors the
Engine Service Life
actual exhaust port temperatures for one bank of Engine efficiency and maximum utilization of engine
cylinders. The ICSM calculates an average exhaust
performance depend on the adherence to proper
port temperature for the bank of cylinders. The ECM
operation and maintenance recommendations. This
sends a map of the desired exhaust port temperature includes use of the recommended lubricants, fuels,
to the ICSM. The ICSM calculates the difference
and coolant/antifreezes. For additional information
between the average exhaust port temperature and
about coolant analysis, see the Special Publication,
the desired exhaust port temperature. The ICSM “Caterpillar Gas Engine Lubricant, Fuel and Coolant
communicates the information to the ECM. The ECM
Recommendations” or consult your Caterpillar dealer.
controls the air choke actuator in order to maintain
the desired exhaust temperature. For the engine maintenance that is required, see this
Operation and Maintenance Manual, “Maintenance
When the load reaches approximately 40 percent,
Interval Schedule” (Maintenance Section).
the air/fuel ratio is controlled by the exhaust bypass
actuator which is trimmed by the combustion burn
time.

Each ICSM calculates an average combustion burn


time for all of the cylinders in one bank. The ECM
sends a map of the desired combustion burn time
to the ICSM. The ICSM calculates the difference
between the average combustion burn time and the
desired combustion burn time. The ICSM sends a
fuel correction factor to the ECM. The ECM controls
the exhaust bypass actuator in order to maintain the
desired combustion burn time.
SEBU7563-09 23
Product Information Section
Model Views and Specifications

i02600144

Specifications
SMCS Code: 1000

Engine Specifications
Table 1
G3600 Engine Specifications
G3606 G3608 G3612 G3616
Operating rpm 750 to 1000 750 to 1000 750 to 1000 750 to 1000
Low idle rpm 550 550 550 550
Arrangement and In-line In-line 50 degree V-12 50 degree V-16
cylinders 6 8
Bore 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch)
Stroke 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch)
Aspiration TA TA TA TA
Compression ratio 9:1 9:1 9:1 9:1
10.5:1 10.5:1
Displacement per 21.2 L (1294 in3) 21.2 L (1294 in3) 21.2 L (1294 in3) 21.2 L (1294 in3)
cylinder
Total displacement 127.2 L (7762 in3) 169.6 L (10 350 in3) 254.4 L (15 528 in3) 339.2 L (20 704 in3)
Mean velocity of the 9 m/s (1772 ft/min) 9 m/s (1772 ft/min) 9 m/s (1772 ft/min) 9 m/s (1772 ft/min)
pistons at 900 rpm
Mean velocity of the 10 m/s (1969 ft/min) 10 m/s (1969 ft/min) 10 m/s (1969 ft/min) 10 m/s (1969 ft/min)
pistons at 1000 rpm
Flywheel rotation Counterclockwise Counterclockwise Counterclockwise Counterclockwise
(standard)
Fuel, Lubricant, and See this Operation and Maintenance Manual, “Refill Capacities and Recommendations”
Coolant (Maintenance Section). Also, see the Application and Installation Guide.
Method of starting Air starting motors Air starting motors Air starting motors Air starting motors
Performance of the See the Application See the Application See the Application See the Application
cooling system and Installation Guide. and Installation and Installation Guide. and Installation Guide.
Guide.
Maximum allowable 3 kPa 3 kPa 3 kPa 3 kPa
exhaust back pressure (12 inches of H2O) (12 inches of H2O) (12 inches of H2O) (12 inches of H2O)
Maximum allowable 3.7 kPa 3.7 kPa 3.7 kPa 3.7 kPa
inlet air restriction (15 inches of H2O) (15 inches of H2O) (15 inches of H2O) (15 inches of H2O)
Air cleaners Remote Remote Remote Remote
24 SEBU7563-09
Product Information Section
Model Views and Specifications

g00891513 g00790805
Illustration 16 Illustration 19
G3606 Engine design G3616 Engine design
(A) Gas admission valves (A) Gas admission valves
(B) Inlet valves (B) Inlet valves
(C) Exhaust valves (C) Exhaust valves

Drives and Gear Trains


Front Drives

g00891514
Illustration 17
G3608 Engine design
(A) Gas admission valves
(B) Inlet valves
(C) Exhaust valves g00790861
Illustration 20
SAE standard engine crankshaft rotation
In-line engines and vee engines
(1) Jacket water pump
(2) Aftercooler and oil cooler pump
(3) Oil pump

g00790801
Illustration 18
G3612 Engine design
(A) Gas admission valves
(B) Inlet valves
(C) Exhaust valves
SEBU7563-09 25
Product Information Section
Model Views and Specifications

Engine Front Gear Train

g00790864
Illustration 21
SAE standard engine crankshaft rotation g00891685
Illustration 22
In-line engines and vee engines SAE standard engine crankshaft rotation
(4) Water outlet In-line engines and vee engines
(5) Water inlet
(1) Crankshaft
(6) Oil outlet
(2) Idler
(7) Oil inlet
(3) Idler
(4) Jacket water pump
Table 2 (5) Aftercooler and oil cooler pump
Front Drives (6) Auxiliary pump
(7) Oil pump
Component Speed(1)
Table 3
Jacket water pump 2522
Front Gear Train
Aftercooler and oil cooler pump 2522
Gear Number Of
Oil pump 1524 Teeth
(1) The speed of the component is listed for an engine that is (1) Crankshaft 96
operating at 1000 rpm. For an engine that is operating at
900 rpm, multiply the speed of the component by .9. For an (2) Idler 68
engine that is operating at 800 rpm, multiply the speed of the
component by .8. (3) Idler 67
(4) Jacket water pump 38
(5) Aftercooler and oil cooler Pump 38
(6) Auxiliary pump 43
(7) Oil pump 63
26 SEBU7563-09
Product Information Section
Model Views and Specifications

Engine Rear Gear Train

g01056736
Illustration 23
SAE standard engine crankshaft rotation
In-line engines
(1) Crankshaft
(2) Large cluster idler
(3) Small cluster idler
(4) Camshaft

g00891688
Illustration 24
SAE standard engine crankshaft rotation
Vee engines
(1) Crankshaft
(2) Large cluster idler
(3) Small cluster idler
(4) Camshaft
(5) Idler

Table 4

Rear Gear Train


Gear Number Of Teeth
(1) Crankshaft 81
(2) Large cluster idler 90
(3) Small cluster idler 45
(4) Camshaft 81
(5) Idler 81
SEBU7563-09 27
Product Information Section
Model Views and Specifications

Reference Weights
Table 5

Approximate Weights Of Package Generator Sets


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

8270 kg (18 232 lb)


(3)

Module 1360 kg (2998 lb) 1410 kg (3109 lb) 1650 kg (3638 lb) 1650 kg (3638 lb)
Mounting base 7820 kg (17 240 lb)(2) 8640 kg (19 048 lb) 12 700 kg (28 000 lb) 12 700 kg (28 000 lb)
8170 kg (18 012 lb)(3)
Coupling 590 kg (1300 lb) 590 kg (1300 lb) 977 kg (2154 lb) 977 kg (2154 lb)
Total 33 750 kg (74 406 lb)(2) 39 040 kg (86 068 lb) 56 266 kg (124 045 lb) 61 074 kg (134 645 lb)
34 070 kg (75 111 lb)(3)
(1) The weights of the engines that are listed includes attachments that are mounted on the engines. The engine weights are dry weights.
(2) Single bearing generator
(3) Double bearing generator

Table 6

Approximate Weights Of Serviceable Parts


Component G3606 Engine G3608 Engine G3612 Engine G3616 Engine
Cylinder block 4638 kg (10 225 lb) 6476 kg (14 260 lb) 6805 kg (14 971 lb) 9625 kg (21 219 lb)
Bearing cap 65 kg (144 lb) 65 kg (144 lb) 65 kg (144 lb) 65 kg (144 lb)
Crankshaft 1782 kg (3929 lb) 2288 kg (5034 lb) 2091 kg (4600 lb) 3800 kg (8378 lb)
Flywheel assembly 491 kg (1082 lb) 491 kg (1082 lb) 491 kg (1082 lb) 491 kg (1082 lb)
Crankshaft vibration damper 183 kg (403 lb) 267 kg (588 lb) 183 kg (403 lb) 183 kg (403 lb)
Cylinder head assembly 196 kg (432 lb) 196 kg (432 lb) 196 kg (432 lb) 196 kg (432 lb)
Cylinder liner 110 kg (243 lb) 110 kg (243 lb) 110 kg (243 lb) 110 kg (243 lb)
Piston assembly 48 kg (106 lb) 48 kg (106 lb) 48 kg (106 lb) 48 kg (106 lb)
Piston pin 19 kg (42 lb) 19 kg (42 lb) 19 kg (42 lb) 19 kg (42 lb)
Piston rod assembly 57 kg (126 lb) 57 kg (126 lb) 57 kg (126 lb) 57 kg (126 lb)
Turbocharger (one) 401 kg (884 lb) 401 kg (884 lb) 401 kg (884 lb) 401 kg (884 lb)
Aftercooler core(1) 52 kg (115 lb) 52 kg (115 lb) 94 kg (207 lb) 125 kg (275 lb)
Front housing 258 kg (569 lb) 258 kg (569 lb) 258 kg (569 lb) 258 kg (569 lb)
Rear housing 222 kg (489 lb) 222 kg (489 lb) 350 kg (772 lb) 350 kg (772 lb)
Used air cleaner element 29 kg (64 lb) 29 kg (64 lb) 29 kg (64 lb) 29 kg (64 lb)
(1) The weight for a single-stage type of aftercooler is listed. The two-stage aftercooler and the aftercooler with a deep core are also available.
28 SEBU7563-09
Product Information Section
Product Identification Information

Product Identification Information Plate


Information
i01519197

Plate Locations and Film


Locations
SMCS Code: 1000; 4450

Engine Identification
Caterpillar engines are identified with serial numbers,
with performance specification numbers, and with Illustration 26
g00361974
arrangement numbers. In some of the cases,
modification numbers are used. These numbers The Information Plate is on the side of the cylinder
are shown on the Serial Number Plate and the block above one of the crankshaft inspection
Information Plate that are mounted on the engine. covers. The following information is stamped on
the Information Plate: engine's maximum altitude,
Caterpillar dealers need these numbers in order to horsepower, high idle, full load rpm, fuel settings, and
determine the components that were included with other information.
the engine. This permits accurate identification of
replacement part numbers.
i01519312

Serial Number Plate Reference Information


SMCS Code: 1000; 4450

Identification of the items in Table 7 may be needed


in order to obtain parts and service. Some of the
numbers are on the engine Serial Number Plate
and/or Information Plate. Locate the information
for your engine. Record the information on the
appropriate space in Table 7. Make a copy of this
list for a record. Retain the information for future
reference.

The top level part numbers in the Parts Manual for


the engine are listed with the engine arrangement
g00123229 number.
Illustration 25

The performance specification can be used by


The Serial Number Plate is on the side of the cylinder
your Caterpillar dealer with the Technical Marketing
block above one of the crankshaft inspection covers.
Information system. Before the engine leaves the
The following information is stamped on the Serial
factory, the engine performance is tested. Detailed
Number Plate: engine serial number, model, and
performance data is recorded. The performance
arrangement number.
specification number can be used for obtaining the
data.
SEBU7563-09 29
Product Information Section
Product Identification Information

Table 7
Record Of Reference Numbers
Item Identification
Engine Model
Serial Number
Arrangement Number
Modification Number
Performance Specification
Power Rating
Personality Module (Revision)
Low Idle rpm
High Idle rpm
Full Load rpm
Overspeed Setpoint
Air Choke Actuator
Exhaust Bypass Actuator
Fuel Actuator
Lubrication Oil Filter Element
Lube Oil Capacity (total)
Air Cleaner Element
Alternator Belt
Supplemental Coolant Additive
Cooling System Capacity (total)
Turbocharger
30 SEBU7563-09
Operation Section
Lifting and Storage

Operation Section Engine Lifting with a Generator


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

i01536259 A lifting plate is provided with the package generator


set. Instructions for lifting the package generator set
Product Lifting are stamped on the lifting plate.
SMCS Code: 7000; 7002
Consult your Caterpillar dealer for information
regarding proper fixtures and lifting devices.

Lifting packaged generator sets will not be level if you


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

The single point lifting eye is secured from the


factory before the enclosure is shipped. The correct
orientation of the single point lifting eye will allow you
to look through the eye when you stand at the side of
the enclosure. The lifting eye may stretch when the
Illustration 27
g00103219 package is lifted. This may cause the locking nuts
to loosen. This could cause the lifting eye to swivel.
Ensure that the lifting eye is correctly oriented on the
NOTICE packaged generator set. Ensure that the lifting eye
Never bend the eyebolts and the brackets. Only load is tightened to the correct torque before you lift the
the eyebolts and the brackets under tension. Remem- packaged generator set.
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.

When it is necessary to remove a component at an


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

Use a hoist to remove heavy components. Use


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

Some removals require lifting fixtures in order to


obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that


are on the engine.

Lifting eyes are designed and installed for the specific


engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.
SEBU7563-09 31
Operation Section
Lifting and Storage

i02046791

Product Storage
SMCS Code: 7002

If the engine will not be started for several weeks, the


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

To help prevent excessive engine wear, use the


following guidelines:

• Complete all of the lubrication recommendations


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

• If freezing temperatures are expected, check the


cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
(Maintenance Section).

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


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

Your Caterpillar dealer will have instructions for


preparing the engine for extended storage periods.

For more detailed information on engine storage, see


Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”.

Generator Storage
For information on generator storage, see the
literature that is provided by the OEM of the
generator. Consult your Caterpillar dealer for
assistance.
32 SEBU7563-09
Operation Section
Features and Controls

Features and Controls


i02597493

Monitoring System
SMCS Code: 1900; 7400; 7450; 7451

The Electronic Control Module (ECM) monitors the


operating parameters of the engine. The ECM can
initiate a warning or a shutdown if a specific engine
parameter exceeds an acceptable range. Some of
the responses are not available for some of the
parameters. Use Caterpillar Electronic Technician
(ET) to perform the following activities:

• Select the available responses.


• Program the level for monitoring.
• Program delay times for each response.
The default settings for the parameters are
programmed at the factory. To accommodate unique
applications and sites, the parameters may be
reprogrammed with Cat ET. The screens of Cat ET
provide guidance for the changing of trip points.

Note: Some of the parameters are protected


by factory passwords. Other parameters can be
changed with customer passwords.

For more detailed information on the monitoring


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

Examples of the default settings for the parameters


are listed in Table 8. The values may have changed.
Use the Cat ET to determine the programming for
your engine. Many of the items can be reprogrammed
in order to accommodate the requirements of
individual sites.

Table 8

Engine ECM Monitoring


Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)
Warning 20
E043 20
(1) volts
Low System Always
Engine This item is not programmable.
Voltage On (1) 18
E042 Shutdown 10
volts
(3)
(continued)
SEBU7563-09 33
Operation Section
Features and Controls

(Table 8, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)

High Engine Warning


E017 On 92°C
Coolant (1)
Temperature Engine
(88° C Jacket Always
E016 Shutdown 98°C
Water Rating) On(1)
(3)

High Engine Warning


E017 On 105°C
Coolant (1)
Temperature Engine 80° to 129°C
(99° C Jacket Always
E016 Shutdown 110°C
Water Rating) On(1) 20 Customer 1 to 60
(3)

High Engine Warning


E017 On 115°C
Coolant (1)
Temperature Engine
(110° C Jacket Always
E016 Shutdown 120°C
Water Rating) On(1)
(3)
Low Engine
Warning
Coolant E038 On 25°C 5° to 80°C
(1)
Temperature
Engine
High Pump Outlet Always 462
E224 Shutdown
Pressure(2) On(1) kPa
(3)
Warning Always 124
10 This item is not programmable.
Low Jacket (1) On(1) kPa
Water Outlet E228 Engine
Pressure(2) Always 103
Shutdown
On(1) kPa
(3)
1017
Engine rpm
Engine Always 800 to 1300
E004 Shutdown or 0 Factory 0
Overspeed On(1) rpm
(3) 1130
rpm
Warning Always
Engine Overload E242 110% 0 This item is not programmable.
(1) On(1)
Warning
E020 On 88°C 5 Customer 85° to 102°C
(1)
High Engine Oil
Engine 1 to 60
Temperature Always
E019 Shutdown 90°C 1 Factory 85° to 104°C
On(1)
(3)
(continued)
34 SEBU7563-09
Operation Section
Features and Controls

(Table 8, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)
Warning Always 175
E100 5
Low Engine Oil (1) On(1) kPa
Pressure(2) Engine
(Under 600 RPM) Always 100
E040 Shutdown 0
On(1) kPa
(3)
This item is not programmable.
Warning Always 400
E100 5
Low Engine Oil (1) On(1) kPa
Pressure(2) Engine
(Over 600 RPM) Always 350
E040 Shutdown 0
On(1) kPa
(3)
Warning 650
E125 On
(1) kPa
High Engine Oil 600 to 1200
Engine 25 Customer
Pressure Always 1000 kPa
E126 Shutdown
On(1) kPa
(3)
Warning 100
E129 Off 15 Customer
High Oil Filter (1) kPa
Differential Engine 0 to 350 kPa
Pressure Always 300
E130 Shutdown 25 Factory
On(1) kPa
(3)
Warning
E127 Off 5 kPa Customer
Low Oil Filter (1) 1 to 60
Differential Engine 10 0 to 150 kPa
Pressure E128 Shutdown Off 3 kPa Factory
(3)
High Fuel Warning
E223 60°C 20 0° to 60°C
Temperature (1)
Low Fuel On
Warning
Differential E864 5 kPa 60 0 to 100 kPa
(1) Customer
Pressure
High Fuel
Warning Always 160
Differential E865 30 0 to 195 kPa
(1) On(1) kPa
Pressure
High System Warning 34
E050 On 20 This item is not programmable.
Voltage (1) volts
(continued)
SEBU7563-09 35
Operation Section
Features and Controls

(Table 8, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)

High Inlet Air Warning


E027 On 82°C
Temperature at (1)
Low Engine Load Engine
54° C SCAC Always
E026 Shutdown 85°C
Rating On(1)
(3)

High Inlet Air Warning


E027 On 77°C
Temperature at (1)
Low Engine Load Engine
43° C SCAC Always
E026 Shutdown 80°C
Rating On(1)
(3)

High Inlet Air Warning


E027 On 72°C
Temperature at (1)
Low Engine Load Engine
32° C SCAC Always
E026 Shutdown 75°C
Rating On(1)
(3)
Default -20°C
High Inlet Air Warning 20 Factory 1 to 60
E027 On 72°C to +5°C
Temperature (1)
at High Engine
Load Engine
Always
54° C SCAC E026 Shutdown 75°C
On(1)
Rating (3)

High Inlet Air Warning


E027 On 65°C
Temperature (1)
at High Engine
Load Engine
Always
43° C SCAC E026 Shutdown 68°C
On(1)
Rating (3)

High Inlet Air Warning


E027 On 57°C
Temperature (1)
at High Engine
Load Engine
Always
32° C SCAC E026 Shutdown 60°C
On(1)
Rating (3)

High Engine Warning Always


E242 110% 0 This item is not programmable.
Load(2) (1) On(1)

High Engine Warning


E123 On 10°C Customer
Oil to Engine (1)
Coolant Engine 60 0° to 80°C 1 to 60
Differential Always
E124 Shutdown 15°C Factory
Temperature On(1)
(3)
(continued)
36 SEBU7563-09
Operation Section
Features and Controls

(Table 8, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)
Warning Always
20 This item is not programmable.
High Inlet Air (1) On(1)
Restriction E385 Engine
(Right) This item is not
Shutdown Off 0 Customer 0 to 65
programmable.
(3) 5.23
Warning Always kPa
20 This item is not programmable.
(1) On(1)
High Inlet Air
E384 Engine This item is not
Restriction (Left)
Shutdown Off 0 Customer programmable. 0 to 65
(3)
(1) This parameter is permanently active. This parameter cannot be turned off.
(2) This event will not appear on the monitor.

Integrated Combustion Sensing


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

Table 9 lists default examples of the values for the


parameters.
SEBU7563-09 37
Operation Section
Features and Controls

Table 9
ICSM Monitoring
Delay Security Delay
System Trip Trip Point
Description Event Code State Time Level Range
Response Point Range
(Seconds) Password (Seconds)
High Exhaust Warning (1) 600°C
Temperature (Port) E801 through 100° to
Engine Off 10
E816 Shutdown 650°C 1000°C
(3)
Exhaust Port Warning (1) On 50°C 240
Temperature High E821 through
Deviation Engine
E836 Shutdown Off 100°C 600
(3) 10° to
Exhaust Port Warning (1) On 120°C 500°C
Temperature Low E841 through
Deviation Engine 300 Customer 1 to 1200
E856 Shutdown Off 400°C
(3)
High Turbo Turbine E245 (Right Warning (1) 600°C
Inlet Temperature Bank) 400 to 700
Engine
E246 (Left Shutdown 650°C °C
Bank) (3)
On 10
High Turbo Turbine E243 (Left Warning (1) 570°C
Outlet Temperature Bank) 400 to
Engine
E244 (Right Shutdown 600°C 650°C
Bank) (3)
38 SEBU7563-09
Operation Section
Features and Controls

i02600163

Control Panel
SMCS Code: 7451

g00799615
Illustration 29
Keypad

Note: At the time of this publication, these keys have


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

The keypad is protected in a sealed membrane.


When you press a key, press firmly. When a key is
pressed sufficiently, a small red indicator in the upper
left corner of the keypad will flash once.
g00824832
Illustration 28
Control panel
When the control panel is powered up, the screen
becomes active. To view the options for the display,
(1) Advisor II display
(2) Keypad for the Advisor II press the “?” key. Table 10 lists the menu.
(3) “EMERGENCY STOP” button
(4) “ENGINE ON” indicator Table 10
(5) “ACTIVE ALARM” indicator
(6) “ENGINE FAILURE” indicator
Menu
(7) “MANUAL PRELUBE” switch and “PRELUBE ACTIVE” 1 Status Screen Mode
indicator
(8) Mode control switch 2 Detonation Levels
(9) “DESIRED SPEED” potentiometer
3 Ignition Times
The features of the control panel are described below. 4 Burn Times
5 Temperatures
Advisor II
6 Secondary Voltages
Advisor II is a device which enables the operator to 7 Not Used
monitor engine operation. The Advisor II receives
information from the Electronic Control Module 8 Events and Diagnostics
(ECM). The device cannot be used for programming. 9 Display Setup
A screen display and a keypad provide the interface
for the operator. ? Menu

To select an option, press the number on the keypad


that corresponds to the selection. To exit the option,
press the “?” key or any of the numbered keys. It
is not necessary to return to the menu in order to
select a different option. When you press a different
numbered key, the corresponding option is displayed.
SEBU7563-09 39
Operation Section
Features and Controls

Status Screen Mode Speed Status

Table 11 The “Speed Status” screen displays parameters that


Status Screen Mode pertain to the engine speed and some additional
parameters. Table 14 lists the information that is
1 Status Screen Menu displayed.
2 Engine Status
Table 14
3 Air/Fuel Ratio Status
Speed Status
4 Speed Status
Engine Speed Desired Engine Percent Load
5 Pressure Status Speed
6 Temperature Status Speed Control Droop Setting Governor Type
7 Misc Status Wastegate Choke command Fuel Command
Command
8 Relay Status
9 Not Used Pressure Status
? Menu
The “Pressure Status” screen displays parameters
that pertain to the engine pressures. Table 15 lists
Status Screen Menu the information that is displayed.
Pressing “1” returns the user to the “Menu” screen. Table 15
Pressure Status
Engine Status
Fuel Pressure Air Pressure Desired Air
The “Engine Status” screen displays basic Pressure
information about the condition of the engine. Table Oil Pressure Differential Oil Crankcase
12 lists the information that is displayed. Pressure pressure
Table 12 Not Used Jacket Water Not Used
Engine Status
Temperature Status
Engine Speed Desired Engine Percent Load
RPM Speed
The “Temperature Status” screen displays
Oil Pressure Air Pressure Air Temperature parameters that pertain to the engine temperatures.
Oil Temperature Jacket Water Fuel Correction Table 16 lists the information that is displayed.
Temperature
Table 16
Temperature Status
Air/Fuel Ratio Status
Air Temperature Jacket Water Oil Temperature
The “Air/Fuel Ratio Status” screen displays the status
Fuel Odd Bank Even Bank
of parameters that pertain to the air and fuel. The Temperature
actual data is continuously updated. Table 13 lists
the information that is displayed. Not Used Not Used Not Used

Table 13
Miscellaneous Status
Air/Fuel Ratio Status
A/F Ratio Desired A/F Fuel Quality The “Miscellaneous Status” screen displays the
Ratio parameters that are listed in Table 17.
Air Pressure Desired Air Specific Gravity Table 17
Pressure
Miscellaneous Status
Air Flow Fuel Flow Feedback Status
Detonation Level Service Hours Battery Voltage
Engine Multi Strike Engine Cylinders
Configuration Feature
Multi Strike Mode Multi Strike Multi Strike
Switch Status
40 SEBU7563-09
Operation Section
Features and Controls

Relay Status Table 20


Ignition Timing
The “Relay Status” screen displays the status of
switches and relays that are identified in Table 18. Even Bank Odd Bank

Table 18
Actual Timing
Base Timing
Relay Status
Speed Status Burn Times
Mode Status
The “Burn Times” screen can display either the
E-Stop Status “Filtered Burn Times” or the “Unfiltered Burn Times”.
Driven Equipment “Filtered Burn Times” displays an average of the
combustion burn time for each bank of cylinders. The
Prelube Solenoid desired combustion burn time and the time for each
Prelube Oil Pressure Switch individual cylinder are also displayed. “Unfiltered
Burn Times” displays the actual instantaneous
Initiate Contact combustion burn time for each individual cylinder.
Start Solenoid The desired combustion burn time and the average
combustion burn time for each bank of cylinders are
Fuel Control Solenoid also displayed.
Hydrax Oil Pressure Switch
Table 21
Normal Stop
Burn Times
Filtered Unfiltered
Not Used
Even Bank Odd Bank
Option 9 of this screen is not used at this time.
Even Bank Odd Bank
Menu Desired Burn Fuel Correction

Pressing “?” returns the user to the “Menu” screen.


Temperatures
Detonation Levels The “Temperatures” screen can display either
“Exhaust Temperatures” or “Turbo Temperatures”.
The “Detonation Levels” screen displays the level of
“Exhaust Temperatures” displays the actual exhaust
detonation for each cylinder as bars on the screen.
port temperature for each cylinder. The average
The average detonation level for all of the cylinders is
temperature for all of the exhaust ports in each bank
also displayed.
is also displayed. If the engine is operating at a load
Table 19 that is less than 40 percent, the desired exhaust
temperature is displayed. If the engine load is greater
Detonation Levels than 40 percent, the desired exhaust temperature
Even Bank Odd Bank is not a factor. “Turbo Temperatures” displays the
temperatures of the exhaust at the inlet and outlet
Engine Average of each turbocharger. The average temperature for
Detonation Level each bank is also displayed.

Table 22
Ignition Timing
Temperatures
The “Ignition Timing” screen displays the current Exhaust Turbo
degrees before top center for the timing of each
cylinder. The values for the programmable desired Even Bank Odd Bank
timing are listed. The current active selected timing Even Bank Odd Bank
is indicated.
Desired Temp Fuel Correction

Secondary Voltages
The “Secondary Voltages” screen display the voltage
drop across the spark plugs as a percent.
SEBU7563-09 41
Operation Section
Features and Controls

Table 23 “EMERGENCY STOP” Button


Secondary Voltage
NOTICE
Even Bank Odd Bank Only use the “Emergency Stop” button in order to stop
Actual Timing the engine in an emergency situation. Do not use the
Base Timing “Emergency Stop” button for normal engine stopping.

To prevent damage to the engine, use the mode con-


Not Used trol switch or use the remote start/stop initiate contact
for normal engine stopping.
Option 7 of this screen is not used at this time.

Events and Diagnostics


The “Events and Diagnostics” screen displays event
codes and diagnostic codes.

Table 24

Codes
Events and Diagnostics

MID Code OCC First Last Act

g00824884
Illustration 30

The fuel and the ignition are immediately shut off


when the “EMERGENCY STOP” button is pressed.
No postlube cycle occurs.

Display Setup The “EMERGENCY STOP” button and the mode


control switch must be reset before the engine will
The “Display Setup” screen enables the operator to start. To reset the “EMERGENCY STOP” button,
adjust the display. The contrast and back lighting can turn the button clockwise. To reset the mode control
be adjusted. Metric units or English units can also be switch, turn the switch to the OFF/RESET position.
selected for the display. Use the left arrow or the right
arrow to navigate the options. Use the up arrow or Note: The engine mounted junction box also has an
the down arrow to select the preference. “EMERGENCY STOP” button.

Table 25 Indicators
Display Setup
The remote panel has three indicators for the status
of the engine operation.
LCD Contrast Backlighting
Offset Lights On

Metric
English
Imperial
Units

Menu
Pressing “?” returns you to the “Menu” screen.
42 SEBU7563-09
Operation Section
Features and Controls

g00824980 g00825028
Illustration 31 Illustration 32
(1) “ENGINE ON” indicator “MANUAL PRELUBE” switch and “PRELUBE ACTIVE” indicator
(2) “ACTIVE ALARM” indicator
(3) “ENGINE FAILURE” indicator
The “MANUAL PRELUBE” switch enables the
operator to prelube the engine by pressing the switch.
Illumination of green “ENGINE ON” indicator (1)
indicates normal operation. A lamp behind the switch illuminates when the
prelube is active. This is the “PRELUBE ACTIVE”
Yellow “ACTIVE ALARM” indicator (2) illuminates if indicator. If the mode control switch is in the “AUTO”
the control system initiates a warning for an event position and the remote start/stop initiate contact
or a diagnostic condition. closes, the prelube system will operate and the lamp
will illuminate. The lamp will also illuminate during
Red “ENGINE FAILURE” indicator (3) illuminates if the postlube.
the control system shuts down the engine due to
an event or a diagnostic condition. The “ENGINE Note: The ECM is programmed to provide engine
FAILURE” indicator also illuminates if an emergency lubrication after the engine is shut off. The typical
stop is performed. duration of the postlube is 180 seconds.

“MANUAL PRELUBE” Switch and Mode Control Switch


“PRELUBE ACTIVE” Indicator
All G3600 Engines require lubrication prior to
start-up. The ECM will not permit the engine to start
until sufficient prelube pressure has been achieved.

Lubrication of the engine is required prior to rotation


of the crankshaft. This includes crankshaft rotation in
order to service the engine. Rotating the crankshaft
before prelube may cause damage to the crankshaft
bearings if the surfaces of the bearings are dry.

g00825037
Illustration 33
Mode control switch in the “AUTO” position

The mode control switch has four positions: “AUTO”,


“START”, “STOP”, and “OFF/RESET”
SEBU7563-09 43
Operation Section
Features and Controls

“AUTO” – When the mode control switch is in “DESIRED SPEED” Potentiometer


the “AUTO” position (12 o'clock), the system is
configured for remote operation. When the remote
start/stop initiate contact closes, the prelube system
will operate. When the prelube pressure is sufficient,
the engine will start. When the remote start/stop
initiate contact opens, the engine will shut off. If the
cool down cycle is programmed, the engine will
operate for the cool down period before the engine
stops. The cool down cycle can be programmed for
a 0 to 30 minute period.

“START” – When the mode control switch is turned


to the “START” position (3 o'clock), the prelube
system will operate. When the prelube pressure
is sufficient, the engine will start. The engine will g00825039
operate until the ECM receives a shutdown signal. Illustration 34
“DESIRED SPEED” potentiometer
The following methods cause a shutdown signal:
The “DESIRED SPEED” potentiometer allows the
• The remote start/stop initiate contact opens when operator to adjust the desired engine speed. This is
the mode control switch is in the “AUTO” position. achieved by providing a 0 to 5 volt input to the ECM.
The desired speed can be viewed on the Advisor
• The mode control switch is turned to the “STOP” panel or by using Cat ET.
position.

• The mode control switch is turned to the


“OFF/RESET” position.

• The “EMERGENCY STOP” button is pressed.


• An undesirable operating condition is sensed and
an engine shutdown is initiated by the ECM.

“STOP” – When the mode control switch is turned


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

“OFF/RESET” – When the mode control switch is


turned to the “OFF/RESET” position (9 o'clock), the
engine is immediately shut off and the diagnostic
lights are reset. Power is removed from the control
panel and the actuators after the engine completes
the postlube cycle.
44 SEBU7563-09
Operation Section
Engine Diagnostics

Engine Diagnostics
i03681549

Configuration Parameters
SMCS Code: 1000; 1900; 1901; 1902

Refer to the Troubleshooting Guide, RENR5910,


“Configuration Parameters” for information about the
programmable parameters for your engine.
SEBU7563-09 45
Operation Section
Engine Starting

Engine Starting Cooling System


• Inspect the cooling system for leaks or loose
i02601065 connections. Inspect the condition of all the pipes
for the cooling system. Ensure that the connections
Before Starting Engine are properly clamped.
SMCS Code: 1000; 1400; 1450 • Inspect the water pumps for evidence of leaks.
Perform the required daily maintenance and other • Check the coolant level. Add coolant, if necessary.
periodic maintenance before starting the engine. This For information on the proper coolant to use, refer
can prevent major repairs at a later date. Refer to this to this Operation and Maintenance Manual, “Refill
Operation and Maintenance Manual, “Maintenance Capacities and Recommendations” (Maintenance
Interval Schedule” (Maintenance Section). Section).

Walk-Around Inspection Driven Equipment


NOTICE • If necessary, check the oil levels of the driven
For any type of leak (coolant, lube, or fuel) clean up the equipment. Perform any maintenance that is
fluid. If leaking is observed, find the source and correct required for the driven equipment. Refer to the
the leak. If leaking is suspected, check the fluid levels literature that is provided by the OEM of the driven
more often than recommended until the leak is found equipment.
or fixed, or until the suspicion of a leak is proved to be
unwarranted. • If the engine is equipped with a clutch, ensure that
the clutch is disengaged.
To obtain maximum service life for your engine, make • For generator set engines, ensure that the main
a thorough inspection before starting the engine. circuit breaker is open.
Make a walk-around inspection of the installation.
Look for items such as oil or coolant leaks, loose
bolts and trash buildup. Remove any trash. Make Electrical System
repairs, if necessary.
Inspect the wiring for the following conditions:
• The guards must be in the proper place. Repair
damaged guards or replace missing guards. • Loose connections

• Ensure that the areas around the rotating parts are • Wiring that is worn or frayed
clear.
Inspect the gauge panel and the control panel
for good condition. Reset any shutoff or alarm
Air Inlet System components.

Unburned gas in the air inlet and exhaust system


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

Before starting an engine that may contain un-


burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.

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

• Ensure that all clamps and connections are secure.


46 SEBU7563-09
Operation Section
Engine Starting

Lubrication System Hydraulic Actuator System


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

Starting System
• Ensure that the barring device is fully disengaged.
• Drain moisture and sediment from the air tank and
g01140341 from any other air piping.
Illustration 35
Engine oil level gauge
• Check the oil level in the lubricator for the air
(1) “ADD” mark starting motor. Keep the lubricator at least half full.
(2) “RUNNING FULL” mark Add oil, if necessary. Use nondetergent “10W” oil
(3) “STOPPED FULL OIL COLD NO PRELUBE” mark
for temperatures that are greater than 0 °C (32 °F).
Use air tool oil for temperatures that are below
• Check the engine oil level. Add engine oil if 0 °C (32 °F).
the level is in the “ADD” zone. If the engine is
running, maintain the level in the “RUNNING
FULL” zone. For information on the proper engine • Check the air pressure before starting. Starting
motors with vanes require air pressure in a range
oil to use, refer to this Operation and Maintenance of 620 to 1550 kPa (90 to 225 psi). Air turbines
Manual, “Refill Capacities and Recommendations”
require air pressure in a range of 414 to 620 kPa
(Maintenance Section).
(60 to 90 psi) or 690 to 1034 kPa (100 to 150 psi).
• Check for leaks at the following components: • Open the air supply valve for the air starting motor.
crankshaft seals, crankcase, engine oil filters,
plugs for the engine oil gallery, sensors, and valve Note: If the engine is equipped with a system for
covers.
external support, prepare the system before starting
the engine. Ensure that all of the systems for engine
• Inspect the tubes, tee pieces, and clamps on the support are enabled. Perform all prestart checks for
crankcase breathers.
the control system.
• If the engine has an air cleaner for crankcase
ventilation, inspect the air cleaner service indicator. i02601106
Service the air cleaner filter element when the
yellow diaphragm enters the red zone, or the red Cold Weather Starting
piston locks in the visible position.
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Fuel System See Gas Engines Application and Installation Guide,
LEBW4980 for more information on the following
• Inspect the fuel lines for loose fittings and leaks. topics:
Ensure that the fuel lines are properly clamped.
• Recommendations for the size and installation of
• Ensure that the fuel is supplied to the engine at the jacket water heaters and oil heaters
correct pressure for the application.

G3600 engines use a fuel pressure of 310 ± 14 kPa


• Requirements for cranking torque and air starting
motors at various temperatures
(45 ± 2 psi).
Consult your Caterpillar dealer for more information
on the starting aids that are available for cold weather
starting.
SEBU7563-09 47
Operation Section
Engine Starting

Jacket Water Heaters i02601115

Jacket water heaters are available as optional Starting the Engine


equipment. Jacket water heaters are recommended
for improving startability in ambient temperatures SMCS Code: 1000; 1450
below 21 °C (70 °F). These heaters are recommended
for all installations that have automatic starting.

Lubricating Oil Heaters Engine exhaust contains products of combustion


which may be harmful to your health. Always start
Note: Oil pan immersion heaters are not and operate the engine in a well ventilated area
recommended for heating the lube oil. To ensure the and, if in an enclosed area, vent the exhaust to the
compatibility of the components, only use equipment outside.
that is recommended by Caterpillar.
NOTICE
NOTICE For initial start-up of a new or rebuilt engine, and for
Heating elements that are in direct contact with the start-up of an engine that has been serviced, make
lubricating oil can cause coking of the oil. provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
To aviod coking of the oil when the oil is heated, follow fuel supply and/or the ignition to the engine.
these recommendations:

The temperature of the heating surface must not ex-


ceed 150 °C (300 °F). The maximum heat density
of the heating surface must not exceed 1.24 w/cm2 Unburned gas in the air inlet and exhaust system
(8W/in2). may ignite when the engine is started. Personal
injury and/or property damage may result.
Oil viscosity affects the amount of torque that is
needed to crank the engine. Oil temperatures Before starting an engine that may contain un-
below 10 °C (50 °F) require cranking torque that is burned gas, purge the unburned gas from the air
excessive. Oil heaters are recommended for heating inlet and exhaust system. Refer to the topic on
the lube oil to 10 °C (50 °F) when the ambient purging unburned gas in the “Starting the Engine”
conditions are below this temperature. section.

Requirements for Starting with Air Note: The “EMERGENCY STOP” button will shut off
both the fuel and the ignition.
To start the engine at colder temperatures, a larger
volume of starting air and/or a higher air pressure Do not start the engine or move any of the controls
is necessary. Ensure a sufficient supply of air if there is a “DO NOT OPERATE” warning tag or
pressure for cold weather starting. Do not exceed the similar warning tag attached to the start switch or to
maximum air pressure for the starting motor. the controls.

Ensure that no one will be endangered before the


Water Separator engine is started and when the engine is started.
Condensation of vapor in the air supply can freeze in Perform the procedures that are described in this
cold weather. This can enable the following problems Operation and Maintenance Manual, “Before Starting
to occur: Engine” (Operation Section).
• Ice that forms in the supply lines will restrict the
air supply. Purging Unburned Gas
• If particles of ice enter the inlet of the starting The following events cause unburned gas to remain
motor, the starting motor can be damaged. in the air inlet and in the exhaust manifold:

A water separator removes vapor from compressed • Emergency stop


air prior to the air storage tank. Dry air is required for
cold weather in order to help prevent ice from forming • Engine overspeed
in the supply lines.
48 SEBU7563-09
Operation Section
Engine Starting

• The engine control is set to the STOP mode and b. For industrial engines, unload the compressor
the gas shutoff valve does not close. or pump. Disengage the clutch (if equipped).
Place the transmission and/or other
• Unsuccessful successive attempts to start the attachments for the power take-off in
engine NEUTRAL.

Unburned gas may remain in the air inlet and exhaust


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

Perform the following procedure in order to purge


the unburned gas:

1. If the Caterpillar Electronic Technician (ET) is not


connected to the engine, connect Cat ET to the
engine.

2. Verify that the value of the “Engine Purge Cycle” g00791099


parameter is equal to ten seconds less than the Illustration 36
value of the “Crank Cycle” parameter. (1) Engine control switch in the “START” position
(2) “DESIRED SPEED” potentiometer
3. Set the engine control to the START mode. The
engine will crank for the “Engine Purge Cycle” 3. Verify that “DESIRED SPEED” potentiometer (2)
time. Then, the gas shutoff valve will be energized is set to an rpm that is appropriate. Verify that
and the ignition will be enabled. The engine will the “IDLE/RATED” display (if equipped) indicates
start. “IDLE”.

4. Continue with your previous procedure. 4. Observe the “Configuration” screen on Caterpillar
Electronic Technician (ET) or on the Advisor
panel. Verify that the “FUEL ENERGY CONTENT”
Automatic Starting and the “SPECIFIC GRAVITY” are correct.

5. Turn engine control switch (1) to the “START”


position.
When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid personal NOTICE
injury, always remain clear of the the engine when The engine must be prelubed before the crankshaft is
the engine is in the AUTOMATIC mode. rotated. Damage can result if the crankshaft is rotated
on dry bearing surfaces.
If the engine control switch is in the “AUTO” position,
the engine will automatically start when the remote Note: The prelube oil pump will operate until the
start/stop initiate contact closes. The engine will pressure switch is made for 30 seconds. The
accelerate to rated rpm when the oil pressure is Electronic Control Module (ECM) will initiate the
sufficient. engine start-up after the prelube pressure switch
detects 1 psi of oil pressure. If the module detects a
Manual Starting signal for preventing the start-up, the corresponding
diagnostic code will be generated.
1. Ensure that fuel is supplied to the engine. Ensure
that no gas is leaking. 6. Allow the engine to idle for three to five minutes.

2. Ensure that the driven equipment is unloaded. The engine speed should stabilize at low idle rpm.
Perform these checks during the warm-up:
a. For generator set engines, open the main
circuit breaker. • Check all of the pressure gauges.
• Inspect the engine for leaks.
• Listen for unusual noises.
SEBU7563-09 49
Operation Section
Engine Starting

When all systems are normal, the rpm may be Apply the load according to the requirements for
increased. temperatures:

Ensure that the oil pressure and the fuel pressure are Before you apply a load up to 49 percent of the
in the normal ranges. After the engine has started rated load, the minimum temperature of the jacket
and the warm-up is complete, the engine can be water is 38 °C (100 °F). The minimum engine oil
operated at rated rpm and low load. The engine will temperature is 10 °C (50 °F).
reach normal operating temperature faster if the
engine is operated at low rpm and with a low power Before you apply a load between 50 and
demand. This procedure is more effective than idling 100 percent of the rated load, the minimum
the engine with no load. The engine should reach temperature of the jacket water is 50 °C (122 °F).
normal operating temperature in a few minutes. The minimum engine oil temperature is 50 °C
(122 °F).
i02606873
Continue to check the gauges and the driven
After Starting Engine equipment.

SMCS Code: 1000 For information on partial load operation, refer to


this Operation and Maintenance Manual, “Engine
Note: For new installations and engines that are Operation” topic (Operation Section).
recently rebuilt, carefully monitor the engine in order
to detect any unusual engine performance. 3. Adjust the load, as needed.

Check the Advisor II panel during the warm-up.


Complete a walk-around inspection. Check for leaks
and unusual noises. Correct any problems before
proceeding.

Engaging the Driven Equipment


Avoid detonation during loading. Generally, no load
operation to full load operation can be accomplished
in one to five minutes without any problems.

DO NOT apply a load to the engine or increase the


rpm until the engine oil pressure is a minimum of
160 kPa (23 psi) at low idle rpm.

1. Increase the engine rpm.

The minimum rpm for operating an engine with a


load is 750 rpm. The maximum rpm for operating
an engine with a load is 1000 rpm.

a. For engines with a “SPEED CONTROL”


potentiometer or a remote speed control, turn
the control to the engine rpm that is desired.

b. For engines with an “IDLE/RATED” switch,


toggle the switch to the “RATED” position.

Ensure that the gauges are in the normal


ranges for the engine rpm.

Note: It may be necessary to apply some load in


order to attain normal operating temperatures.

2. After verifying that the engine systems are normal,


engage the driven equipment.
50 SEBU7563-09
Operation Section
Engine Operation

Engine Operation Partial Load Operation


Extended operation at low idle or at a reduced load
i03679822 will cause increased consumption of engine oil and
carbon buildup in the cylinders. Carbon buildup
Engine Operation results in the following effects:
SMCS Code: 1000 • Accelerated wear of components
Proper operation and maintenance are key factors in • Loss of control of the exhaust emissions
attaining the maximum service life and economy for
the engine. Follow the instructions in this Operation • Narrow margin for detonation
and Maintenance Manual in order to minimize
operating costs and maximize the service life of the • Poor performance
engine.
• Power loss
Observe the Advisor display or the Caterpillar
Electronic Technician (ET) frequently while the Caterpillar Engines can be operated at very light
engine is operating. Record the data from the gauges loads for limited times with no harmful effects. Table
in a log. Average the data that is recorded during 26 lists the limits for hours of operation at various
operation and record the average values for each loads.
day. Compare the data to the specifications for
normal engine operation. Comparing the data over After the time limit for reduced load operation
time will help to detect trends in engine performance. has expired, operate the engine for a minimum of
two hours at a load that is more than 70 percent
Investigate any significant change in the readings. of the rated load.
Monitor the engine operation and take action when
discrepancies are found. For example, an engine is operating at 20 percent of
the rated load. The engine may be operated at this
Operating the Engine and the load factor for a maximum of one-half hour. After the
one-half hour, operate this engine for at least two
Driven Equipment hours at a load factor of more than 70 percent.
Apply the load according to the following requirements To keep engine maintenance at a minimum, follow
for temperatures. Lack of compliance could result the guidelines that are listed in Table 26.
in scuffing of the piston skirt or seizure in some
applications. Table 26
Time Limits for Low Load Operation
• Before you apply a load up to 49 percent of the
rated load, the minimum temperature of the jacket Engine Load Time Limit
water is 38 °C (100 °F). The minimum engine oil
0 to 30 percent 1/2 hour
temperature is 10 °C (50 °F).
31 to 50 percent 2 hours
• Before you apply a load between 50 and 100 51 to 100 percent Continuous (1)
percent of the rated load, the minimum temperature
of the jacket water is 50 °C (122 °F). The minimum (1) For continuous operation, the manifold air pressure must be
engine oil temperature is 50 °C (122 °F). greater than the atmospheric pressure.

The minimum rpm for operating an engine with a Oil Consumption


load is 750 rpm. The maximum rpm for operating an
engine with a load is 1000 rpm. The rate of oil consumption is called Brake Specific
Oil Consumption (BSOC). The unit of measure is
Check the Advisor display and the driven equipment grams per brake kilowatt hour or pounds per brake
frequently while the engine is operating under a load. horsepower hour. The BSOC depends on the engine
The engine can be operated continuously at full load. model, the operating load, and the oil that is used.

Table 27 lists the normal mid-life BSOC for G3600


engines under the following conditions:

• Load factor of 100 percent


SEBU7563-09 51
Operation Section
Engine Operation

• Maintenance is performed according to this


Operation and Maintenance Manual, “Maintenance
Interval Schedule”.

Table 27
BSOC for G3600 Engines
0.304 g/bkw h (.00052 lb/bhp h)
52 SEBU7563-09
Operation Section
Engine Stopping

Engine Stopping Emergency Stop Button

i02601387

Emergency Stopping
SMCS Code: 1000; 7418

NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.

Ensure that any system that provides external


support to the engine is secured after the engine is
stopped. Turn off the auxiliary systems for engine
operation after the engine is stopped.

NOTICE
Do not start the engine until the problem necessitating
the emergency stop has been located and corrected. Illustration 37
g00792865

(1) Emergency stop button


Pressing the emergency stop button may cause (2) Mode control switch in the “OFF/RESET” position
unburned gas to remain in the air inlet and in the
exhaust manifold. The emergency stop button is in the OUT position for
normal engine operation. For an emergency stop,
push emergency stop button (2). The engine will not
start when the button is locked. To reset the button,
turn the button clockwise or pull the button. The
Unburned gas in the air inlet and exhaust system spring-loaded button will return to the OUT position.
may ignite when the engine is started. Personal
injury and/or property damage may result. The control panel must also be reset before the
engine will start. To reset the control panel, turn mode
Before starting an engine that may contain un- control switch (1) to the “OFF/RESET” position.
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on Another emergency stop button is located on the
purging unburned gas in the “Starting the Engine” ECM junction box on the rear of the engine.
section.

i01748696

Manual Stop Procedure


SMCS Code: 1000; 7418

NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of engine components.

Excessive temperatures in the turbocharger center-


housing will cause oil coking problems.

Allow the engine to gradually cool before stopping the


engine

Note: Remove the load at a rate that will avoid


detonation.
SEBU7563-09 53
Operation Section
Engine Stopping

1. Disengage or unload the driven equipment. The engine will coast to a stop. Ensure that any
system that provides external support to the engine
a. For generator set engines, open the main is secured after the engine is stopped. Turn off
circuit breaker. the auxiliary systems for engine operation after the
engine is stopped.
b. For industrial engines, unload the compressor
or pump. Disengage the clutch (if equipped). The power to the control panel will be maintained
Place the transmission and/or other until the engine control switch is turned to the
attachments for the power take-off in “OFF/RESET” position.
NEUTRAL.
i02508920
Note: Extended idling can cause excessive oil
consumption and related problems. See this
Operation and Maintenance Manual, “Engine
After Stopping Engine
Operation” topic (Operation Section). SMCS Code: 1000
2. Reduce the engine rpm to low idle.
• Check the engine crankcase oil level. Maintain the
oil level between the “ADD” and “FULL” marks
Note: If the cooldown feature is not utilized, operate on the “ENGINE STOPPED” side of the oil level
the engine at low idle rpm for a cooldown period of gauge.
approximately one to two minutes before stopping
the engine.
• If necessary, perform minor adjustments. Repair
any leaks and tighten loose bolts.
3. Use one of the following methods in order to stop
the engine:
• Note the service hour reading. Perform the
maintenance that is scheduled in this Operation
and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section).

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

• Allow the engine to cool. Check the coolant level.


• If freezing temperatures are expected, check the
g00825057 coolant for protection against freezing. The cooling
Illustration 38
system must be protected against freezing to the
Engine control switch in the “STOP” position lowest expected outside temperature. Add the
proper coolant/water mixture, if necessary.
a. Turn the engine control switch to the “STOP”
position. • Perform all required periodic maintenance on all
driven equipment. Refer to the instructions that are
b. If the engine control switch is in the “AUTO” provided by the OEM of the driven equipment.
position, the engine will stop when the remote
start/stop initiate contact opens.

If the cooldown feature is utilized, the engine


will operate for a programmed period of time
before the engine stops. Otherwise, the engine
will immediately shut off. When the engine
rpm is reduced to approximately 100 rpm, the
postlube cycle will operate for approximately
180 seconds.
54 SEBU7563-09
Maintenance Section
Refill Capacities

Maintenance Section Lubricant Capacities


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

Table 28
i03679347
Approximate Refill Capacity of Crankcase
Refill Capacities and Sales Model Liters US Gallons
Recommendations G3606 708 187
G3608 912 241
SMCS Code: 1348; 1395; 7560
G3612 1030 272
NOTICE G3616 1325 351
Every attempt is made to provide accurate, up to date
information. By use of this document you agree that
Caterpillar Inc. is not responsible for errors or omis- Hydraulic Actuator System
sions. The information that is provided are the latest
recommendations for Cat gas engines. This informa- Hydraulic Oil
tion supersedes all previous recommendations which
have been published for Cat gas engines. Special flu- Caterpillar offers two hydraulic oil products:
ids may be required for some engines and it will be
necessary to continue to use these special products.
Refer to the applicable Operation and Maintenance
• Cat HYDO Advanced 10
Manual.
• Cat Bio HYDO Advanced
NOTICE Cat HYDO Advanced 10 (Hydraulic Oil)
These recommendations are subject to change with-
out notice. Consult your local Caterpillar dealer for the CatHYDO Advanced 10 fully replaced CatHYDO oil.
most up to date recommendations. CatHYDO is no longer available.

CatHYDO Advanced 10 is preferred in most hydraulic


Refer to Special Publication, SEBU6400, “Caterpillar systems and in most hydrostatic systems when
Gas Engine Lubricant, Fuel, and Coolant ambient temperature is between −20 °C (−4 °F) and
Recommendations” for further information. 40 °C (104 °F).

Lubrication System If a different viscosity is required due to ambient


temperatures, the following Caterpillar oils can be
Note: Instructions for the installation of the filter are used:
printed on the side of each Cat spin-on filter. For
non-Cat filters, refer to the installation instructions • Cat DEO ULS Multigrade
that are provided by the supplier of the filter.
• Cat DEO Multigrade
Lubricant Recommendations
• Cat DEO ULS SYN
Due to the significant variations in the quality and
in the performance of commercially available oils, • Cat Arctic DEO SYN
Caterpillar makes the following recommendations, in
order of oil performance: • Cat TDTO

• Cat Natural Gas Engine Oil (NGEO) EL350 • Cat Arctic TDTO

• Cat Natural Gas Engine Oil (NGEO) EL250 • Cat TDTO-TMS

• Cat Natural Gas Engine Oil (NGEO) • Cat MTO


SEBU7563-09 55
Maintenance Section
Refill Capacities

Cat Bio HYDO Advanced (Hydraulic Oil) Permissible fuels must be analyzed in order to
determine the following characteristics:
Cat Bio HYDO Advanced is biodegradable non-toxic
hydraulic oil that is recommended for use in hydraulic • Composition
systems when environmental compliance is required
or desired. Cat Bio HYDO Advanced has a renewable • Contaminants
content that exceeds 90% and complies with the
European Eco-Label. Consult Federal, state, or • Heat value
local authorities for guidance on hydraulic oils
environmental requirements in your area. • Methane number
• Specific gravity
Field gas can have varying characteristics of
combustion. Field gas can contain numerous harmful
impurities. The impurities can alter the BTU value.
The impurities can also alter the methane number.
The impurities include everything from water up to
complex hydrocarbons that can lead to detonation
and severe engine damage. In order to minimize
these effects, Caterpillar recommends the following
guidelines:

• Evaluate the fuel with the most current revision


level of Caterpillar Methane Number Program,
g00103844
Illustration 39 LEKQ6378.

Machines with this symbol are filled with • Methane values below 30 are not recommended
biodegradable hydraulic oil. This symbol is located for use in a Cat engine. Fuels with a methane
on the hydraulic tank. number that is below 30 must first be processed in
order to remove harmful impurities in the fuel and
Capacity of the Electrohydraulic raising the methane number into the acceptable
range.
Actuator's System
Table 29 • If necessary, use an engine that is configured for a
fuel that has a high energy. Consult the appropriate
G3600 Electrohydraulic Actuator System manual for the engine in order to determine the
Approximate Refill Capacity recommended engine timing.
Compartment or System Liters US Gallons
Hydraulic Oil Tank 19 5
• Reduce the oil change interval according to the
results of the oil analysis.

Before the engine arrangement is ordered, use the


Fuel methane number in order to determine the following
characteristics for the new engine:
Gaseous fuels consist primarily of hydrocarbons
(combinations of hydrogen and carbon) and some
inert gases. Pipeline natural gas has been used for • Compression ratio
many years. Other types of fuels such as wellhead
gas, bio-gas, and manufactured gas need to be • Fuel system components
reviewed for acceptability.
• Ignition timing
Each commercial fuel gas is a mixture of gases.
Some of the gases are combustible and some of • Rated load
the gases are inert. The compositions of these gas
For a detailed explanation of methane numbers,
mixtures have extreme variations.
refer to the most current revision level of Special
Publication, LEBW4977, “Gaseous Fuels -
Cat gas engines will operate successfully on a broad
Application and Installation Guide”.
range of gaseous fuels. Adjustments must be made
to the fuel system when the engine is commissioned
or when the fuel is changed. Consult your Caterpillar
dealer about the proper adjustments.
56 SEBU7563-09
Maintenance Section
Refill Capacities

Cooling System • Caterpillar dealer

Coolant Recommendations • Local water utility company

During shipping and storage, the engine must be • Agricultural agent


protected from damage that can be caused by
freezing of the cooling system. If the engine is • Independent laboratory
shipped to a site with freezing temperatures and/or
if the engine is stored in a location with freezing Glycol
temperatures, the cooling system must contain
antifreeze that will withstand the lowest ambient NOTICE
temperature. Frequently check the concentration Do not use Extended Life Coolant (ELC) with Cat Gas
of glycol in the coolant/antifreeze. Make sure that Engines.
the concentration is adequate in order to prevent
freezing. Otherwise, the cooling system must be ELC was not formulated for use in Cat Gas Engines.
completely drained and all of the drain plugs must
be removed. Do not use heat transfer fluids in Cat Gas Engines.

Coolant/antifreeze is normally composed of three Use only the coolant/antifreeze that is recommended.
elements: water, glycol, and additives. Each element
must meet specific guidelines.
Preferred – Cat NGEC (Natural Gas Engine
Water Coolant)

Deionized water or distilled water is Alternatively, use Cat DEAC (Diesel Engine
recommended for use in engine cooling systems. Antifreeze/Coolant) or a commercial heavy-duty
If distilled water or deionized water is not available, antifreeze/coolant that meets “ASTM D6210” or
use water with the properties that are listed in Table “ASTM D4985” specifications.
30.
NOTICE
Table 30 Do not use a commercial coolant/antifreeze that only
Caterpillar Minimum Acceptable Water Requirements meets the ASTM “D3306” specification. This type of
coolant/antifreeze is made for light duty automotive
Property Maximum Limit ASTM Test applications.
40 mg/L “D512”,
Chloride (Cl)
(2.4 grains per US gal) “D4327” Use only the coolant/antifreeze that is recommended.
100 mg/L
Sulfate (SO4) “D516”
(5.9 grains per US gal) Acceptable – In applications that do not require
170 mg/L protection from boiling or from freezing, a mixture of
Total Hardness “D1126” Caterpillar SCA and water that meets the properties
(10 grains per US gal)
that are listed in Table 30 is acceptable.
340 mg/L
Total Solids “D1888”
(20 grains per US gal) Note: The preferred coolant/antifreeze and the
Acidity pH of 5.5 to 9.0 “D1293” acceptable mixture of SCA and water require
different concentrations of SCA. Refer to the Special
Publication, SEBU6400, “Caterpillar Gas Engine
NOTICE Lubricant, Fuel, and Coolant Recommendations”,
Use of water that does not meet the recommendations “Supplemental Coolant Additive (SCA)” topic.
for the cooling system will damage the cooling system.
Table 31 is a list of the coolant/antifreeze that is
Do not use these types of water in the cooling system: recommended for Caterpillar Gas Engines. The
sea water, softened water that has been conditioned service life of the coolant/antifreeze that is used in
with salt, hard water, and tap water. Caterpillar Gas Engines is also listed. To achieve
this service life, the coolants must be properly
Only use water that meets the recommendations for maintained. The maintenance program includes
the cooling system. S·O·S coolant analysis.

If you are not sure about the properties of your water,


consult one of the following sources for a water
analysis:
SEBU7563-09 57
Maintenance Section
Refill Capacities

Table 31 Table 32
Recommended Coolant/Antifreeze and Service G3606 Engine Cooling System
Life of the Coolant/Antifreeze Approximate Refill Capacities
Coolant/Antifreeze Service Life (1) Compartment or System Liters US Gallons
Cat NGEC Jacket Water 340 90
Three Years
Cat DEAC Aftercooler 61 16
Commercial Heavy-Duty Accessory Module 345 91
Antifreeze/Coolant that Two Years
meets “ASTM D6210” External System

Commercial Heavy-Duty Total Cooling System


Antifreeze/Coolant that One Year
meets “ASTM D4985” Table 33
Cat SCA and Water Two Years G3608 Engine Cooling System
Approximate Refill Capacities
Commercial SCA and
One Year
Water Compartment or System Liters US Gallons
(1) The service life of coolant is also limited by use (service hours). Jacket Water 469 124
Refer to the specific engine's Operation and Maintenance
Manual, “Maintenance Interval Schedule”. Aftercooler 61 16
Accessory Module 345 91
Additives
External System
Preferred – Cat SCA (Supplemental Coolant
Total Cooling System
Additive)

Acceptable – A commercial SCA that provides Table 34


1400 mg/L (82 grains per US gal) or 1400 ppm of G3612 Engine Cooling System
nitrites in the final mixture of coolant/antifreeze Approximate Refill Capacity

Note: A 50/50 concentration of Cat NGEC or of Compartment or System Liters US Gallons


Cat DEAC does not require a treatment with Jacket Water 669 177
an SCA at the initial fill. Commercial heavy-duty
antifreeze/coolant that meets “ASTM D6210” Aftercooler 64 17
or “ASTM D4985” specifications may require a Accessory Module 345 91
treatment with an SCA at the initial fill. Read the label
or the instructions that are provided by the OEM of External System
the product. Total Cooling System

To ensure that the correct amount of SCA is in the Table 35


cooling system, the concentration of SCA must be
tested on a scheduled basis. Obtain an S·O·S coolant G3616 Engine Cooling System
analysis (Level 1) or use a test kit to check the Approximate Refill Capacity
concentration of the SCA according to this Operation Compartment or System Liters US Gallons
and Maintenance Manual, “Maintenance Interval
Schedule”. Jacket Water 900 238
Aftercooler 72 19
Coolant Capacities Accessory Module 345 91
To properly maintain the cooling system, the total External System
cooling system capacity must be determined. The
Total Cooling System
total cooling system capacity will vary between
individual installations. The external system capacity
includes the following components: expansion tank,
heat exchanger, radiator, and piping. Refer to the
specifications that are provided by Caterpillar or by
the OEM of the equipment. Record the total cooling
system capacity in the appropriate Tables:
58 SEBU7563-09
Maintenance Section
Maintenance Recommendations

Maintenance 1. Stop the engine.

Recommendations 2. Wait for ten minutes.

Do not loosen the high pressure fuel lines in order to


i02909163 remove air pressure from the fuel system.
System Pressure Release
Engine Oil
SMCS Code: 1250; 1300; 1350; 5050
To relieve pressure from the lubricating system, turn
Coolant System off the engine.

i03681563

Welding on Engines with


Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra- Electronic Controls
diator is cool. Then loosen cap slowly to relieve
the pressure. SMCS Code: 1000

NOTICE
To relieve the pressure from the coolant system, turn
Because the strength of the frame may decrease,
off the engine. Allow the cooling system pressure cap
some manufacturers do not recommend welding onto
to cool. Remove the cooling system pressure cap
a chassis frame or rail. Consult the OEM of the equip-
slowly in order to relieve pressure.
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
Fuel System
Proper welding procedures are necessary in
To relieve the pressure from the fuel system, turn off order to avoid damage to the engine's electronic
the engine. control module (ECM), sensors, and associated
components. When possible, remove the component
High Pressure Fuel Lines (If Equipped) from the unit and then weld the component. If
removal of the component is not possible, the
following procedure must be followed when you weld
on a unit that is equipped with a Caterpillar Electronic
Engine. The following procedure is considered to be
Contact with high pressure fuel may cause fluid
the safest procedure to weld on a component. This
penetration and burn hazards. High pressure fu-
procedure should provide a minimum risk of damage
el spray may cause a fire hazard. Failure to fol-
to electronic components.
low these inspection, maintenance and service in-
structions may cause personal injury or death.
NOTICE
Do not ground the welder to electrical components
The high pressure fuel lines are the fuel lines that such as the ECM or sensors. Improper grounding can
are between the high pressure fuel pump and the cause damage to the drive train bearings, hydraulic
high pressure fuel manifold and the fuel lines that are components, electrical components, and other com-
between the fuel manifold and cylinder head. These ponents.
fuel lines are different from fuel lines on other fuel
systems. Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
This is because of the following differences: as possible to the weld. This will help reduce the pos-
sibility of damage.
• The high pressure fuel lines are constantly charged
with high pressure.
1. Stop the engine. Turn the switched power to the
• The internal pressures of the high pressure fuel OFF position.
lines are higher than other types of fuel system.
2. Disconnect the negative battery cable from the
Before any service or repair is performed on the battery. If a battery disconnect switch is provided,
engine fuel lines, perform the following tasks: open the switch.
SEBU7563-09 59
Maintenance Section
Maintenance Recommendations

3. Disconnect the J1/P1 and J2/P2 connectors from 5. Protect the wiring harness from welding debris
the ECM. Move the harness to a position that will and spatter.
not allow the harness to accidentally move back
and make contact with any of the ECM pins. 6. Use standard welding practices to weld the
materials.

g01075639
Illustration 40
Use the example above. The current flow from the welder to
the ground clamp of the welder will not cause damage to any
associated components.
(1) Engine
(2) Welding rod
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Maximize distance between the component that is being
welded and any electrical/electronic component.
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder

4. Connect the welding ground cable directly to the


part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to bearings,
hydraulic components, electrical components, and
ground straps.

Note: If electrical/electronic components are used


as a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.
60 SEBU7563-09
Maintenance Section
Maintenance Interval Schedule

i03915129 Every 250 Service Hours


Maintenance Interval Schedule Battery Electrolyte Level - Check .......................... 71
Cooling System Coolant Sample (Level 1) -
(G3600 Engines That Use Obtain ................................................................. 77
Wellhead or Natural Gas and Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 78
Have a Compression Ratio of Engine Oil Sample - Obtain .................................. 97
9.2:1)
Initial 1000 Service Hours
SMCS Code: 1000; 4450; 7500
Air Starting Motor Lines Screen - Clean ............... 67
Ensure that all safety information, warnings, Air Starting Motor Lubricator Bowl - Clean ........... 67
and instructions are read and understood before Crankcase Blowby - Measure/Record .................. 80
any operation or any maintenance procedures Cylinder Pressure - Measure/Record ................... 81
are performed. The user is responsible for the Electrohydraulic System Oil Filter - Change ......... 87
performance of all maintenance including the Engine Crankcase Breather - Clean ..................... 91
following procedures: all adjustments, the use of Engine Protective Device Connections - Inspect .. 98
proper lubricants, fluids, filters, and the installation Engine Speed/Timing Sensor - Clean/Inspect .... 100
of new components due to normal wear and aging . Engine Valve Lash - Inspect/Adjust .................... 101
The performance of this product may be diminished if Engine Valve Rotators - Inspect ......................... 102
proper maintenance intervals and procedures are not Valve Stem Projection - Measure/Record ........... 122
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures Every 1000 Service Hours
are not followed.
Actuator Control Linkage - Lubricate .................... 66
Belts - Inspect/Adjust/Replace .............................. 71
Note: Use whichever of the following that occurs Hoses and Clamps - Inspect/Replace ................ 105
first in order to determine the maintenance intervals:
Ignition System Spark Plugs - Check/Adjust ...... 108
fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all
maintenance from the previous intervals must be Every 2000 Service Hours
performed. Aftercooler Condensation - Drain ......................... 67
Cooling System Coolant Sample (Level 2) -
Products that operate in severe operating conditions Obtain ................................................................. 77
may require more frequent maintenance. Crankshaft Vibration Damper - Inspect ................. 80
Engine Crankcase Breather - Clean ..................... 91
When Required Engine Mounts - Check ........................................ 92
Engine Valve Lash - Inspect/Adjust .................... 101
Actuator Control Linkage - Replace ...................... 66
Engine Valve Rotators - Inspect ......................... 102
Barring Device - Lubricate .................................... 69 Valve Stem Projection - Measure/Record ........... 122
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 77
Engine Air Cleaner Element (Single Element) -
Every 5000 Service Hours
Clean/Replace .................................................... 87 Air Starting Motor Lines Screen - Clean ............... 67
Engine Air Precleaner - Clean .............................. 91 Air Starting Motor Lubricator Bowl - Clean ........... 67
Overhaul Considerations ..................................... 116 Combustion Sensor - Clean/Inspect/Replace ....... 72
Valve Stem Projection - Measure/Record ........... 122 Cooling System Level Switch - Inspect ................. 77
Crankcase Blowby - Measure/Record .................. 80
Daily Cylinder Pressure - Measure/Record ................... 81
Driven Equipment - Check .................................... 82
Air Starting Motor Lubricator Oil Level - Check .... 68
Electrohydraulic System - Check/Adjust ............... 85
Air Tank Moisture and Sediment - Drain ............... 69
Electrohydraulic System Oil - Change .................. 86
Control Panel - Inspect ......................................... 74 Electrohydraulic System Oil Filter - Change ......... 87
Cooling System Coolant Level - Check ................ 76
Engine Oil - Change ............................................. 92
Driven Equipment - Inspect/Replace/Lubricate ... 83
Engine Oil Filter - Change .................................... 93
Electrohydraulic System - Inspect ........................ 86 Engine Protective Device Connections - Inspect .. 98
Engine Oil Level - Check ...................................... 96
Engine Protective Devices - Check .................... 100
Fuel System Fuel Filter Differential Pressure -
Exhaust Bypass - Recondition ............................ 102
Check ................................................................ 103 Gas Shutoff Valve - Inspect ................................ 105
Walk-Around Inspection ...................................... 123
Ignition System Spark Plugs - Replace ............... 111
Inlet Air System - Inspect ..................................... 111
SEBU7563-09 61
Maintenance Section
Maintenance Interval Schedule

Inlet Gas Manifold and Piping - Inspect/Replace .. 111


Prechamber Check Valves - Clean ...................... 118
Starting Motor - Inspect ....................................... 119
Turbocharger - Inspect ........................................ 121

Every 10 000 Service Hours


Alternator - Inspect ............................................... 69
Cooling System Water Temperature Regulator -
Replace ............................................................... 79
Electrohydraulic Actuator - Inspect ....................... 83
Engine Oil Temperature Regulator - Replace ....... 98
Engine Speed/Timing Sensor - Clean/Inspect .... 100
Exhaust Shields - Inspect ................................... 102
Gas Pressure Regulator - Inspect/Replace ........ 104
Prechamber Check Valves - Replace .................. 119
Prelube Pump - Inspect ....................................... 119
Water Pump - Inspect ......................................... 124

Every 20 000 Service Hours or 3 Years


Cooling System Coolant (NGEC) - Change .......... 74

Every 25 000 Service Hours


Gas Admission Valve Seals - Inspect/Replace ... 104
Overhaul (Top End) .............................................. 114
Prechamber - Clean/Inspect ................................ 118

Every 50 000 Service Hours


Electrohydraulic Actuator - Recondition ................ 84
Gas Admission Valve - Recondition .................... 103
Overhaul (In-Frame) ............................................ 112

Every 100 000 Service Hours


Overhaul (Major) .................................................. 113
62 SEBU7563-09
Maintenance Section
Maintenance Interval Schedule

i03915106 Every 250 Service Hours


Maintenance Interval Schedule Battery Electrolyte Level - Check .......................... 71
Cooling System Coolant Sample (Level 1) -
(G3600 Engines That Use Obtain ................................................................. 77
Natural Gas and Have a Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 78
Compression Ratio of 10.5:1 Engine Oil Sample - Obtain .................................. 97
or 11:1)
Initial 1000 Service Hours
SMCS Code: 1000; 4450; 7500
Air Starting Motor Lines Screen - Clean ............... 67
Ensure that all safety information, warnings, Air Starting Motor Lubricator Bowl - Clean ........... 67
and instructions are read and understood before Crankcase Blowby - Measure/Record .................. 80
any operation or any maintenance procedures Cylinder Pressure - Measure/Record ................... 81
are performed. The user is responsible for the Electrohydraulic System Oil Filter - Change ......... 87
performance of all maintenance including the Engine Crankcase Breather - Clean ..................... 91
following procedures: all adjustments, the use of Engine Protective Device Connections - Inspect .. 98
proper lubricants, fluids, filters, and the installation Engine Speed/Timing Sensor - Clean/Inspect .... 100
of new components due to normal wear and aging . Engine Valve Lash - Inspect/Adjust .................... 101
The performance of this product may be diminished if Engine Valve Rotators - Inspect ......................... 102
proper maintenance intervals and procedures are not Valve Stem Projection - Measure/Record ........... 122
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures Every 1000 Service Hours
are not followed.
Actuator Control Linkage - Lubricate .................... 66
Belts - Inspect/Adjust/Replace .............................. 71
Note: Use whichever of the following that occurs Hoses and Clamps - Inspect/Replace ................ 105
first in order to determine the maintenance intervals:
Ignition System Spark Plugs - Replace ............... 111
fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all
maintenance from the previous intervals must be Every 2000 Service Hours
performed. Aftercooler Condensation - Drain ......................... 67
Cooling System Coolant Sample (Level 2) -
Products that operate in severe operating conditions Obtain ................................................................. 77
may require more frequent maintenance. Crankshaft Vibration Damper - Inspect ................. 80
Engine Crankcase Breather - Clean ..................... 91
When Required Engine Mounts - Check ........................................ 92
Engine Valve Lash - Inspect/Adjust .................... 101
Actuator Control Linkage - Replace ...................... 66
Engine Valve Rotators - Inspect ......................... 102
Barring Device - Lubricate .................................... 69 Valve Stem Projection - Measure/Record ........... 122
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 77
Engine Air Cleaner Element (Single Element) -
Every 5000 Service Hours
Clean/Replace .................................................... 87 Air Starting Motor Lines Screen - Clean ............... 67
Engine Air Precleaner - Clean .............................. 91 Air Starting Motor Lubricator Bowl - Clean ........... 67
Overhaul Considerations ..................................... 116 Combustion Sensor - Clean/Inspect/Replace ....... 72
Valve Stem Projection - Measure/Record ........... 122 Cooling System Level Switch - Inspect ................. 77
Crankcase Blowby - Measure/Record .................. 80
Daily Cylinder Pressure - Measure/Record ................... 81
Driven Equipment - Check .................................... 82
Air Starting Motor Lubricator Oil Level - Check .... 68
Electrohydraulic System - Check/Adjust ............... 85
Air Tank Moisture and Sediment - Drain ............... 69
Electrohydraulic System Oil - Change .................. 86
Control Panel - Inspect ......................................... 74 Electrohydraulic System Oil Filter - Change ......... 87
Cooling System Coolant Level - Check ................ 76
Engine Oil - Change ............................................. 92
Driven Equipment - Inspect/Replace/Lubricate ... 83
Engine Oil Filter - Change .................................... 93
Electrohydraulic System - Inspect ........................ 86 Engine Protective Device Connections - Inspect .. 98
Engine Oil Level - Check ...................................... 96
Engine Protective Devices - Check .................... 100
Fuel System Fuel Filter Differential Pressure -
Exhaust Bypass - Recondition ............................ 102
Check ................................................................ 103 Gas Shutoff Valve - Inspect ................................ 105
Walk-Around Inspection ...................................... 123
Inlet Air System - Inspect ..................................... 111
Inlet Gas Manifold and Piping - Inspect/Replace .. 111
SEBU7563-09 63
Maintenance Section
Maintenance Interval Schedule

Prechamber Check Valves - Clean ...................... 118


Starting Motor - Inspect ....................................... 119
Turbocharger - Inspect ........................................ 121

Every 10 000 Service Hours


Alternator - Inspect ............................................... 69
Cooling System Water Temperature Regulator -
Replace ............................................................... 79
Electrohydraulic Actuator - Inspect ....................... 83
Engine Oil Temperature Regulator - Replace ....... 98
Engine Speed/Timing Sensor - Clean/Inspect .... 100
Exhaust Shields - Inspect ................................... 102
Gas Pressure Regulator - Inspect/Replace ........ 104
Prechamber Check Valves - Replace .................. 119
Prelube Pump - Inspect ....................................... 119
Water Pump - Inspect ......................................... 124

Every 15 000 Service Hours


Gas Admission Valve Seals - Inspect/Replace ... 104
Overhaul (Top End) .............................................. 114
Prechamber - Clean/Inspect ................................ 118

Every 20 000 Service Hours or 3 Years


Cooling System Coolant (NGEC) - Change .......... 74

Between 45 000 and 48 000 Service Hours


Electrohydraulic Actuator - Recondition ................ 84
Gas Admission Valve - Recondition .................... 103
Overhaul (In-Frame) ............................................ 112

Between 75 000 and 80 000 Service Hours


Overhaul (Major) .................................................. 113
64 SEBU7563-09
Maintenance Section
Maintenance Interval Schedule

i03915101 Every 125 Service Hours


Maintenance Interval Schedule Engine Oil Sample - Obtain .................................. 97
(G3600 Engines That use Every 250 Service Hours
Bio-Gas)
Battery Electrolyte Level - Check .......................... 71
SMCS Code: 1000; 4450; 7500 Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 77
Ensure that all safety information, warnings, Cooling System Supplemental Coolant Additive
and instructions are read and understood before (SCA) - Test/Add ................................................. 78
any operation or any maintenance procedures
are performed. The user is responsible for the Initial 1000 Service Hours
performance of all maintenance including the
following procedures: all adjustments, the use of Air Starting Motor Lines Screen - Clean ............... 67
Air Starting Motor Lubricator Bowl - Clean ........... 67
proper lubricants, fluids, filters, and the installation
Crankcase Blowby - Measure/Record .................. 80
of new components due to normal wear and aging .
The performance of this product may be diminished if Cylinder Pressure - Measure/Record ................... 81
Electrohydraulic System Oil Filter - Change ......... 87
proper maintenance intervals and procedures are not
Engine Crankcase Breather - Clean ..................... 91
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures Engine Protective Device Connections - Inspect .. 98
Engine Speed/Timing Sensor - Clean/Inspect .... 100
are not followed.
Engine Valve Lash - Inspect/Adjust .................... 101
Note: Use whichever of the following that occurs Engine Valve Rotators - Inspect ......................... 102
Valve Stem Projection - Measure/Record ........... 122
first in order to determine the maintenance intervals:
fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all Every 1000 Service Hours
maintenance from the previous intervals must be Actuator Control Linkage - Lubricate .................... 66
performed. Belts - Inspect/Adjust/Replace .............................. 71
Combustion Sensor - Clean/Inspect/Replace ....... 72
Products that operate in severe operating conditions Hoses and Clamps - Inspect/Replace ................ 105
may require more frequent maintenance. Ignition System Spark Plugs - Replace ............... 111
Prechamber Check Valves - Clean ...................... 118
When Required
Actuator Control Linkage - Replace ...................... 66 Every 2000 Service Hours
Barring Device - Lubricate .................................... 69 Aftercooler Condensation - Drain ......................... 67
Cooling System Coolant Sample (Level 2) - Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 77 Obtain ................................................................. 77
Engine Air Cleaner Element (Single Element) - Crankshaft Vibration Damper - Inspect ................. 80
Clean/Replace .................................................... 87 Cylinders - Inspect ................................................ 82
Engine Air Precleaner - Clean .............................. 91 Engine Crankcase Breather - Clean ..................... 91
Engine Oil - Change ............................................. 92 Engine Mounts - Check ........................................ 92
Engine Oil Filter - Change .................................... 93 Engine Valve Lash - Inspect/Adjust .................... 101
Overhaul Considerations ..................................... 116 Engine Valve Rotators - Inspect ......................... 102
Valve Stem Projection - Measure/Record ........... 122 Valve Stem Projection - Measure/Record ........... 122
Daily Every 5000 Service Hours
Air Starting Motor Lubricator Oil Level - Check .... 68 Air Starting Motor Lines Screen - Clean ............... 67
Air Tank Moisture and Sediment - Drain ............... 69 Air Starting Motor Lubricator Bowl - Clean ........... 67
Control Panel - Inspect ......................................... 74 Cooling System Level Switch - Inspect ................. 77
Cooling System Coolant Level - Check ................ 76 Crankcase Blowby - Measure/Record .................. 80
Driven Equipment - Inspect/Replace/Lubricate ... 83 Cylinder Pressure - Measure/Record ................... 81
Electrohydraulic System - Inspect ........................ 86 Driven Equipment - Check .................................... 82
Engine Air Cleaner Service Indicator - Inspect ..... 90 Electrohydraulic System - Check/Adjust ............... 85
Engine Oil Level - Check ...................................... 96 Electrohydraulic System Oil - Change .................. 86
Fuel System Fuel Filter Differential Pressure - Electrohydraulic System Oil Filter - Change ......... 87
Check ................................................................ 103 Engine Protective Device Connections - Inspect .. 98
Turbocharger - Clean .......................................... 120 Engine Protective Devices - Check .................... 100
Walk-Around Inspection ...................................... 123 Exhaust Bypass - Recondition ............................ 102
Gas Shutoff Valve - Inspect ................................ 105
SEBU7563-09 65
Maintenance Section
Maintenance Interval Schedule

Inlet Air System - Inspect ..................................... 111


Inlet Gas Manifold and Piping - Inspect/Replace .. 111
Prechamber Check Valves - Replace .................. 119
Starting Motor - Inspect ....................................... 119
Turbocharger - Inspect ........................................ 121
Turbocharger Cleaner Tube - Replace ............... 122

Between 10 000 and 14 000 Service Hours


Gas Admission Valve Seals - Inspect/Replace ... 104
Overhaul (Top End) .............................................. 114
Prechamber - Clean/Inspect ................................ 118

Every 10 000 Service Hours


Alternator - Inspect ............................................... 69
Cooling System Water Temperature Regulator -
Replace ............................................................... 79
Electrohydraulic Actuator - Inspect ....................... 83
Engine Oil Temperature Regulator - Replace ....... 98
Engine Speed/Timing Sensor - Clean/Inspect .... 100
Exhaust Shields - Inspect ................................... 102
Gas Pressure Regulator - Inspect/Replace ........ 104
Prelube Pump - Inspect ....................................... 119
Water Pump - Inspect ......................................... 124

Every 20 000 Service Hours or 3 Years


Cooling System Coolant (NGEC) - Change .......... 74

Between 27 000 and 33 000 Service Hours


Electrohydraulic Actuator - Recondition ................ 84
Gas Admission Valve - Recondition .................... 103
Overhaul (In-Frame) ............................................ 112

Between 36 000 and 44 000 Service Hours


Gas Admission Valve Seals - Inspect/Replace ... 104
Overhaul (Top End) .............................................. 114

Between 52 000 and 54 000 Service Hours


Overhaul (Major) .................................................. 113
66 SEBU7563-09
Maintenance Section
Actuator Control Linkage - Lubricate

i02601608 i02236400

Actuator Control Linkage - Actuator Control Linkage -


Lubricate Replace
(If applicable) SMCS Code: 1265-510
SMCS Code: 1265-086 Inspect the rod ends of the following components for
wear:

Note: Use of a platform may be necessary to reach


The linkage can move and form a pinch point the linkages.
which can cause personal injury. Keep hands
away from the linkage. • Air choke actuator

Before performing this procedure, ensure that the • Exhaust bypass actuator
linkage is meant to be lubricated. If the linkage is
meant to be lubricated, this article applies to the • Fuel control actuator
following: air choke actuator, fuel control actuator,
and exhaust bypass actuator. • Linkages
If necessary, replace the rod ends.
Apply Dow Corning 41 Extreme High Temperature
Bearing Grease to the rod ends (bearings) of the
control linkage for the actuator. For more information Removal and Installation
on grease, see the Special Publication, SEBU6400,
“Caterpillar Gas Engine Lubricant, Fuel, and Coolant
Recommendations”.

Note: The exhaust heat shields must be in place and


snug around the shaft of the wastegate in order to
provide maximum life of rod ends.

Hydraulic Actuators

g00799207
Illustration 42
Typical example of rod ends on an actuator and on the linkage
for an actuator

For instructions on removal and installation of the


control linkage for the actuators, see the Disassembly
and Assembly Manual. See the Specifications
Manual for instructions on adjusting the actuators.
Consult your Caterpillar dealer for assistance.

g01120800
Illustration 41
Typical locations of grease fittings
SEBU7563-09 67
Maintenance Section
Aftercooler Condensation - Drain

i01762572 i01762654

Aftercooler Condensation - Air Starting Motor Lines


Drain Screen - Clean
SMCS Code: 1063 SMCS Code: 1451-070-LI

The aftercooler is similar to a radiator. Coolant


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

Condensation can form in the passages of the


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

g00789123
Illustration 45
(1) Plug
(2) Screen

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 (1).


g00788934
Illustration 43
A drain plug is located on the right side near the rear of the engine.
3. Carefully remove screen (2). Clean the screen
with nonflammable solvent. Inspect the screen for
(1) Plug
damage. If the screen is damaged, replace the
damaged screen with a new screen.

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


the plug.

i02654935

Air Starting Motor Lubricator


Bowl - Clean
SMCS Code: 1451-070

If the engine is equipped with an air starting motor,


g00788946 use the following procedure:
Illustration 44
A drain plug is located on the left side near the front of the engine.
(2) Plug

1. Ensure that the engine is not running.

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

3. Drain the moisture into suitable containers.

4. Install the plugs.


68 SEBU7563-09
Maintenance Section
Air Starting Motor Lubricator Oil Level - Check

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


bowl is cracked, replace the damaged bowl with
a new bowl. Inspect the gasket. If the gasket is
Personal injury can result from removing hoses or
damaged, replace the gasket.
fittings in a pressure system.
6. Install the bowl.
Failure to relieve pressure can cause personal in-
jury.
7. Make sure that drain valve (3) is closed.
Do not disconnect or remove hoses or fittings un-
8. For instructions on filling the lubricator, see this
til all pressure in the system has been relieved.
Operation and Maintenance Manual, “Air Starting
Motor Lubricator Oil Level - Check” topic.
1. Ensure that the air supply to the lubricator is OFF.
i02654969

Air Starting Motor Lubricator


Oil Level - Check
SMCS Code: 1451-535

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

g01333332
Illustration 46
(1) Filler plug
(2) Bowl
(3) Drain valve

2. Slowly loosen filler plug (1) 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, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- g01333366
Illustration 47
ing any compartment or disassembling any compo-
nent containing fluids. 1. Observe the oil level in sight gauge (3). If the oil
level is less than 1/2, add oil to the lubricator bowl.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Personal injury can result from removing hoses or
Dispose of all fluids according to local regulations and fittings in a pressure system.
mandates.
Failure to relieve pressure can cause personal in-
jury.
3. Place a suitable container under bowl (2) and
open drain valve (3) in order to drain the oil from Do not disconnect or remove hoses or fittings un-
the bowl. til all pressure in the system has been relieved.
4. Remove bowl (2). Clean the bowl with warm water.
2. Ensure that the air supply to the lubricator is OFF.
Slowly loosen filler plug (4) in order to release
pressure from the lubricator bowl.
SEBU7563-09 69
Maintenance Section
Air Tank Moisture and Sediment - Drain

3. Remove filler plug (4). Pour oil into the lubricator 1. Open the drain valve that is on the bottom of the
bowl. Use nondetergent SAE 10W oil for air tank. Allow the moisture and sediment to drain.
temperatures that are greater than 0 °C (32 °F).
Use air tool oil for temperatures that are below 2. Close the drain valve.
0 °C (32 °F).
i02601719
4. Install filler plug (4).
Alternator - Inspect
Adjust the Lubricator
SMCS Code: 1405-040
Note: Adjust the lubricator with a constant rate of air
flow. After the adjustment, the lubricator will release Inspect the alternator for the following conditions:
oil in proportion to variations of the air flow.
• Proper connections
1. Ensure that the fuel supply to the engine is OFF.
• Clean ports for cooling airflow
NOTICE
Do not crank the engine continuously for more than • Proper charging of the battery
30 seconds. Allow the starting motor to cool for two
Observe battery voltage on the Advisor panel or
minutes before cranking the engine again.
Cat ET during engine operation to evaluate the
performance of the alternator.
2. Operate the air starting motor. Observe the drops
of oil that are released in dome (1). Make repairs, if necessary. See the Service Manual
for service procedures. Consult your Caterpillar
Note: Some lubricators have an adjustment screw dealer for assistance.
rather than a knob.
i02601741
3. If necessary, adjust the lubricator in order
to release from one to three drops of oil per Barring Device - Lubricate
second. To increase the rate, turn knob (2)
counterclockwise. To decrease the rate, turn the SMCS Code: 1235-086
knob clockwise.
NOTICE
i00351324 Do not use an impact wrench to operate the barring
device. The use of an impact wrench will cause gear
Air Tank Moisture and tooth failure.
Sediment - Drain
SMCS Code: 1466-543-M&S
Guards must be in place prior to operating barring
Moisture and sediment in the air starting system can device motor.
cause the following conditions:
Remove all hand tools prior to operating barring
• Freezing device motor.
• Corrosion of internal parts
Note: Prelube of the engine is required before the
• Malfunction of the air starting system crankshaft is rotated for normal maintenance.

The barring device provides a means for slowly


turning the flywheel in order to service the engine.
When the barring device is in the engaged position,
When opening the drain valve, wear protective the engine starting system is disabled.
gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could When the barring device is not used, the barring
cause debris to be blown and result in personal device must be fully disengaged from the flywheel
injury. and secured in the disengaged position. Refer to the
Service Manual for information on operation of the
barring device.
70 SEBU7563-09
Maintenance Section
Barring Device - Lubricate

Lubricating the Reducer


NOTICE
Do not operate the engine starting motor until the bar-
ring group pinion gear is fully disengaged from the fly-
wheel ring gear. Serious damage to the engine could
result.

Electric Barring Device


Note: This type of barring device may be electrically
driven or manually driven.

g00991445
Illustration 50

1. Ensure that the barring device is locked in the


disengaged position.

2. Remove level plugs (2) and check the lubricant


level.

3. If necessary, remove cap (1) and add Caterpillar


4C-6767 Synthetic Oil until the oil is visible at the
level plugs.
g00334420
Illustration 48
Rear view of an electrically driven barring device 4. Reinstall the level plugs and reinstall the cap.

Lubricating the Pinion Manual Barring Device

g01098831 g01098833
Illustration 49 Illustration 51
Section view of a barring device without the electric motor (1) Grease fitting
(1) Grease fitting (2) Gear end
(2) Vent
1. Ensure that the barring device is locked in the
1. Ensure that the barring device is locked in the disengaged position.
disengaged position.
2. Lubricate grease fitting (1) with Cat Advanced
2. Lubricate grease fitting (1) with Cat Advanced 3Moly Grease until the grease is visible at gear
3Moly Grease until the grease is visible at vent (2). end (2).
SEBU7563-09 71
Maintenance Section
Battery Electrolyte Level - Check

i02601752 i02601764

Battery Electrolyte Level - Belts - Inspect/Adjust/Replace


Check SMCS Code: 1357-025; 1357-040; 1357-510
SMCS Code: 1401-535-FLV
Inspection
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries Inspect the alternator belt and the fan drive belts for
may not fully recharge. Ensure a full charge in order wear and for cracking. Replace the belts if the belts
to help prevent the battery from freezing. are not in good condition.

Check the belt tension according to the information in


the Service Manual, “Specifications”.
All lead-acid batteries contain sulfuric acid which Slippage of loose belts can reduce the efficiency
can burn the skin and clothing. Always wear a face of the driven components. Vibration of loose belts
shield and protective clothing when working on or can cause unnecessary wear on the following
near batteries. components:

1. Remove the filler caps. Maintain the electrolyte • Belts


level to the “FULL” mark on the battery.
• Pulleys
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean • Bearings
water that is low in minerals. Do not use artificially
softened water. If the belts are too tight, unnecessary stress is placed
on the components. This reduces the service life of
2. Check the condition of the electrolyte with the the components.
245-5829 Coolant Battery Tester Refractometer.
Adjusting the Alternator Belt
3. Keep the batteries clean.

Clean the battery case with one of the following


cleaning solutions:

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


1 L (1 qt) of clean water

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


(1 qt) of clean water

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean the


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

g01092641
Illustration 52
Typical alternator
(1) Mounting bolt
(2) Adjusting nuts
(3) Mounting bolt

1. Remove the drive belt guard.


72 SEBU7563-09
Maintenance Section
Combustion Sensor - Clean/Inspect/Replace

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


mounting bolt (3).

3. Turn adjusting nuts (2) in order to increase or


decrease the drive belt tension.

4. Tighten adjusting nuts (2). Tighten mounting bolt


(3). Tighten mounting bolt (1). For the proper
torque, see the Service Manual, “Specifications”
module.

5. Reinstall the drive belt guard.

If new drive belts are installed, check the drive belt


tension again after 30 minutes of engine operation at
the rated rpm.

Adjusting the Fan Drive Belt


Note: Do not overtighten the drive belts.
Overtightening can result in failure of the drive shaft.

Replacement
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
g00789241
drive belt to carry more load because the older drive Illustration 53
belts are stretched. The additional load on the new Section view of a cylinder head with a combustion sensor
drive belt could cause the new drive belt to fail. (1) Harness connector
(2) Connector
(3) Extension
i02601781 (4) Sensor
(5) Gasket
Combustion Sensor - (6) Discs

Clean/Inspect/Replace Note: Use of a platform may be necessary to reach


the combustion sensor.
SMCS Code: 1900; 1905
Note: Clean the connections and polish the
To provide a signal without interference to the engine
connections with a clean, dry cloth. Always install
control module, the sensor must be in good condition.
a new O-ring seal in connector (1) when the
The connections must be clean.
combustion sensor is serviced.

1. Disconnect harness connector (1) from connector


(2). Remove the O-ring seal from the harness
connector. Clean the end of the harness
connector. Install a new O-ring seal.

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


connector's adapters.

3. Remove extension (3). Clean both ends of the


extension.
SEBU7563-09 73
Maintenance Section
Combustion Sensor - Clean/Inspect/Replace

Light brown deposits or beige deposits around the


electrode is produced by normal operation. White
deposits or gray deposits may be caused by the
Pressurized air can cause personal injury. When
following substances:
pressurized air is used for cleaning, wear a pro-
tective face shield, protective clothing, and pro-
tective shoes. • Excessive oil
• Use of the wrong oil
Note: The maximum air pressure for cleaning
purposes must be below 207 kPa (30 psi). • A substance that is introduced through the fuel
system or the air system
4. The area around sensor (4) may have debris.
Thoroughly remove any debris. Use compressed A buildup of ash on the electrode reduces the
air. Ensure that the area around the sensor is efficiency of the sensor.
clean and free of debris.
8. Measure the resistance between terminal post (6)
5. Loosen sensor (4) with a 15.9 mm (5/8 inch) spark and electrode (10).
plug socket and an extension. After the sensor
has been loosened, remove the sensor by hand in The sensor must pass a low voltage check for
order to detect problems with the threads. continuity between the terminal post and the
electrode. The resistance must not exceed five
If the sensor resists removal by hand, apply ohms.
penetrating oil to the threads. Use the wrench
and apply steady pressure to the sensor until the 9. Thoroughly clean the sensor.
sensor is loose.
Clean the shell and the electrode that is inside of
the shell. Do not use a wire brush. Glass beads
are the preferred method for cleaning. Follow
these guidelines for the use of glass beads:

• Always use clean glass beads.


• Use care in order to clean only the electrode
Illustration 54
g00789274 and the insulator near the electrode.
Combustion sensor
(6) Terminal post
• Do not use glass beads on the outside of the
(7) Insulator
shell or on the upper part of the insulator.
(8) Shell
(9) Gasket Ensure that the sensor is clean and free of dirt
(10) Electrode and oil.

6. After the sensor is removed, discard gasket (9). Note: Do not use anti-seize compound on the sensor.
Most of the heat is transferred through the threads
7. Inspect the sensor closely for damage. and the seat area of the sensor. The surfaces must
be in contact in order to provide the heat transfer that
Terminal post (6) must not move. If the terminal is required.
post can be moved by hand, discard the sensor.
10. Place a new 108-3515 Plug Gasket on the
Inspect insulator (7) for cracks. If a crack is found, sensor. Install the sensor by hand until the sensor
discard the sensor. bottoms out. Tighten the sensor to 38 ± 2 N·m
(28 ± 2 lb ft).
Inspect shell (8) for damage. Cracks can
be caused by overtightening the sensor. 11. Install extension (3). Make sure that discs (5)
Overtightening can also loosen the shell. Discard are positioned in order to align the extension's
any sensor that has a shell that is cracked or connectors with sensor (4) and connector (2).
loose.
12. Make sure that the O-ring seal on connector (2) is
Inspect electrode (10) for excessive wear. in good condition. Install the connector.

13. Attach harness connector (1) to connector (2).


74 SEBU7563-09
Maintenance Section
Control Panel - Inspect

i01762721

Control Panel - Inspect


SMCS Code: 4490-040; 7451-040

Inspect the condition of the panel. If a component is


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

Inspect the wiring for good condition. Ensure that the


wiring connections are secure.

Record the Data and Review the Illustration 55


g00792409

Data Location of cooling system drain valves or drain plugs on the water
pumps
If equipped, check the gauges and check the (1) Jacket water pump
indicators frequently during normal operation. Record (2) Aftercooler and oil cooler pump
the data in a log. Compare the new data to the data
that was previously recorded. Comparing the new
data to the recorded data will establish the normal
gauge readings for the engine. A gauge reading that
is abnormal may indicate a problem with operation
or with the gauge.

i02601979

Cooling System Coolant


(NGEC) - Change
SMCS Code: 1350-044
g00901833
Clean the cooling system before the recommended Illustration 56
maintenance interval if the following conditions exist: Location of drain plug for the jacket water system

• The engine overheats frequently. 3. Open the cooling system drain valves (if
equipped). Remove the cooling system drain
• Foaming is observed. plugs. Allow the coolant to drain.

• The oil has entered the cooling system and the NOTICE
coolant is contaminated.
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
NOTICE coolant for reuse in engine cooling systems. The full
Use of commercially available cooling system clean- distillation procedure is the only method acceptable by
ers may cause damage to cooling system compo- Caterpillar to reclaim the used coolant.
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
Drain the Cooling System dealer or consult Caterpillar Dealer Service Tools
Group:
1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the Outside Illinois: 1-800-542-TOOL
cooling system is drained. Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
SEBU7563-09 75
Maintenance Section
Cooling System Coolant (NGEC) - Change

Clean the Cooling System 2. Close the cooling system drain valves (if
equipped). Clean the cooling system drain plugs
1. Flush the cooling system with clean water in order and install the cooling system drain plugs.
to remove any debris.
3. Fill the cooling system with a mixture of clean
2. Close the cooling system drain valves (if water and Caterpillar Fast Acting Cooling System
equipped). Clean the cooling system drain plugs Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
and install the cooling system drain plugs. (1 to 2 US gal) of the cooling system capacity.
Install the cooling system filler cap.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) 4. Start the engine. Operate the engine for a
per minute in order to avoid air locks. Proper venting minimum of 90 minutes with a coolant temperature
of the cooling system is essential to fill at this rate. of at least 82 °C (180 °F).

5. Stop the engine and allow the engine to cool.


3. Fill the cooling system with a mixture of clean Loosen the cooling system filler cap slowly in
water and Caterpillar Fast Acting Cooling System order to relieve any pressure. Remove the cooling
Cleaner. Add .5 L (1 pint) of cleaner per 15 L system filler cap. Open the cooling system drain
(4 US gal) of the cooling system capacity. Install valves (if equipped). Remove the cooling system
the cooling system filler cap. drain plugs. Allow the water to drain.

4. Start the engine. Operate the engine for a NOTICE


minimum of 30 minutes with a coolant temperature Improper or incomplete rinsing of the cooling system
of at least 82 °C (180 °F). can result in damage to copper and other metal com-
ponents.
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in To avoid damage to the cooling system, make sure
order to relieve any pressure. Remove the cooling to completely flush the cooling system with clear wa-
system filler cap. Open the cooling system drain ter. Continue to flush the system until all signs of the
valves (if equipped). Remove the cooling system cleaning agent are gone.
drain plugs. Allow the water to drain.

NOTICE 6. Flush the cooling system with clean water until


Improper or incomplete rinsing of the cooling system the water that drains is clean. Close the cooling
can result in damage to copper and other metal com- system drain valves (if equipped). Clean the
ponents. cooling system drain plugs and install the cooling
system drain plugs.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa- Fill the Cooling System
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
6. Flush the cooling system with clean water until per minute in order to avoid air locks. Proper venting
the water that drains is clean. Close the cooling of the cooling system is essential to fill at this rate.
system drain valves (if equipped). Clean the
cooling system drain plugs and install the cooling
Note: For information about the proper coolant to
system drain plugs.
use, and the capacity of the cooling system, see
this Operation and Maintenance Manual, “Refill
Cleaning a Cooling System that Capacities and Recommendations” (Maintenance
has Heavy Deposits or Plugging Section).

Note: For the following procedure to be effective, 1. Fill the cooling system with coolant/antifreeze. Do
there must be an active flow through the cooling not install the cooling system filler cap.
system components.
2. Start the engine. Operate the engine in order to
1. Flush the cooling system with clean water in order purge the air from the cavities of the engine block.
to remove any debris. Allow the coolant to warm and allow the coolant
level to stabilize. Stop the engine.
76 SEBU7563-09
Maintenance Section
Cooling System Coolant Level - Check

3. Check the coolant level. Maintain the coolant to If the engine is equipped with a sight gauge, observe
the proper level on the sight gauge (if equipped). the position of the coolant in the sight gauge. At
If a sight gauge is not equipped, maintain the normal operating temperature, the proper coolant
coolant to the level that is specified by the OEM level is in the upper half of the sight gauge. If the
of the cooling system. coolant level is low, add the proper coolant mixture.

4. Clean the cooling system filler cap. Inspect Engines That Are Not Equipped
the gaskets of the cooling system filler cap. If
the gaskets of the cooling system filler cap are With a Sight Gauge
damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the
gaskets of the cooling system filler cap are not
damaged, use a 9S-8140 Pressurizing Pump in
order to pressure test the cooling system filler cap. Pressurized System: Hot coolant can cause seri-
The correct pressure is stamped on the face of ous burns. To open the cooling system filler cap,
the cooling system filler cap. If the cooling system stop the engine and wait until the cooling system
filler cap does not retain the correct pressure, components are cool. Loosen the cooling system
install a new cooling system filler cap. pressure cap slowly in order to relieve the pres-
sure.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature. Check the coolant level when the engine is stopped
and cool. Check the coolant level only after the
engine has been stopped and the cooling system
i02062976
filler cap is cool enough to touch with your bare hand.
Cooling System Coolant Level
Remove the cooling system filler cap slowly in order
- Check to relieve any pressure. Maintain the coolant within
13 mm (0.5 inch) below the bottom of the filler pipe.
SMCS Code: 1350-535-FLV
Add Coolant
Note: For the proper coolant mixture to use, see
Climbing equipment may be required to access this Operation and Maintenance Manual, “Refill
this service point. Refer to the Operation and Capacities and Recommendations” (Maintenance
Maintenance Manual, “Mounting and Dismount- Section).
ing” topic for safety information.
1. Stop the engine. Allow the engine to cool.
Engines That Are Equipped With a 2. Remove the cooling system filler cap slowly in
Sight Gauge order to relieve any pressure. Pour the proper
coolant mixture into the filler pipe.

g00750429
Illustration 57 g00103639
Illustration 58
(1) Filler cap
(2) Sight gauge Gaskets
SEBU7563-09 77
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

3. Clean the cooling system filler cap. Inspect the • In order to avoid contamination, immediately place
gaskets of the cooling system filler cap. If the the sample in the tube that is provided for mailing.
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler Submit the sample for Level 1 analysis.
cap. Install the cooling system filler cap.
Note: Level 1 results may indicate a need for
4. Start the engine. Inspect the cooling system for Level 2 Analysis.
leaks.
For additional information about coolant analysis,
see the Special Publication, SEBU6400, “Caterpillar
i02064894
Gas Engine Lubricant, Fuel and Coolant
Cooling System Coolant Recommendations” or consult your Caterpillar dealer.

Sample (Level 1) - Obtain


i02168823

SMCS Code: 1350-008; 1395-008; 1395-554; 7542


Cooling System Coolant
NOTICE Sample (Level 2) - Obtain
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling. SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This NOTICE
contaminate may cause a false analysis and an incor- Always use a designated pump for oil sampling, and
rect interpretation that could lead to concerns by both use a separate designated pump for coolant sampling.
dealers and customers. Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
For conventional heavy-duty coolant/antifreeze, contaminate may cause a false analysis and an incor-
check the concentration of supplemental coolant rect interpretation that could lead to concerns by both
additive (SCA) regularly. The concentration of SCA dealers and customers.
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. Supplies
Obtain the sample of the coolant as close as possible for collecting samples can be obtained from your
to the recommended sampling interval. In order Caterpillar dealer.
to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order Refer to this Operation and Maintenance Manual,
to establish a pertinent history of data, perform “Cooling System Coolant Sample (Level 1) - Obtain”
consistent samplings that are evenly spaced. (Maintenance Section) for the guidelines for proper
Supplies for collecting samples can be obtained from sampling of the coolant.
your Caterpillar dealer.
Submit the sample for Level 2 analysis.
Use the following guidelines for proper sampling of
the coolant: For additional information about coolant analysis,
see the Special Publication, SEBU6400, “Caterpillar
• Never collect samples from expansion bottles. Gas Engine Lubricant, Fuel, and Coolant
Recommendations” or consult your Caterpillar dealer.
• Never collect samples from the drain for a system.
i01519993
• Keep the unused sampling bottles stored in plastic
bags. Cooling System Level Switch
• Keep the lids on empty sampling bottles until you - Inspect
are ready to collect the sample.
SMCS Code: 7422-040
• Complete the information on the label for the
sampling bottle before you begin to take the The low coolant level switch actuates an alarm or a
samples. shutoff if the coolant level is low. A low coolant level
could cause the engine to overheat. This could result
• Obtain coolant samples directly from the coolant in damage to the engine.
sample port. You should not obtain the samples
from any other location.
78 SEBU7563-09
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

If the coolant level is low, coolant must be added to Note: Caterpillar recommends an S·O·S coolant
the expansion tank or the heat exchanger. analysis (Level 1).

Test the Concentration of the SCA


Coolant/Antifreeze and SCA

NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.

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


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

Illustration 59
g00789360 Water and SCA
(1) Switch
(2) Lines NOTICE
Do not exceed the recommended eight percent sup-
For proper operation of the switch, the lines and the plemental coolant additive concentration.
switch must be clean.

1. Drain the coolant to a level below lower line (2). Test the concentration of the SCA with the 8T-5296
Drain the coolant into a clean container so that the Coolant Conditioner Test Kit. Use the instructions
coolant can be reused. that follow:

2. Remove switch (1). Inspect the openings of the 1. Fill the syringe to the “1.0 ml” mark with the
inlet and the outlet for plugging. If an opening is coolant.
plugged, clean the switch.
2. Dispense the 1.0 mL coolant sample from the
3. Inspect lines (2) for plugging. Clean the lines, if syringe into the empty mixing bottle.
necessary. Pressure air or a flexible wire can be
used to clean the lines. 3. Add tap water to the mixing bottle in order to bring
the level up to the “10 ml” mark. Place the cap on
4. Install switch (1). the bottle and shake the bottle.

5. Pour the coolant into the cooling system. Verify 4. Add 2 to 3 drops of the “NITRITE INDICATOR
that the low coolant level switch is operating SOLUTION B” to the mixing bottle. Move the bottle
properly. A switch that is operating properly will in a circular motion in order to mix the solution.
activate an alarm until a sufficient amount of
coolant is added. 5. Add 1 drop of “NITRITE TEST SOLUTION A” to
the mixing bottle. Move the bottle in a circular
motion in order to mix the solution.
i02017557
6. Repeat 5 until the solution changes color from red
Cooling System Supplemental to light gray, green, or blue. Record the number of
Coolant Additive (SCA) - drops of “NITRITE TEST SOLUTION A” that were
required to cause the color change.
Test/Add
7. Use Table 36 to interpret the results.
SMCS Code: 1352-045; 1395-081

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.
SEBU7563-09 79
Maintenance Section
Cooling System Water Temperature Regulator - Replace

Table 36 4. Clean the cooling system filler cap. Install the


Number of Concentration Maintenance
cooling system filler cap.
Drops of SCA Required
Less than 25 Less than the Add SCA. i02168842
recommended Retest the
concentration of coolant. Cooling System Water
SCA Temperature Regulator -
25 to 30 The
recommended
None
Replace
concentration of
SCA SMCS Code: 1355-510
More than 30 More than the Remove the Replace the water temperature regulators for these
recommended coolant. systems:
concentration of Replace with
SCA water only
Retest the • Jacket water
coolant.
• Oil cooler
Add the SCA, If Necessary • Aftercooler
Replace the water temperature regulators before
the water temperature regulators fail. This is a
recommended preventive maintenance practice.
Pressurized System: Hot coolant can cause seri- Replacing the water temperature regulators reduces
ous burns. To open the cooling system filler cap, the chances for unscheduled downtime.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system A water temperature regulator that fails in a
pressure cap slowly in order to relieve the pres- partially opened position can cause overheating or
sure. overcooling of the engine.

A water temperature regulator that fails in the closed


1. Remove the cooling system filler cap slowly.
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
Note: Always dispose of fluids according to local
head or a seizure of the pistons.
regulations.
A water temperature regulator that fails in the open
2. If necessary, drain some coolant in order to allow
position will cause the engine operating temperature
space for the addition of the SCA.
to be too low during partial load operation. Low
engine operating temperatures during partial loads
NOTICE could cause an excessive carbon buildup inside the
Excessive supplemental coolant additive concentra- cylinders. This excessive carbon buildup could result
tion can form deposits on the higher temperature sur- in an accelerated wear of the piston rings and wear
faces of the cooling system, reducing the engine's of the cylinder liner. Also, a low temperature can
heat transfer characteristics. Reduced heat transfer allow moisture to condense in the oil. This can form
could cause cracking of the cylinder head and other damaging acids.
high temperature components.
NOTICE
Excessive supplemental coolant additive concentra-
Failure to replace the water temperature regulator on
tion could also result in blockage of the heat exchang-
a regularly scheduled basis could cause severe en-
er, overheating, and/or accelerated wear of the water
gine damage.
pump seal.
Never operate an engine without the water tempera-
Do not exceed the recommended amount of supple-
ture regulator installed.
mental coolant additive concentration.
If the water temperature regulator is installed incor-
3. Add the proper amount of SCA. The concentration rectly, the engine may overheat, causing cylinder head
of the SCA depends on the type of coolant that damage. Ensure that the new water temperature reg-
is used. To determine the proper amount, see ulator is installed in the original position.
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” topic.
80 SEBU7563-09
Maintenance Section
Crankcase Blowby - Measure/Record

Note: If only the water temperature regulators are Excessive crankcase blowby may indicate the need
replaced, drain the coolant from the cooling system to for an overhaul. By keeping a record of the results,
a level that is below the water temperature regulator a gradual increase in the amount of the crankcase
housing. blowby will be noted until the amount of crankcase
blowby has become excessive.
i02602965
Use the 1U-8860 Large Engine Blowby Pickup
Crankcase Blowby - Group to measure the blowby. Refer to Special
Instruction, SEHS8984, “1U-8860 Large Engine
Measure/Record Blowby Pickup Group” that is provided with the tool.

SMCS Code: 1317 Record the crankcase blowby for the engine. Keep a
record of the results.
Note: The typical crankcase blowby on a new engine
is approximately 0.02 m3/bkW h (.50 ft3/bhp h). For more information, see the Service Manual,
“Systems Operation/Testing and Adjusting”. For
Measure the crankcase blowby of new engines. assistance, consult your Caterpillar dealer.
Record the data. Continue to periodically measure
the crankcase blowby. Comparing the recorded
data to the new data provides information about the i02062446

condition of the engine. Crankshaft Vibration Damper


Note: Crankcase blowby is one of the three factors - Inspect
that help to determine the in-frame overhaul interval.
For more information, see the Operation and SMCS Code: 1205-040
Maintenance manual, “Overhaul (In-Frame)” topic in
the Maintenance Section. The crankshaft vibration damper limits the torsional
vibration of the crankshaft. The visconic damper has
After a new engine is used for a short time, the a weight that is located inside a fluid filled case.
crankcase blowby can decrease as the piston rings
are seated. The crankcase blowby will gradually Damage to the crankshaft vibration damper or failure
increase as the following components show wear: of the damper can increase torsional vibrations. This
can result in damage to the crankshaft and to other
• piston rings engine components. A deteriorating damper can
cause excessive gear train noise at variable points
• cylinder liners in the speed range.

Note: A problem with the piston rings causes the A damper that is hot is due to excessive torsional
oil to deteriorate rapidly. Information regarding the vibration. Monitor the temperature of the damper
condition of the piston rings can be obtained from during operation.
the measurement of the crankcase blowby and the
results of oil analysis. The 8T-2821 Temperature Indicator or the 8T-2822
Temperature Indicator are recommended for
The crankcase blowby of a worn engine may exceed monitoring the temperature of the damper. Evenly
the crankcase blowby of a new engine by two times space four of the adhesive indicators around the
or more. outer diameter of the damper.

A sudden increase in crankcase blowby could Note: If you use an infrared thermometer to monitor
indicate a broken piston ring. The following conditions the temperature of the damper, use the thermometer
are other potential sources of crankcase blowby: during operation with similar loads and speeds. Keep
a record of the data. If the temperature begins to rise,
• Worn valve guides reduce the interval for inspecting the damper. It is
important to regularly monitor the temperature of the
• A turbocharger seal that leaks damper. It is important to document the temperature
of the damper when it increases and decreases. This
A rebuilt engine can have a high crankcase blowby will verify that damper service is necessary.
due to the following factors:
If the temperature of the damper reaches 110 °C
• The piston rings are not seated properly. (230 °F), consult your Caterpillar dealer.

• Worn parts such as valve guides were not replaced. Inspect the damper for evidence of dents, cracks,
and leaks of the fluid.
SEBU7563-09 81
Maintenance Section
Cylinder Pressure - Measure/Record

If a fluid leak is found, determine the type of fluid. • Minimize the cranking time. This will enable a
The fluid in the damper is silicone. Silicone has maximum consistent cranking speed for the check.
the following characteristics: transparent, viscous, Also, the starting air or battery power will be
smooth, and sticky. If leaking silicone is found, repair conserved.
the damper or replace the damper.
A loss of cylinder pressure or a change of pressure
If the fluid leak is oil, inspect the crankshaft seal for in one or more cylinders may indicate the following
leaks. If a leak is observed, replace the seal. conditions. These conditions may indicate a problem
with lubrication:
Inspect the damper and repair or replace the damper
for any of the following reasons. • Excessive deposits
• The damper is dented, cracked, or leaking. • Guttering of valves
• The paint on the damper is discolored from heat. • A broken valve
• The engine has had a failure because of a broken • A piston ring that sticks
crankshaft.
• A broken piston ring
• An analysis of the oil has revealed that the front
bearing of the crankshaft is badly worn. • Worn piston rings
• There is a large amount of gear train wear that is • Worn cylinder liners
not caused by a lack of oil.
If the cylinder pressure has risen by one or more
compression ratios, the engine needs a top end
Removal and Installation overhaul in order to remove deposits. Failure to
Refer to the Service Manual, “Disassembly and remove the deposits will increase the chance for
detonation. Severe guttering of the valves will occur.
Assembly” or consult your Caterpillar dealer for
information about damper replacement.
To measure the cylinder pressure, refer to Special
Instruction, GMG00694, “Analyzing Cylinder
i02602007 Condition By Measuring Air Flow”. Also, use the
146-2739 Cylinder Pressure Adapter.
Cylinder Pressure -
Measure/Record Illustration 60 is a graph of typical cylinder pressures
for engines with different compression ratios.
SMCS Code: 1223-082-CC; 1223; 7450-082

Measure the cylinder pressure of new engines.


Record the data. Continue to periodically measure
the cylinder pressure. Comparing the recorded data
to the new data provides information about the
condition of the engine.

Note: Cylinder pressure is one of the three factors


that help to determine the in-frame overhaul interval.
For more information, refer to this Operation
and Maintenance manual, “Overhaul (In-Frame)”
(Maintenance Section).

Cylinder pressure can be measured during inspection


of the spark plugs. Use the following guidelines for
checking the cylinder pressure:

• Remove all of the spark plugs.


• Verify that the choke is fully open.
82 SEBU7563-09
Maintenance Section
Cylinders - Inspect

When possible, insert the borescope through the


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

• Valve wear
• Deposits on the valve seat
• Deposits on the valve face
• Polishing of the cylinder walls
• Scratching of the cylinder walls
• Deposits on the cylinder walls that are above the
Illustration 60
g00789376 upper limit of the piston stroke
(Y) Cylinder pressure in kPa (psi)
(X) Compression ratio Deposits that are on the valve face and the valve
(1) Normal range for cylinder pressure seat can cause guttering of the valve. Inspect the
valve seat and the valve face for excessive deposits.
Record the pressure for each cylinder. Use Operation If excessive deposits are found, replace the valve
and Maintenance Manual, “Valve Data Sheet” and the valve seat.
(Reference Materials Section).
Determine whether the exhaust valve face has
erosion from pitting. This requires the exhaust valve
i01765658 to be in the open position. To obtain as much detail
Cylinders - Inspect as possible, obtain a close up view of the valve
face. Erosion of the exhaust valve face can lead
(Inspect the Combustion to guttering of the valve. If erosion is found on the
exhaust valve face, recondition the cylinder head as
Chamber) soon as possible.
SMCS Code: 1223-040; 1223
Note: Operation at loads that are less than 50 percent
of the rated load can result in an excessive buildup
Excessive deposits can accumulate in the combustion
of carbon deposits in the combustion chamber.
chambers of engines that use gas with a low BTU
The deposits can lead to detonation and premature
such as bio-gas fuel, landfill gas, etc. The deposits
ignition. This condition is more obvious at certain
can affect the characteristics of combustion. Erratic
engine speeds and loads.
operation can result. The rate of recession of the
exhaust valves can increase. The risk of guttering of
the exhaust valves can increase. i02602013

Note: Use of a platform may be necessary to inspect Driven Equipment - Check


the combustion chamber.
SMCS Code: 3279-535
Use a borescope to inspect the combustion chamber.
The inspection will provide information about the Every 5000 Service Hours
internal condition of the engine.

A borescope with a lens that can be rotated is Engines That Are Not Attached To the
recommended. This type of borescope provides a Base with a Dowel
clear view of the combustion chamber and of the
bottom deck of the cylinder head. Photographic If some engines are too rigidly mounted, excessive
documentation or video documentation is also stress may affect the internal support of the cylinder
recommended. Consult your Caterpillar dealer for block. This could cause the following problems:
information on available borescopes.
SEBU7563-09 83
Maintenance Section
Driven Equipment - Inspect/Replace/Lubricate

• Distortion of the bores of the main bearing • Unusual noise and vibration
• Distortion of the alignment of the bore • Loose connections
Severe damage to the engine could result. The • Damaged parts
service life of the engine could be severely reduced.
Perform any maintenance that is recommended
For engines that are not attached to the base with a by the OEM of the driven equipment. Refer to the
dowel, check the following: literature of the OEM of the driven equipment for the
following service instructions.
• Check the alignment after every 5000 service
hours. • Inspection
• Inspect the drive coupling according to the • Lubricating grease and lubricating oil requirements
specifications of the OEM.
• Specifications for adjustment
Every 10,000 Service Hours
• Replacement of components
Engines That Are Attached To the Base • Requirements for ventilation
with a Dowel
i01610487
Some engines must be more rigidly mounted. Due to
thermal expansion, a cold engine will expand after
the engine achieves operating temperature.
Electrohydraulic Actuator -
Inspect
Some engines are attached to the base with a dowel
in the rear mounting support. This installation forces SMCS Code: 1716-040
the thermal growth forward. The driven equipment
is also attached with a dowel in order to maintain Inspect the actuators for the fuel control, the
alignment with the engine. wastegate, and the air choke.

For this type of installation, check the alignment after


every 10,000 service hours.
During operation, the linkage of the electrohy-
Check the Alignment draulic actuators can form pinch points which
can cause personal injury. Shut down the engine
The alignment between the engine and the driven before you service the electrohydraulic actuators.
equipment must be maintained properly. Improper
alignment will cause damage to the engine, the
coupling, and the driven equipment.

Check the alignment according to the instructions


that are provided by the following manufacturers:

• Caterpillar
• OEM of the coupling
• OEM of the driven equipment

i00935098

Driven Equipment - Illustration 61


g00833473

Inspect/Replace/Lubricate (1)
(2)
Receptacle for the wiring harness
Solenoid
(3) Bolt
SMCS Code: 3279-040 (4) Guards

Observe the driven equipment during operation. Look


for the following items:
84 SEBU7563-09
Maintenance Section
Electrohydraulic Actuator - Recondition

1. Disconnect the wiring harness from receptacle (1). 10. Install guards (4).
Inspect the connectors for damage and corrosion.
Make repairs, if necessary. 11. Connect the wiring harness to receptacle (1).

2. Inspect the joint between solenoid (2) and the


i01610640
housing for leaks.

If a leak is found between the solenoid and the


Electrohydraulic Actuator -
housing, replace the O-ring seal for the solenoid. Recondition
For instructions, refer to this Operation and
Maintenance Manual, “Electrohydraulic Actuator - SMCS Code: 1716-020
Recondition”.
Recondition the actuators for the fuel control, the
3. Check the solenoid's mounting bolts (3) for wastegate, and the air choke. The main components
tightness. of each actuator include the housing, a piston
assembly, and a solenoid which actuates the piston.
4. Remove guards (4). The piston assembly and the solenoid can be
serviced separately.

Note: New parts or remanufactured parts may be


used for reconditioning the actuators.

During operation, the linkage of the electrohy-


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

g00833477
Illustration 62
(5) Rod end
(6) Clevis
(7) Boot

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

6. Remove clevis (6).

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


damage. If the boot is damaged, obtain a new
boot for assembly.
g00833592
Illustration 63
There may be a small amount of hydraulic fluid (1) Receptacle for the wiring harness
inside of the boot. Wipe off the boot and reinstall (2) Guards
the boot.
1. Disconnect the wiring harness from receptacle (1).
If an excessive amount of hydraulic fluid is found Inspect the connectors for damage and corrosion.
inside the boot, the seal for the actuator's shaft Make repairs, if necessary.
is probably worn. If this is the case, replace
the piston assembly. For instructions, refer 2. Remove guards (2).
to this Operation and Maintenance Manual,
“Electrohydraulic Actuator - Recondition”. 3. Disconnect the supply line (not shown) and the
return line (not shown) for the hydraulic oil.
8. Install boot (7). Make sure that the outer end of
the boot folds inward when the actuator's shaft
moves from the fully open position to the fully
closed position.

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


SEBU7563-09 85
Maintenance Section
Electrohydraulic System - Check/Adjust

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


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

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


assembly.

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


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

g00833594
9. Remove bolts (10) in order to remove solenoid
Illustration 64 (11). Remove O-ring seal (12) from the joint
(3) Rod end between the solenoid and the housing.
(4) Clevis
(5) Boot
(6) Nut 10. Install a new O-ring seal (12) and solenoid (11).
Install bolts (10). Tighten the bolts according to
4. Disconnect rod end (3) from clevis (4). the engine's Specifications.

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

6. Remove nut (6) in order to remove the actuator 14. Install guards (2).
from the bracket.
15. Connect the supply line and the return line for the
Note: Do not allow debris to enter the actuator. Seal hydraulic oil.
the openings with clean covers immediately after the
solenoid and/or the piston assembly is removed. 16. Connect the wiring harness to receptacle (1).

i01525261

Electrohydraulic System -
Check/Adjust
SMCS Code: 1716-025; 1716-535

Check the Pressure Relief Valve


Check the pressure relief valve for the hydraulic
system according to the procedure that is in Systems
Operation/Testing and Adjusting. Adjust the pressure
according to the instructions.
g00833595
Illustration 65
(7) Housing
(8) Piston assembly
(9) O-ring seal
(10) Bolt
(11) Solenoid
(12) O-ring seal

Note: The spring in the housing will be loose after


the piston assembly is removed.
86 SEBU7563-09
Maintenance Section
Electrohydraulic System - Inspect

i02214104 Inspect the hoses and lines for wear and leaks.
Ensure that the hoses and lines are properly
Electrohydraulic System - clamped. Inspect the connections for leaks. Ensure
Inspect that the connections are secure.

SMCS Code: 1716-040 Inspect the following items for leaks and good
condition:
Inspect the conditions of these items for the
electrohydraulic system: • Actuators

• Oil level • Pressure relief valve

• Hoses, lines, connections, and components • Pump


Make repairs, if necessary.

i02603161

Electrohydraulic System Oil -


Change
SMCS Code: 1716-510-OC

Ensure that the engine cannot start during this


procedure.

g00792283
Illustration 66
(1) Sight gauge
(2) Hose
(3) Line

Check the Oil Level


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

The oil should be between the “ADD” and “FULL”


marks on the tank.

Note: For the proper oil to use, refer to this Operation Illustration 67
g00792335
and Maintenance Manual, “Refill Capacities and
(1) Oil filler cap
Recommendatons” topic (Maintenance Section). (2) Valve

2. If necessary, remove the oil filler cap. Pour the 1. Remove oil filler cap (1).
correct oil into the oil filler.
Note: Drain the oil into a suitable container. Dispose
3. Clean the oil filler cap. Install the oil filler cap. of fluids according to local regulations.

Inspect the Lines, Connections, 2. Place a suitable container under valve (2). Open
the valve. Allow the oil to drain. After the oil has
and Components drained, close the valve.

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


Publication, SEBU6400, “Caterpillar Gas Engine
The linkage can move and form a pinch point Lubricant, Fuel and Coolant Recommendations” .
which can cause personal injury. Keep hands
away from the linkage. 3. Pour the proper oil into the oil filler. Clean the oil
filler cap. Install the oil filler cap.

4. Clean up any oil that may have spilled.


SEBU7563-09 87
Maintenance Section
Electrohydraulic System Oil Filter - Change

i02246458 5. Start the engine. Check the oil level in sight gauge
(2). The oil should be between the “ADD” and
Electrohydraulic System Oil “FULL” marks on the tank. If necessary, remove
Filter - Change oil filler cap (4). Pour the correct oil into the oil
filler. Clean the oil filler cap. Install the oil filler cap.
SMCS Code: 1716-510-FI
i02169249

Engine Air Cleaner


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

NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
Illustration 68
g00792302 engine causes premature wear and damage to engine
(1) Filter
components. Air cleaner elements help to prevent air-
(2) Sight gauge borne debris from entering the air inlet.
(3) Filler cap

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


Never service the air cleaner element with the engine
2. Clean the sealing surface of the filter mounting running since this will allow dirt to enter the engine.
base. Ensure that all of the old filter gasket is
removed.
Servicing the Air Cleaner Elements
Note: Use of a platform may be necessary to reach
the air cleaner element.

If the air cleaner element becomes plugged, the air


can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
wear. Your Caterpillar dealer has the proper air
cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily for


accumulation of dirt and debris. Remove any dirt
and debris, as needed.
g00103713
Illustration 69
Typical filter mounting base and gasket • Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner
Note: For the proper oil to use, refer to this Operation element.
and Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section). • The air cleaner element may be cleaned up to
six times if the element is properly cleaned and
3. Apply clean hydraulic oil to the new filter gasket. inspected.

4. Install the filter by hand. Tighten the filter until the • The air cleaner element should be replaced at least
gasket contacts the mounting base. Tighten the one time per year. This replacement should be
filter according to the instructions that are shown performed regardless of the number of cleanings.
on the filter. Do not overtighten the filter.
88 SEBU7563-09
Maintenance Section
Engine Air Cleaner Element (Single Element) - Clean/Replace

Replace the dirty paper air cleaner elements with Use clean air cleaner elements while dirty elements
clean air cleaner elements. Before installation, the are being cleaned.
air cleaner elements should be thoroughly checked
for tears and/or holes in the filter material. Inspect NOTICE
the gasket or the seal of the air cleaner element for Do not clean the air cleaner elements by bumping or
damage. Maintain a supply of suitable air cleaner tapping. This could damage the seals. Do not use el-
elements for replacement purposes. ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
1. Remove the air cleaner cover. Remove the air damage could result.
cleaner element.

Note: Refer to “Cleaning the Air Cleaner Elements”. Visually inspect the air cleaner elements before
cleaning. Inspect the air cleaner elements for damage
2. Cover the air inlet with tape in order to keep dirt to the seal, the gaskets, and the outer cover. Discard
out. any damaged air cleaner elements.

3. Clean the inside of the air cleaner cover and body There are two common methods that are used to
with a clean, dry cloth. clean air cleaner elements:

4. Remove the tape for the air inlet. Install an air • Pressurized air
cleaner element that is new or cleaned.
• Vacuum cleaning
5. Install the air cleaner cover.
Pressurized Air
6. Reset the air cleaner service indicator.
Pressurized air can be used to clean air cleaner
Cleaning the Air Cleaner Elements elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
NOTICE pressure of 207 kPa (30 psi).
Caterpillar recommends certified air filter cleaning ser-
vices that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt to


clean the filter element:

Do not tap or strike the filter element in order to re-


move dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove


the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the Illustration 70
g00281692
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage Note: When the air cleaner elements are cleaned,
to the pleats. always begin with the clean side (inside) in order to
force dirt particles toward the dirty side (outside).
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to Aim the hose so that the air flows inside the element
engine components. along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
The air cleaner element can be used up to six times if of air directly at the air cleaner element. Dirt could be
the element is properly cleaned and inspected. When forced further into the pleats.
the air cleaner element is cleaned, check for rips or
tears in the filter material. The air cleaner element Note: Refer to “Inspecting the Air Cleaner Elements”.
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.
SEBU7563-09 89
Maintenance Section
Engine Air Cleaner Element (Single Element) - Clean/Replace

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

Note: Refer to “Inspecting the Air Cleaner Elements”.

Inspecting the Air Cleaner Elements

g00281694
Illustration 72

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


protective covering for storage. An airflow restriction
may result. To protect against dirt and damage,
wrap the air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.

Place the air cleaner element into a box for storage.


For identification, mark the outside of the box and
mark the air cleaner element. Include the following
information:
g00281693
Illustration 71
• Date of cleaning
Inspect the clean, dry air cleaner element. Use a 60
watt blue light in a dark room or in a similar facility. • Number of cleanings
Place the blue light in the air cleaner element. Rotate Store the box in a dry location.
the air cleaner element. Inspect the air cleaner
element for tears and/or holes. Inspect the air cleaner
element for light that may show through the filter Crankcase Air Cleaner
material. If it is necessary in order to confirm the
result, compare the air cleaner element to a new air Engines that are equipped with positive crankcase
cleaner element that has the same part number. ventilation have an air cleaner for crankcase
ventilation. Clean the air cleaner element or replace
Do not use an air cleaner element that has any tears the air cleaner element when the following conditions
and/or holes in the filter material. Do not use an air occur:
cleaner element with damaged pleats, gaskets or
seals. Discard damaged air cleaner elements. • The yellow diaphragm enters the red zone.

Storing Air Cleaner Elements • The red piston locks in a visible position.

If an air cleaner element that passes inspection will • The air restriction reaches 0.25 kPa (1 inch of H2O).
not be used, the air cleaner element can be stored
for future use.
90 SEBU7563-09
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

g00294189 g00789538
Illustration 73 Illustration 74
(1) Service indicator Service indicator
(2) Cover
Observe the service indicator. Clean the air cleaner
1. Remove cover (2). element or replace the air cleaner element when one
of the following conditions occur:
2. Remove the used element and dispose of the
element. • The yellow diaphragm enters the red zone.
3. Clean the inside of cover (2) and clean the inside • The red piston locks in the visible position.
of the body.
• The air filter restriction reaches .25 kPa
4. Install a new element. Install cover (2). (1 inch of H2O).

5. Reset service indicator (1), if necessary. Inspect the service indicator daily for cracks, holes, or
loose fittings. If any of these conditions are present,
repair the service indicator or replace the service
i01520297
indicator.
Engine Air Cleaner Service
Indicator - Inspect Test the Service Indicator
SMCS Code: 7452-040 Service indicators are important instruments.

Some engines are equipped with an air cleaner for • Check for ease of resetting. The service indicator
crankcase ventilation. should reset in less than three pushes.

This air cleaner filters air that is drawn into the • Check the movement of the yellow core when the
crankcase. The air dilutes the harmful fumes that engine is accelerated to the engine rated rpm.
may accumulate in the crankcase. The air and the The yellow core should latch approximately at the
fumes are drawn away from the crankcase. greatest vacuum that is attained.

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


yellow core does not latch at the greatest vacuum,
replace the service indicator. If the new service
indicator will not reset, the fitting for the service
indicator may be plugged.
SEBU7563-09 91
Maintenance Section
Engine Air Precleaner - Clean

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

2. Clean the inside of the cup.

3. Install the cup. Fasten the clips.

i01765695

Engine Crankcase Breather -


Clean
SMCS Code: 1317-070

g00351792
If the crankcase breather is not maintained on a
Illustration 75 regular basis, the crankcase breather will become
Porous filter plugged. A plugged crankcase breather will cause
excessive crankcase pressure that can shut down
A porous filter is part of a fitting that is used for the engine. Leakage of the crankshaft seal can occur.
mounting of the service indicator. Inspect the filter
for cleanliness. Clean the filter, if necessary. Use Note: Use of a platform may be necessary to reach
compressed air or a clean, nonflammable solvent. the engine crankcase breather.

The service indicator may need to be replaced Perform this maintenance when the engine is
frequently in environments that are severely dusty. stopped.
Replace the service indicator annually regardless
of the operating conditions. Replace the service
indicator when the engine is overhauled, and
whenever major engine components are replaced.

Note: When a new service indicator is installed,


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

i00935352

Engine Air Precleaner - Clean


SMCS Code: 1055-070 g00789623
Illustration 77
Note: More frequent cleaning may be required in (1) Breather assembly
(2) Tee
dusty environments. (3) Hose clamp
(4) O-ring seal
(5) Retaining clamp

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


(3). Remove breather assemblies (1) and O-ring
seals (4).

2. Wash the breather elements in clean


nonflammable solvent. Inspect tee (2) for cracks
that can be caused by vibration. Replace the old
tee with a new tee if cracking is found.

3. Install new O-ring seals (4).

g00476231
Illustration 76
(1) Clip
(2) Cup
92 SEBU7563-09
Maintenance Section
Engine Mounts - Check

4. Allow the breather elements to dry before Engines That Use Bio-Gas
installation. Install the breather assemblies in the
original position. Coat the rubber parts with clean The oil change interval is determined by the results
engine oil or petroleum jelly in order to make of oil analysis. Change the lubrication oil when oil
installation easier. Tighten the retaining clamps analysis determines that the oil has reached the
and the hose clamps according to the engine's condemning limit. Also, change the engine oil filters.
Specifications manual.
Change the Engine Oil
i01612978

Engine Mounts - Check


SMCS Code: 1152-535 Hot oil and components can cause personal in-
jury.
Check the torque of the bolts for the mounting
plates. For the proper torque, refer to Gas Engines Do not allow hot oil or components to contact
Application and Installation Guide, LEKQ7252, skin.
“G3600 Mounting, Alignment”.
NOTICE
Engine vibration can be caused by the following
Ensure that the engine is stopped before performing
conditions:
this procedure. Attach a DO NOT OPERATE tag to the
starting controls.
• Improper mounting of the engine
• Deterioration of the isolators Do not drain the oil when the engine is cold. As the
oil cools, suspended waste particles settle on the
Settling of the isolators will result in misalignment bottom of the oil pan. The waste particles are not
between the engine and the driven equipment. removed when the cold oil is drained. Drain the
Inspect the condition of isolators, if necessary. Keep crankcase with the oil warm. This draining method
the isolators clean and dry. Ensure that the isolators allows the waste particles that are suspended in the
are free of oil and contamination. Inspect the isolators oil to be drained properly.
for deterioration.
Failure to follow this recommended procedure will
Replace any isolator that shows deterioration. allow the waste particles to be recirculated through
For more information, refer to the literature that is the engine lubrication system with the new oil.
provided by the OEM of the isolators. Also refer to
the following publications: 1. After the engine has been operated at normal
operating temperature, STOP the engine.
• Gas Engines Application and Installation Guide,
LEKQ7252, “G3600 Mounting, Alignment” Note: Drain the oil into a suitable container. Dispose
of fluids according to local regulations.
• Special Instruction, SEHS9162, “Spring Isolator
Group Installation and Adjustment Procedure”

Consult your Caterpillar dealer for assistance.

i02602019

Engine Oil - Change


SMCS Code: 1348-044; 1348

Oil Change Interval


Considerations for the oil change interval include
the type of fuel and the engine application. An Illustration 78
g00789667
established S·O·S oil analysis program enables used (1) Drain valve
oil to be evaluated. The evaluation can be used to
determine if this oil change interval is suitable for 2. Open drain valve (1) in order to drain used oil.
your specific engine. After the oil has drained, close drain valve (1).
SEBU7563-09 93
Maintenance Section
Engine Oil Filter - Change

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


the oil from the oil pan, ensure that the suction device NOTICE
is clean. This will prevent dirt from entering the oil Engine damage can occur if the crankcase is filled
pan. Be careful not to strike the engine oil suction above the “FULL” mark on the oil level gauge (dip-
tubes or the piston cooling jets. stick).

3. Clean the oil suction screen. An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
Note: Approximately 1 L (1 qt) of oil will remain in the oped and also force air bubbles into the oil. These
housing after the sump has been completely drained. bubbles (foam) can cause the following problems: re-
This oil will pour out of the housing when the cover duction of the oil's ability to lubricate, reduction of oil
for the oil suction screen is removed. Prepare to pressure, inadequate cooling, oil blowing out of the
catch the oil in a suitable container. Clean up any crankcase breathers, and excessive oil consumption.
spilled oil with rags. DO NOT use absorbent particles
to clean up the oil. Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.

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

Note: For the amount of oil to use, refer to


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

5. Remove the oil filler cap. Fill the crankcase


Illustration 79
g00789729 through the oil filler tube only. Clean the oil filler
(2) Screen assembly cap. Install the oil filler cap.

a. Loosen the bolts of the cover for the oil suction 6. Follow this Operation and Maintenance Manual,
screen. Remove the cover and the gasket. “Starting The Engine” procedure (Operation
Discard the old gasket. Slide screen assembly Section). Operate the engine at low idle for two
(2) from the tube. minutes. Inspect the engine for oil leaks. Ensure
that the oil level is at the “FULL” mark on the
b. Wash the screen assembly in clean “LOW IDLE” side of the oil level gauge.
nonflammable solvent. Allow the screen
assembly to dry before installation. 7. Stop the engine and allow the oil to drain back into
the sump for a minimum of ten minutes.
c. Install the screen assembly. Install a new
gasket. Install the cover. 8. Remove the oil level gauge and check the oil level.
Maintain the oil level above the “ADD” mark.
4. Change the engine oil filters. Refer to this
Operation and Maintenance Manual, “Engine Oil i01520518
Filter - Change” topic (Maintenance Section).
Engine Oil Filter - Change
NOTICE
Only use oils that are recommended by Caterpillar. SMCS Code: 1308-510; 1308
For the proper oil to use, refer to this Operation and
Maintenance Manual, “Engine Oil” topic (Maintenance Replace the engine oil filters when the following
Section). conditions are met:

• Every oil change


• The engine oil filter differential pressure reaches
100 kPa (15 psi).
94 SEBU7563-09
Maintenance Section
Engine Oil Filter - Change

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
Personal injury can result from parts and/or cov-
that are supplied with the service tools. If the service
ers under spring pressure.
tools are not used, perform the following appropriate
procedure.
Spring force will be released when covers are re-
moved.
Replacing the Engine Oil Filters
With the Engine Stopped 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
Hot oil and components can cause personal in-
but do not remove the last two bolts or nuts that
jury.
are located at opposite ends of covers (3). Before
removing the last two bolts or nuts, pry the covers
Do not allow hot oil or components to contact
loose or tap the covers with a rubber mallet in
skin.
order to relieve any spring pressure.

Perform the following procedure after the oil has


been drained.

Note: Use this procedure if the engine oil filters do


not have a control valve.

g00789772
Illustration 81
(5) Wire rack
(6) O-ring seal
(7) Element

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


g00789754 the housing. Use a pan to catch the oil that drips
Illustration 80
(1) Pressure gauge when wire racks (5) are removed. Remove wire
(2) Drain racks (5). Remove used elements (7). Clean up
(3) Cover any oil that is spilled.
(4) Control valve

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


suitable container in order to catch the oil. Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
2. Open both drain valves (2). Allow the oil to drain. Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
Note: Some oil will remain in the housing after the oil the larger waste particles from unfiltered oil entering
has been drained. This oil will pour out of the housing the engine lubricating system. Only use oil filters
when cover (3) is removed. Prepare to catch the oil recommended by Caterpillar.
in a suitable container. Clean up any spilled oil with
rags. DO NOT use absorbent particles to clean up 5. Ensure that the new oil filter elements are in good
the oil. condition. Place the elements on wire rack (5).
Install the wire rack and the elements.
SEBU7563-09 95
Maintenance Section
Engine Oil Filter - Change

6. Ensure that the surfaces for O-ring seals (6) are 3. Open drain valve (2) and drain the lower oil filter
clean. Inspect the O-ring seals. If the old O-ring housing. Observe pressure gauge (1) until the
seals are damaged or deteriorated, replace the pressure is “0”.
old O-ring seals with new O-ring seals. Install the
O-ring seals. Note: Some oil will remain in the housing after the oil
has been drained. This oil will pour out of the housing
7. Install covers (3). Ensure that the spring is seated when cover (3) is removed. Prepare to catch the oil
properly between elements (7) and covers (3). in a suitable container. Clean up any spilled oil with
Close drain valves (2). rags. DO NOT use absorbent particles to clean up
the oil.
8. Ensure that the crankcase is filled with oil. Operate
the prelube pump and rotate the control valve (if
equipped) to the “FILL” position for each housing.
After both of the housings are full of oil, turn the Personal injury can result from parts and/or cov-
control valve (if equipped) to the “RUN” position. ers under spring pressure.
9. Start the engine. Check for oil leaks. Spring force will be released when covers are re-
moved.
Replacing the Engine Oil Filters
Be prepared to hold spring loaded covers as the
During Engine Operation bolts are loosened.

4. After zero pressure has been reached, remove


cover (3). Be alert to the spring force. The cover
Filter contains hot pressurized fluid when engine has a spring force up to 240 N (54 lb). Gradually
is running. loosen but do not remove the last two bolts or
nuts that are located at opposite ends of cover (3).
Follow instructions on control valve to avoid per- Before removing the last two bolts or nuts, pry the
sonal injury. cover loose or tap the cover with a rubber mallet
in order to relieve any spring pressure.
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.

g00789772
Illustration 83
(5) Wire rack
(6) O-ring seal
(7) Element

Illustration 82
g00789754 5. Elements (7) are mounted on wire rack (5) inside
the housing. Use a pan to catch the oil that drips
(1) Pressure gauge
(2) Drain when wire rack (5) is removed. Remove wire rack
(3) Cover (5). Remove used elements (7). Clean up any oil
(4) Control valve that is spilled.

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


container in order to catch the oil.

2. Rotate control valve (4) to the “LOWER SERVICE”


position.
96 SEBU7563-09
Maintenance Section
Engine Oil Level - Check

Aluminum debris may indicate problems with the


NOTICE bearings of the front gears. If aluminum is found in
Caterpillar oil filters are built to Caterpillar speci- the filter, inspect the crankshaft vibration damper and
fications. Use of an oil filter not recommended by the front idler gear bearing.
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of Due to normal wear and friction, it is not uncommon
the larger waste particles from unfiltered oil entering to find small amounts of debris in the oil filter element.
the engine lubricating system. Only use oil filters If an excessive amount of debris is found in the oil
recommended by Caterpillar. filter element, consult your Caterpillar dealer in order
to arrange for further oil analysis.
6. Ensure that the new oil filter elements are in good
condition. Place the elements on wire rack (5). i02602034
Install the wire rack and the elements.
Engine Oil Level - Check
7. Ensure that the surfaces for O-ring seal (6) are
clean. Inspect the O-ring seal. If the old O-ring seal SMCS Code: 1348-535-FLV
is damaged or deteriorated, replace the old O-ring
seal with a new O-ring seal. Install the O-ring seal. The most accurate check of the oil level is
performed when the engine is stopped. Perform this
8. Install cover (3). Ensure that the spring is seated maintenance on a surface that is as level as possible.
properly between element (8) and cover (3). Close
drain valve (2).

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


position. Observe pressure gauge (1). Check
cover (3) for leaks.

Note: A hydraulic stop will limit the rotation of the


control valve until the oil filter housing is full of oil.

10. After the pressure of the lower oil filter and the
upper oil filter is equal, rotate control valve (4) to
the “UPPER SERVICE” position. Repeat Step 1
through Step 9 for the upper oil filter.
g00789822
Illustration 84
11. After the oil filters have been serviced and after
the pressure of the lower oil filter and the upper oil (1) Oil level gauge
(2) Oil filler
filter is equal, rotate control valve (4) to the “RUN”
position.

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
g01140702
on the steel and the cast iron parts of the engine. Illustration 85
Nonferrous metals may indicate wear on the (3) “ADD” mark
aluminum parts, the brass parts, or the bronze parts (4) “RUNNING FULL” mark
of the engine. Parts that may be affected include the (5) “STOPPED FULL OIL COLD NO PRELUBE” mark
following components: main bearings, rod bearings,
turbocharger bearings, and cylinder heads. Note: For engines with powered crankcase
ventilation, remove the oil filler cap. Allow the
crankcase pressure to stabilize before checking the
engine oil level.
SEBU7563-09 97
Maintenance Section
Engine Oil Sample - Obtain

1. Ensure that oil level gauge (1) is seated. Obtain the Sample and the Analysis
2. Remove the oil level gauge and observe the oil
level. Add engine oil if the level is in the “ADD”
zone. If the engine is running, maintain the level
in the “RUNNING FULL” zone. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip- Before you take the oil sample, complete the Label,
stick). PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
An overfull crankcase can cause the crankshaft to dip the following information:
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These • Engine model
bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil • Service hours on the engine
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption. • The number of hours that have accumulated since
the last oil change
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De- • The amount of oil that has been added since the
posits in the combustion chamber lead to the following last oil change
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner. To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
If the oil level is above the “FULL” mark on the oil level sample.
gauge, drain some of the oil immediately.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
3. If necessary, remove oil filler cap (2) and add samples must be clean.
oil. For the correct oil to use, see this Operation
and Maintenance Manual, “Refill Capacities and Caterpillar recommends using the sampling valve
Recommendations” topic (Maintenance Section). in order to obtain oil samples. The quality and the
Wipe off the oil level gauge and reinstall the oil consistency of the samples are better when the
level gauge. Clean the oil filler cap and reinstall sampling valve is used. The location of the sampling
the oil filler cap. valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
4. Record the amount of oil that is added. For the
next oil sample and analysis, include the total The 169-8373 Fluid Sampling Bottle is
amount of oil that has been added since the recommended for use with the sampling valve. The
previous sample. This will help to provide the most fluid sampling bottle includes the parts that are
accurate oil analysis. needed for obtaining oil samples. Instructions are
also provided.
Note: Some engines are equipped with an automatic
oil level controller. The oil level should still be
checked on a daily basis with the oil level gauge. NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
i03542996 Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
Engine Oil Sample - Obtain contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
SMCS Code: 1348-554-SM dealers and customers.
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil If the engine is not equipped with a sampling valve,
analysis at regularly scheduled intervals in order use the 1U-5718 Vacuum Pump. The pump is
to monitor the condition of the engine and the designed to accept sampling bottles. Disposable
maintenance requirements of the engine. S·O·S oil tubing must be attached to the pump for insertion
analysis provides infrared analysis, which is required into the sump.
for determining nitration and oxidation levels.
98 SEBU7563-09
Maintenance Section
Engine Oil Temperature Regulator - Replace

For instructions, see Special Publication, PEgj0047,


“How To Take A Good S·O·S Oil Sample”. Consult
your Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine.

i00839584

Engine Oil Temperature


Regulator - Replace
SMCS Code: 1330-510

The oil temperature regulators divert the engine


oil to the oil cooler in order to maintain engine oil
temperature.

For instructions on replacing the oil temperature


regulators, see the Service Manual, “Disassembly
and Assembly” module.
g00449867
Illustration 86
i02601497 Typical examples of electrical connectors
(A) Military Standard connector
Engine Protective Device (1) Plug
Connections - Inspect (2) Receptacle
(B) Deutsch HD connector
(C) Phoenix terminal strip
SMCS Code: 7400-040
Note: Military Standard (MS), Caterpillar
Inspect the wiring and the electrical connections for Environmental (CE), and Vehicle Environmental
these components: (VE) connectors are similar in design. However, the
wiring is soldered to the pins and sockets of Military
• Connectors Standard connectors. In CE and VE connectors,
the wiring is crimped into the pins and sockets. The
• Control panel wiring is crimped into the pins and sockets of Deutsch
HD connectors also.
• Junction box
1. Turn the mode control switch to the “OFF/RESET”
• Sensors position. Open the circuit breaker of the main
power supply.

2. Inspect all of the wiring for the following conditions:

• Fraying
• Damaged insulation
• Corrosion
Make repairs, as needed.
SEBU7563-09 99
Maintenance Section
Engine Protective Device Connections - Inspect

Perform a pull test for each wire. This test will


ensure that the wiring is properly attached. Test
each wire individually.

a. Pull each wire with approximately 45 N (10 lb)


of force. Pull the wire firmly.

If a wire is loose, repair the connection. For


instructions on connecting wires, see the
Service Manual, “Troubleshooting” module.

4. Inspect the wiring at the relays and terminal strips


for these conditions:

• Corrosion
• Fraying
a. If corrosion is found, scrape large deposits.
Use cotton swabs with isopropyl alcohol to
clean any corrosion that remains.
g01302112
Illustration 87
Inside of control panel (front)
Investigate the source of the corrosion. Correct
the condition.

If damage is found, replace the part.

b. Remove frayed strands of wire or tin the wire.

c. Perform Steps 6 and 7 for the connectors of


the control panel and the junction box.

5. Check the wiring for secure connections at these


points:

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

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


the body of the connector with one hand. Pull
g01201607
Illustration 88 each wire with approximately 45 N (10 lb) of
Inside of control panel (rear) force. Pull the wire firmly.
(1) Terminal strips
b. Before testing the wiring of the sensors, ensure
3. Check the wiring for secure connections at these that the sensors are securely installed. Then
points of the junction box and the control panel: pull each wire with approximately 45 N (10 lb)
of force.
• Connectors
If a wire is loose, repair the connection. For
• Relays instructions on connecting wires, see the
Service Manual, “Troubleshooting” module.
• Switches
6. Disconnect the connectors at the following
• Terminal strips locations. Inspect the connectors.

• Engine sensors
100 SEBU7563-09
Maintenance Section
Engine Protective Devices - Check

• Junction box
NOTICE
• Modules of the control panel During testing, abnormal operating conditions must be
simulated.
a. Inspect each pin and each socket for corrosion
and damage. The tests must be performed correctly in order to pre-
vent possible damage to the engine.
If corrosion is found, scrape large deposits.
Use cotton swabs with isopropyl alcohol to
clean any corrosion that remains. To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
Investigate the source of the corrosion. Correct perform the tests.
the condition.
Visual Inspection
If damage is found, replace the part.
Visually check the condition of all gauges, sensors
7. Reconnect the connectors. and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
a. For Military Standard, CE, and VE connectors, or components should be repaired or replaced
ensure the following conditions: immediately.

• The connection is threaded properly.


i01762818
• The connection is threaded completely. Very Engine Speed/Timing Sensor -
little thread or no thread is visible.
Clean/Inspect
b. For Deutsch HD connectors, ensure the
following conditions: SMCS Code: 1905-040; 1905-070; 1907-040;
1907-070
• The index markings of the plug and the
receptacle are aligned. The engine speed/timing sensor is located at the
right rear side of the engine.
• The connection is turned fully.
• The plug and the receptacle are securely
connected.

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

i00626013

Engine Protective Devices -


Check
SMCS Code: 7400-535

Alarms and shutoffs must function properly. Alarms Illustration 89


g00901865
provide timely warning to the operator. Shutoffs help (1) Engine speed/timing sensor
to prevent damage to the engine. It is impossible (2) Bolt
to determine if the engine protective devices are
in good working order during normal operation. 1. Disconnect the wiring harness from engine
Malfunctions must be simulated in order to test the speed/timing sensor (1).
engine protective devices.
2. Remove bolt (2) in order to remove engine
A calibration check of the engine protective devices speed/timing sensor (1).
will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective 3. Inspect the sensor for damage.
devices are functioning properly.
If the sensor is damaged, obtain a new sensor for
installation.
SEBU7563-09 101
Maintenance Section
Engine Valve Lash - Inspect/Adjust

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


NOTICE
If the O-ring seal is damaged, obtain a new O-ring The prelube pump should not be operated continu-
seal for installation. ously for extended periods of time. If, during repairs,
the prelube pump has run continuously for a period
5. Clean the tip of the sensor. of three hours or more, it will be necessary to remove
any oil that may have collected in the cylinders and/or
Note: The engine speed/timing sensor does not above the valves.
require any special adjustments.

6. Install the sensor. Make sure that the sensor is Prelube of the engine is required before the
properly seated. Tighten bolt (2). crankshaft is rotated for normal maintenance.
Activate the prelube pump for rotating the engine
7. Inspect the wiring harness. Make sure that the crankshaft.
connector is in good condition. Attach the wiring
harness to the sensor. Make sure that the mating NOTICE
of the connectors is proper. Do not use an impact wrench to operate the barring
device. The use of an impact wrench will cause gear
tooth failure.
i01765700

Engine Valve Lash - The barring device provides a means for slowly
turning the flywheel in order to service the engine.
Inspect/Adjust The barring device can also be used to prevent
rotation of the crankshaft.
SMCS Code: 1102-025

For instructions on the following procedures, refer to Valve Bridge


Systems Operation/Testing and Adjusting. Consult
your Caterpillar dealer for assistance. NOTICE
Do NOT attempt to adjust the valves if the crankshaft
Note: Use of a platform may be necessary for these and camshaft are not synchronized. Disregard for this
procedures. can result in engine damage such as bent valves.

Check the Timing of the Crankshaft Check the valve bridges. Perform the procedure for
and Camshaft both valve bridges for each cylinder.

The timing of the crankshaft and camshaft must be After the valve bridge is checked for each cylinder,
checked, and the valve bridge must be adjusted check the valve lash for the exhaust valves, the inlet
before the valve lash is adjusted. valves, and the gas admission valves.

NOTICE Engine Valve Lash


If the camshaft is rotated with the timing pin installed,
the timing pin will break. This can result in further dam- If the valve lash is within the tolerance, an adjustment
age. Make sure to remove the timing pin before the of the valve lash is NOT necessary.
camshaft is rotated.
The crankshaft and camshaft timing must be
checked, and valve bridge adjustment must be
NOTICE performed before making a valve lash adjustment.
DO NOT use the starting motor to rotate the crank-
shaft. The lubrication oil can drain out from between Perform the valve lash setting when the engine is
the crankshaft and the engine bearings if the engine cold. After the engine has been shut down and the
has not been operated for a period of time. Damage valve covers are removed, the engine is considered
can result if the crankshaft is rotated on dry bearing cold.
surfaces.
Before performing maintenance, prevent the entry of
To prevent damage to the crankshaft bearings, DO foreign matter into the top of the cylinder head and
NOT crank the engine before prelube, especially after the valve mechanism. Thoroughly clean the area
this maintenance procedure. around the valve mechanism covers.
102 SEBU7563-09
Maintenance Section
Engine Valve Rotators - Inspect

Gas Admission Valve i01765718

Check the valve lash for the gas admission valve Exhaust Bypass - Recondition
when the valve lash for the inlet valves and exhaust
valves are checked. Adjust the valve lash for the gas SMCS Code: 1057-020
admission valves, if necessary.

i01765711

Engine Valve Rotators - Inspect


SMCS Code: 1109-040

NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
g00799396
and cylinder head damage. Illustration 90
Typical example
(1) Rod ends
Note: Use of a platform may be necessary to reach (2) Cover and seal
the engine valve rotators. (3) Shaft

Perform this procedure after the valve lash has been Note: Use of a platform may be necessary in order to
set. reach the components of the exhaust bypass.
1. Mark the tops of the valve rotators with a Replace the following parts:
permanent marker. Note the position of the marks.
• Rod ends (1)
2. Install the valve covers. See the Service Manual
for the procedure. • Cover and seal (2)
3. Start the engine. Operate the engine for 5 minutes. • Shaft (3)
Stop the engine.
For instructions on assembling the exhaust bypass,
4. Remove the valve covers. Observe the position of refer to the Specifications.
the marks that are on the valve rotators.

If a valve fails to rotate, consult your Caterpillar i00457458


dealer.
Exhaust Shields - Inspect
SMCS Code: 1067-040

Hot engine components can cause injury from


burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
SEBU7563-09 103
Maintenance Section
Fuel System Fuel Filter Differential Pressure - Check

i01765725
NOTICE
The exhaust shields can be damaged if work is per-
Gas Admission Valve -
formed on the exhaust shields or around the exhaust Recondition
shields.
SMCS Code: 1105-020-GS
Remove the exhaust shields or protect the exhaust
shields before performing work on the exhaust shields Note: Use of a platform may be necessary to reach
or around the exhaust shields. Handle the exhaust the gas admission valves.
shields carefully.
For the procedure to remove the gas admission valve,
Do not tear the foil that is inside of the exhaust shields. refer to the engine's Disassembly and Assembly.
Torn foil will allow the insulation to absorb flammable
liquids and a fire can result from engine heat. When you disassemble the gas admission valve,
inspect the seals. Replace the seals, if necessary.
Refer to this Operation and Maintenance Manual,
Ensure that the exhaust manifold is cool. Inspect the
“Gas Admission Valve Seals - Inspect/Replace”.
exhaust shields. Replace any exhaust shield that
is damaged. Refer to the Service Manual for the
procedure to remove the exhaust shields and install
the exhaust shields.

i02602064

Fuel System Fuel Filter


Differential Pressure - Check
SMCS Code: 1261-535

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


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

A fuel filter differential pressure gauge indicates the


difference in fuel pressure between the inlet side
and the outlet side of the fuel filter. The differential
pressure increases as the fuel filter becomes
plugged.

Operate the engine with a full load at the rated rpm


and at the normal operating temperature. Check the
fuel filter differential pressure at full load.
g00833978
Illustration 91
Service the fuel filter when the fuel filter differential
pressure reaches 1.7 kPa (0.25 psi). Exploded view and section view of the parts for the gas admission
valve
For instructions, refer to Special Instruction, (1) Retainer locks
(2) Valve rotator
SEHS9298, “Installation and Maintenance of (3) Outer valve spring
Gaseous Fuel Filters”. Consult your Caterpillar dealer (4) Inner valve spring
for assistance. (5) Valve guide
(6) Support assembly
(7) Valve

To recondition the gas admission valve, replace


retainer locks (1), valve rotator (2), outer valve spring
(3), inner valve spring (4), and valve (7).
104 SEBU7563-09
Maintenance Section
Gas Admission Valve Seals - Inspect/Replace

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


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

It is unlikely for support assembly (6) to require


replacement. However, inspect the valve seat in the
support assembly.

g00833994
Illustration 92
g00833829
Angle and dimensions for the valve seat in the support assembly Illustration 93
Exploded view and section view of the parts for the gas admission
If the valve seat is worn, the valve seat can be slightly valve
ground according to these specifications: (1) Upper valve stem seal
(2) Lower valve stem seal
(3, 4, and 5) O-ring seals for the support assembly
• The angle for the valve seat is 44.75 ± 0.5 degrees.
Note: The portion of the valve stem in lower valve
• The gauge diameter of the valve seat within a stem seal (2) may be slightly worn. This shallow wear
maximum depth of 2.0 mm (0.079 inch) from
does not affect the performance of the gas admission
the end of the support assembly is 39.75 mm
valve.
(1.565 inch).
Inspect valve stem seals (1) and (2). Inspect O-ring
Use some Prussian blue to verify complete contact of
seals (3), (4), and (5). Replace the seals, if necessary.
the valve in the valve seat.

i00679524
i01765734

Gas Admission Valve Seals - Gas Pressure Regulator -


Inspect/Replace Inspect/Replace
SMCS Code: 1105-040-GS; 1105-510-GS SMCS Code: 1550-040; 1550-510

The camshaft operates the mechanism for the gas Inspect the gas pressure regulator for the following
admission valve in order to allow fuel to enter the conditions:
inlet port of the cylinder.
• Wear
Note: Use of a platform may be necessary to reach
the gas admission valves. • Cracks

For the procedure to remove the gas admission valve, • Pin holes
refer to the engine's Disassembly and Assembly.
• Improper operation
SEBU7563-09 105
Maintenance Section
Gas Shutoff Valve - Inspect

If any of those conditions are found, the gas pressure 8. Remove bolts (4) and cover (5) in order to inspect
regulator must be repaired or replaced. the internal parts of the GSOV.

For information on replacing the gas pressure 9. Clean the internal parts. Inspect the diaphragm,
regulator, see the Service Manual. Consult your the center pin for the diaphragm, and the shaft
Caterpillar dealer for assistance. for the solenoid. If any of the parts are damaged,
replace the entire GSOV.
i01611465
10. Inspect the internal passages. Remove any
Gas Shutoff Valve - Inspect debris.

SMCS Code: 1329-040 11. Reassemble the diaphragm, the center pin for the
diaphragm, and the shaft for the solenoid. Install
The gas shutoff valve (GSOV) has a solenoid that is cover (5) with bolts (4).
operated with 24 VDC. When power is supplied to the
solenoid, fuel flows through the GSOV to the engine. 12. Install cap (3). Connect the wiring harness to
When the power is interrupted, the gas is shut off. receptacle (1).

1. Shut off the engine. 13. Turn on the fuel supply to the GSOV. Use a gas
detector to check for gas leaks.
2. Shut off the fuel supply to the GSOV.
i03847809

Hoses and Clamps -


Inspect/Replace
SMCS Code: 7554-040; 7554-510

Hoses and clamps must be inspected periodically


in order to ensure safe operation and continuous
operation of the engine. Take proper safety
precautions before inspecting or replacing hoses and
clamps.

Note: Always use a board or cardboard when the


Illustration 94
g00834076 engine components are checked for leaks. Leaking
fluid that is under pressure can cause serious
(1) Receptacle
(2) Gasket
injury or possible death. This includes leaks that
(3) Cap are the size of a pin hole. Refer to Operation and
(4) Bolt Maintenance Manual, “General Hazard Information”
(5) Cover for more information.

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


Inspect the connectors for damage and corrosion. Inspect the Hoses and the Clamps
Make repairs, as needed.
Inspect all hoses for leaks that are caused by the
4. Inspect gasket (2) for damage and wear. Replace following conditions. Replace any hose which exhibits
the gasket, if necessary. any of the following conditions. Failure to replace a
hose which exhibits any of the following conditions
5. Remove cap (3). Remove the washer under the may result in a hazardous situation.
cap in order to inspect the solenoid.
• Hoses which are cracked
6. Inspect the solenoid for damage. If the epoxy
coating is cracked or damaged, obtain a new • Hoses which are soft
solenoid for assembly.
• Outer covering that is chafed or cut
7. Inspect the cavity for the solenoid. Look for
moisture, debris, and abrasion of the wiring. Make • Exposed wire that is used for reinforcement
repairs, if necessary. Thoroughly clean the cavity.
• Outer covering that is ballooning locally
106 SEBU7563-09
Maintenance Section
Hoses and Clamps - Inspect/Replace

• Flexible part of the hose that is kinked or crushed Replace the Hoses and the Clamps
• Armoring that is embedded in the outer covering NOTICE
Care must be taken to ensure that fluids are contained
• Hoses which exhibit signs of leakage which are not during performance of inspection, maintenance, test-
the result of loose couplings or clamps
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
Inspect all clamps for the following conditions.
ing any compartment or disassembling any compo-
Replace any clamp which exhibits signs of any of the
nent containing fluids.
following conditions.
Refer to Special Publication, NENG2500, “Caterpillar
• Cracking Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and
• Looseness Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
• Damage
Dispose of all fluids according to local regulations and
Inspect all couplings for leaks. Replace any coupling
mandates.
which exhibits signs of leaks.

Each installation application can be different. The Cooling System


differences depend on the following factors:

• Type of hose
• Type of fitting material Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
• Anticipated expansion and contraction of the hose stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
• Anticipated expansion and contraction of the pressure cap slowly in order to relieve the pres-
fittings sure.

Due to extreme temperature changes, the hose will


heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps. Personal injury can result from removing hoses or
fittings in a pressure system.
Replace hoses that are cracked or soft. Replace
hoses that show signs of leakage. Replace hoses Failure to relieve pressure can cause personal in-
that show signs of damage. Replace hose clamps jury.
that are cracked or damaged. Tighten or replace
hose clamps which are loose. Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.

1. Stop the engine.

2. Allow the engine to cool.

3. Before servicing a coolant hose, slowly loosen the


filler cap for the cooling system in order to relieve
any pressure.

4. Remove the filler cap for the cooling system.

5. Drain the coolant from the cooling system to a


level that is below the hose that is being replaced.
Drain the coolant into a suitable clean container.
The coolant can be reused.

6. Remove the hose clamps.


SEBU7563-09 107
Maintenance Section
Hoses and Clamps - Inspect/Replace

7. Disconnect the old hose. Note: High pressure fuel lines may be installed
between the high pressure fuel pump and the fuel
8. Replace the old hose with a new hose. injectors. High pressure fuel lines are constantly
charged with high pressure. Do not check the high
9. Install hose clamps which have been inspected or pressure fuel lines with the engine or the starting
install new hose clamps. Refer to Specifications, motor in operation. Wait for 10 minutes after the
SENR3130, “Torque Specifications”, “Hose engine stops before you perform any service or repair
Clamps” for information about selecting and on high pressure fuel lines in order to allow pressure
installing the proper hose clamps. to be purged.

10. Refill the cooling system. 1. Drain the fuel from the fuel system to a level that
is below the hose that is being replaced.
11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap 2. Remove the hose clamps.
if the gaskets are damaged. Install the filler cap.
3. Disconnect the old hose.
12. Start the engine. Inspect the cooling system for
leaks. 4. Replace the old hose with a new hose.

Fuel System 5. Install hose clamps which have been inspected or


install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
Personal injury can result from removing hoses or
fittings in a pressure system. 6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
Failure to relieve pressure can cause personal in- engine.
jury.
Note: Fuel must be added to the fuel system ahead
Do not disconnect or remove hoses or fittings un- of the fuel filter.
til all pressure in the system has been relieved.
7. Refill the fuel system. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime” for
information about priming the engine with fuel.

Contact with high pressure fuel may cause fluid 8. Start the engine. Inspect the fuel system for leaks.
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol- Lubrication System
low these inspection, maintenance and service in-
structions may cause personal injury or death.

NOTICE Hot oil and hot components can cause personal


Do not bend or strike high pressure lines. Do not in- injury. Do not allow hot oil or hot components to
stall bent or damaged lines, tubes or hoses. Repair contact the skin.
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec- 1. Drain the oil from the lubrication system to a level
ommended torque. that is below the hose that is being replaced.

2. Remove the hose clamps.


NOTICE
Do not allow dirt to enter the fuel system. Thoroughly 3. Disconnect the old hose.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis- 4. Replace the old hose with a new hose.
connected fuel system components.
5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
108 SEBU7563-09
Maintenance Section
Ignition System Spark Plugs - Check/Adjust

6. Refill the lubrication system. Refer to this Removing the Spark Plug
Operation and Maintenance Manual, “Engine
Oil Level - Check” in order to ensure that the
lubrication system is filled with the proper amount
of engine oil.

7. Start the engine. Inspect the lubrication system


for leaks.

Air System
1. Remove the hose clamps.

2. Disconnect the old hose.

3. Replace the old hose with a new hose. g00823378


Illustration 95
4. Install hose clamps which have been inspected or (1) Harness connector
install new hose clamps. Refer to Specifications, (2) Bolt
(3) Transformer
SENR3130, “Torque Specifications”, “Hose (4) O-ring seal
Clamps” for information about selecting and (5) Extension
installing the proper hose clamps. (6) Spark plug

5. Start the engine. Inspect the air lines for leaks. 1. Ensure that the mode control switch is in the
“STOP” or “OFF/RESET” position.
i03915150
NOTICE
Ignition System Spark Plugs - Pulling on the wiring harness may break the wires. Do
not pull on the wiring harness.
Check/Adjust
SMCS Code: 1555-535 2. Remove the lockwire. Disconnect harness
connector (1). Use pliers to turn the connector
Maintenance of the spark plugs is required in order to counterclockwise.
obtain the following benefits:
3. Remove bolts (2).
• Normal fuel consumption
4. Remove transformer (3). Inspect O-ring seal (4).
• Normal levels of emissions If the O-ring seal is worn or damaged, discard
the O-ring seal and use a new O-ring seal for
• Maximum service life of the spark plugs assembly.

The service life of the spark plugs is affected by 5. Remove extension (5).
fouling due to deposits from the oil and by peak
voltage. Maintenance of the ignition system is also
affected by voltage. Higher voltage is required by
higher inlet manifold air pressure and a higher
compression ratio. Higher voltage reduces the Pressurized air can cause personal injury. When
service life of components such as spark plug wires pressurized air is used for cleaning, wear a pro-
and transformers. tective face shield, protective clothing, and pro-
tective shoes.

6. Debris may have collected near the spark plug.


Thoroughly remove any debris. Use compressed
air. The maximum air pressure for cleaning
purposes must be below 207 kPa (30 psi). Ensure
that the area around the spark plug is clean and
free of dirt and debris.
SEBU7563-09 109
Maintenance Section
Ignition System Spark Plugs - Check/Adjust

7. Use a 4C-4601 Spark Plug Socket and an Faint marks may extend from shell (3) onto the
extension to loosen spark plug (6). After the spark insulator. The marks may be a result of corona that
plug has been loosened, remove the spark plug by forms at the top of the shell. The corona develops
hand in order to detect problems with the threads. when a high voltage potential ionizes the air that
After the spark plug has been removed, discard surrounds a conductor, which is a normal condition.
the used gasket. This condition is not an indication of leakage between
the shell and the insulator.
NOTICE
The use of a thread tap will remove metal unnecessar- Inspect shell (3) for damage. Cracks can be caused
ily. This will also reduce the heat transfer for the spark by overtightening the spark plug. Overtightening can
plug. This can result in a reduction of the spark plug also loosen the shell. Discard any spark plug that has
service life and a reduction of the detonation margin. a shell that is cracked or loose.

Inspect electrode (5) for excessive wear. Flat


If the spark plug resists removal by hand, apply surfaces with sharp edges provide the best conditions
penetrating oil to the threads. Use the wrench and for creating a spark. An electrode will become worn
apply steady pressure to the spark plug until the from use. The surfaces erode. A higher voltage is
spark plug is loose. required in order to produce a spark.

If the spark plug cannot be removed by hand, clean


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

Inspecting the Spark Plug

g00760569
Illustration 97
(6) Precious metal pads on the electrode and the ground strap

Caterpillar spark plugs have precious metal pads (6)


on the tips of the electrode and the ground strap.
This material will gradually erode.

Illustration 96
g00838300 Replace the spark plug if the precious metal is worn
off.
(1) Terminal post
(2) Insulator
(3) Shell Light brown deposits or beige deposits around the
(4) Gasket electrode are produced by normal operation. White
(5) Electrode deposits or gray deposits may be caused by the
following substances:
Inspect the spark plug closely for damage. The
condition of the spark plug can indicate the operating • Excessive oil
condition of the engine.
• Use of the wrong oil
Terminal post (1) must not move. If the terminal post
can be moved by hand, discard the spark plug. • A substance that is introduced through the fuel
system or the air system
Inspect insulator (2) for cracks. If a crack is found,
discard the spark plug. A spark plug can operate despite a buildup of
ash. However, a buildup of ash can cover the
electrode gap. The buildup will cause misfire. Large
deposits may retain heat which can cause premature
fuel ignition. Premature fuel ignition can lead to
uncontrollable detonation.
110 SEBU7563-09
Maintenance Section
Ignition System Spark Plugs - Check/Adjust

Cleaning the Spark Plug


NOTICE
Thoroughly clean the spark plug. Do not use a wire Do not overtighten the spark plug. The shell can be
brush. Glass beads are the preferred method for cracked and the gasket can be deformed. The met-
cleaning. al can deform and the gasket can be damaged. The
shell can be stretched. This will loosen the seal that is
Follow these guidelines for using glass beads: between the shell and the insulator, allowing combus-
tion pressure to blow past the seal. Serious damage
• Always use clean glass beads. to the engine can occur.

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

• Do not use glass beads on the outside of the shell 4. Install the spark plug by hand until the spark
or on the upper part of the insulator. plug bottoms out. For the 301-6663 Spark Plug,
tighten the spark plug to 48 ± 5 N·m (35 ± 4 lb ft).
For the 243-4291 Spark Plug, tighten the spark
Installing the Spark Plug plug to 45 ± 5 N·m (33 ± 3 lb ft).
Note: Use the 9U-7516 Spark Plug Gauge to 5. Inspect the extension and clean the extension.
measure the electrode gap. Do not use a flat feeler
gauge for measuring the electrode gap of used
spark plugs. A feeler gauge will produce a false
measurement because the used precious metal
surfaces will be curved.

1. Before installing the spark plug, set the electrode


gap to 0.29 ± 0.03 mm (.011 ± 0.001 inch).

Adjust the electrode gap by bending the ground


electrode at the existing bend. Then bend the
strap near the weld in order to achieve proper
alignment and even spacing between the two
precious metal surfaces. Measure the electrode
gap after the alignment. Correct the electrode
gap, if necessary. Illustration 98
g00823413

(1) O-ring seal


Note: Do not use anti-seize compound on spark (2) Connection of the extension and the transformer
plugs. Most of the heat is transferred through the (3) Connection of the extension and the spark plug
threads and the seat area of the spark plug. The
surfaces must be in contact in order to provide the a. Inspect O-ring seal (1). If the O-ring seal is
heat transfer that is required. hard, cracked, or melted, use a new O-ring
seal for assembly.
2. Ensure that the spark plug is clean and free of dirt
and oil. b. Use a mild abrasive cleaner to clean deposits
and/or corrosion from the extension at
3. Always use a new gasket when a spark plug is connection points (2) and (3).
installed. If a used spark plug is installed, place a
new 9Y-6792 Gasket on the spark plug. Orient c. Apply one of the following lubricants to O-ring
the tabs of the gasket toward the electrode. seal (1) and to the extension at connection
Otherwise, the gasket may not seat properly. If a points (2) and (3):
gasket for a spark plug is installed incorrectly, do
not increase the torque on the spark plug in order • 4C-9504 Dielectric Grease
to improve the seal. Do not reuse the gasket.
Install a new gasket. • 8T-9020 Dielectric Grease
This lubricant will help to protect the connection
points of the extension from corrosion.

6. Ensure that the internal spring exerts force on the


connection points. Install the extension onto the
spark plug.
SEBU7563-09 111
Maintenance Section
Ignition System Spark Plugs - Replace

7. Ensure that the transformer assembly is clean and Make repairs, if necessary. For information regarding
free of dirt and oil. Assemble the extension into removal and installation of the components, refer
the transformer. Install the transformer. to Service Manual, “Disassembly and Assembly”.
Consult your Caterpillar dealer for assistance.
8. Connect the wiring harness. Tighten the connector
clockwise with pliers until the connector cannot be
i00683392
loosened by hand. Replace the lockwire.
Inlet Gas Manifold and Piping -
i01612988 Inspect/Replace
Ignition System Spark Plugs - SMCS Code: 1550-040; 1550-510
Replace
Inspect the components of the fuel inlet system for
SMCS Code: 1555-510 the following conditions:

Remove the used spark plugs. Install new spark • Cracks


plugs.
• Deterioration
For instructions on removing and installing spark
plugs, refer to this Operation and Maintenance • Leaks
Manual, “Ignition System Spark Plugs - Check/Adjust”
topic (Maintenance Section). • Loose connections
• Wear
i01935380

Inlet Air System - Inspect Inspect the following components:

SMCS Code: 1058-040; 1071-040; 1087-040 • Fuel lines from the source to the gas regulator

Use of a platform may be necessary to inspect the • Fuel lines from the gas regulator to the fuel inlet
following components of the air inlet system:
• Fuel inlet
• Piping between the air cleaner and the turbocharger
• Control valve
• Rubber hoses in the air lines
• Fuel manifold
• Turbocharger
• Connections of the fuel manifold and the fuel lines
• Piping between the turbocharger and the
aftercooler • Connections of the fuel lines to the orifice

• Aftercooler • Connections of the fuel lines to the cylinder head

• Connection of the aftercooler to the air plenum • Connections of the fuel lines to the precombustion
chamber
• Connection of the air plenum to the cylinder head
• Fuel pressure sensor
Inspect the components for the following conditions:
• Fuel temperature sensor
• Cracks Ensure that all of the connections are secure. Ensure
that the components of the fuel system are in good
• Leaks condition.
• Loose connections Make repairs, if necessary. For information regarding
removal and installation of the components, see the
• Debris Service Manual. Consult your Caterpillar dealer for
Ensure that all of the connections are secure. Ensure assistance.
that the components are in good condition and free
of debris.
112 SEBU7563-09
Maintenance Section
Overhaul (In-Frame)

i02252012 Note: These indications do not require an engine


to be shut down for service. These indications
Overhaul (In-Frame) only mean that an engine should be scheduled for
service in the near future. If the engine operation
SMCS Code: 1000-020 is satisfactory, an immediate overhaul is not a
requirement.
Scheduling an In-Frame Overhaul
An in-frame overhaul does not typically require
Table 37 lists the approximate number of service the engine to be removed. Instead, the service is
hours before an in-frame overhaul for different G3600 performed with the engine in place.
Engine applications.
Note: The generator or the driven equipment may
Table 37 also require service when the engine overhaul is
Estimated Service Hours Before An
performed.
In-Frame Overhaul
Service In-Frame Overhaul Information
Fuel Compression Ratio
Hours
An in-frame overhaul includes all of the work that is
Wellhead gas or done for a top end overhaul. Additionally, some other
9.2:1 50000
natural gas components that wear are replaced. The condition
45000 to of components is inspected. Those components are
Natural gas 10.5:1 replaced, if necessary.
48000
27000 to Inspect the following components according to
Bio-gas 9.2:1
33000
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Scheduling an in-frame overhaul normally depends Parts and Salvage Operations, SEBF8029, “Index
on the following three conditions: of Publications on Reusability or Salvage of Used
Parts”.
• An increase of oil consumption
Your Caterpillar dealer can provide these services
• An increase of crankcase blowby and components. Your Caterpillar dealer can ensure
that the components are operating within the
• A decrease and a variation of cylinder compression appropriate specifications.

Each individual condition may not indicate a need If you elect to perform an overhaul without the
for an overhaul. However, evaluating the three services of a Caterpillar dealer, be aware of the
conditions together is the most accurate method of following recommendations.
determining when an overhaul is necessary.
The following definitions explain the terminology for
The engine may not require an overhaul if the the services that are performed during an overhaul:
engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder Inspect – Inspect the components according to
compression. the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Periodically measure each of the three conditions. Parts and Salvage Operations, SEBF8029, “Index
The first measurement should occur during the first of Publications on Reusability or Salvage of Used
scheduled maintenance. This establishes a baseline Parts”. The guidelines were developed in order to
for future measurements. Additional measurements help Caterpillar dealers and customers to avoid
are scheduled at regular intervals in order to unnecessary expenditures. New parts are not
determine a schedule for the next in-frame overhaul. required if the existing parts can still be used,
reconditioned, or repaired. If the components are
The following changes in the three conditions not in the reusability guidelines, refer to the Service
normally require a scheduled overhaul: Manual, “Specifications” module.

• A 300 percent increase in oil consumption Rebuild – The component can be reconditioned in
order to comply with reusability guidelines.
• A 200 percent increase in crankcase blowby
• A 20 percent loss of cylinder compression
SEBU7563-09 113
Maintenance Section
Overhaul (Major)

Replace – The service life of the part is exhausted. i02252260


The part may fail before the next maintenance
interval. The part must be replaced with a part that Overhaul (Major)
meets functional specifications. The replacement part
may be a new part, a CAT remanufactured part, a SMCS Code: 7595-020-MJ
rebuilt part, or a used part. Various worn components
may be exchanged with your Caterpillar dealer. Scheduling a Major Overhaul
Consult your Caterpillar dealer about repair options
for your engine. Table 39 lists the approximate number of service
hours before a major overhaul for different G3600
Table 38
Engine applications.
In-Frame Overhaul (1)
Table 39
Procedure Component
Estimated Service Hours Before a Major Overhaul
Inspect Aftercooler
Replace Service
Cylinder liners Fuel Compression Ratio
Hours
Oil cooler
Pistons Wellhead gas or
9.2:1 100000
natural gas
Rebuild Gas admission valve
Electrohydraulic actuators
75000 to
Natural gas 10.5:1
Vibration damper 80000
Replace Camshaft bearings 52000 to
Bio-gas 9.2:1
54000
Camshaft followers
Connecting rod bearings The need for a major overhaul is determined by
Crankshaft seals several factors:
Engine oil pump • An increase of oil consumption
Exhaust shields
• An increase of crankcase blowby
Gaskets and seals
Electrohydraulic system's • A decrease and variation of cylinder compression
oil pump
The following changes in the three conditions
Main bearings normally require a scheduled overhaul:
Oil temperature regulators
• A 300 percent increase in oil consumption
Piston rings
Prechamber assemblies • A 200 percent increase in crankcase blowby
Water pumps
• A 20 percent loss of cylinder compression
Water temperature
regulators Note: These indications do not require an engine
(1) In addition to these procedures, perform the procedures for
to be shut down for service. These indications
the top end overhaul. only mean that an engine should be scheduled for
service in the near future. If the engine operation
is satisfactory, an immediate overhaul is not a
requirement.

The engine does not require an overhaul if the


engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder
compression.

Other factors must also be considered for determining


a major overhaul:
114 SEBU7563-09
Maintenance Section
Overhaul (Top End)

• The service hours of the engine Inspect – Inspect the components according to
the instructions that are in Caterpillar reusability
• The wear metal analysis of the lube oil publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
• An increase in the levels of noise and vibration of Publications on Reusability or Salvage of Used
Parts”. The guidelines were developed in order to
An increase of wear metals in the lube oil indicates help Caterpillar dealers and customers to avoid
that the bearings and the surfaces that wear may unnecessary expenditures. New parts are not
need to be serviced. An increase in the levels of required if the existing parts can still be used,
noise and vibration indicates that rotating parts reconditioned, or repaired. If the components are
require service. not in the reusability guidelines, refer to the Service
Manual, “Specifications” module.
Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder Rebuild – The component can be reconditioned in
liners may be worn so that polishing of the bore order to comply with reusability guidelines.
occurs. Also, the increased use of lube oil will dilute
the wear metals. Replace – The service life of the part is exhausted.
The part may fail before the next maintenance
Monitor the engine as the engine accumulates interval. The part must be replaced with a part that
service hours. Consult your Caterpillar dealer about meets functional specifications. The replacement
scheduling a major overhaul. part may be a new part, a CAT remanufactured part,
a rebuilt part, or a used part. Some worn components
Note: The driven equipment may also require service may be exchanged with your Caterpillar dealer.
when the engine is overhauled. Refer to the literature Consult your Caterpillar dealer about repair options
that is provided by the OEM of the driven equipment. for your engine.

Table 40
Major Overhaul Information
Major Overhaul(1)
A major overhaul includes all of the work that is done Procedure Component
for a top end overhaul. A major overhaul can also
include all of the work that is done for an in-frame Inspect Camshafts
overhaul. A major overhaul includes additional parts Replace
Connecting rods
and labor. Additional parts and labor may be required
in order to completely rebuild the engine. In some Crankshaft
cases, the engine is relocated for disassembly. Rebuild Inlet air piping

For the major overhaul, bearings, seals, gaskets, and Replace Aftercooler
components that wear are disassembled. The parts Camshaft lifters
are cleaned and inspected. If necessary, the parts
are replaced. The crankshaft is measured for wear. Exhaust manifolds
The crankshaft may require regrinding. Alternatively, Gear train bearings
the crankshaft may be replaced with a Caterpillar
replacement part. Oil cooler
(1) In addition to these procedures, perform the procedures for
Your Caterpillar dealer can provide these services both the top end overhaul and the in-frame overhaul.
and components. Your Caterpillar dealer can ensure
that the components are operating within the
i03247357
appropriate specifications.

If you elect to perform an overhaul without the


Overhaul (Top End)
services of a Caterpillar dealer, be aware of the SMCS Code: 7595-020-TE
following recommendations.

The following definitions explain the terminology for Scheduling a Top End Overhaul
the services that are performed during an overhaul:
Table 41 lists the approximate number of service
hours before a top end overhaul for different G3600
Engine applications.
SEBU7563-09 115
Maintenance Section
Overhaul (Top End)

Table 41 • Cleaning equipment


Estimated Service Hours Before a Top End Overhaul
• Rebuilding equipment
Fuel Compression Ratio Service
Hours Caterpillar dealers are equipped with these tools.
Wellhead gas or 9.2:1 25000 Caterpillar dealers can provide a flat rate price for
natural gas a top end overhaul.
Natural gas 10.5:1 15000 Unexpected problems may be found during a top
Bio-gas 9.2:1 10000 to end overhaul. Plan to correct these problems, if
14000 necessary.

Top end overhauls are normally scheduled according


• Buildup in the cylinders from excessive oil
consumption
to the projection of exhaust valve stems. This
measurement provides an accurate indication of the
rate of valve wear. This measurement can be used to
• Plugging of the aftercooler from coolant that is
poorly maintained
predict when a cylinder head requires replacement.

Measure the projection of the exhaust valve stems at


• Degradation of the oil cooler from hydrogen sulfide
in the fuel
the first 1000 service hours. This measurement is the
baseline. The baseline is a reference for subsequent Inspect the following components according to
measurements. Continue to periodically measure the instructions that are in Caterpillar reusability
the projection. publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
Plan for the top end overhaul as the valve stem of Publications on Reusability or Salvage of Used
projection approaches the maximum limit. Perform Parts”.
the top end overhaul when the valve stem projection
has increased by a total of 2.3 mm (.09 inch). Do not Your Caterpillar dealer can provide these services
allow the projection of the exhaust valve stems and components. Your Caterpillar dealer can ensure
to exceed this limit. that the components are operating within the
appropriate specifications.
Note: Generally, cylinder heads wear out at different
rates. In some cases, servicing the cylinder heads at If you elect to perform an overhaul without the
different times may be the most economic decision. services of a Caterpillar dealer, be aware of the
This depends on the valve stem projection of the following recommendations.
individual cylinders. However, this decision must
include the costs of additional downtime that is The following definitions explain the terminology for
caused by this procedure. Perform an economic the services that are performed during an overhaul:
analysis in order to determine if cylinder heads should
be serviced as a group or divided into smaller groups. Inspect – Inspect the components according to
the instructions that are in Caterpillar reusability
Note: The generator or the driven equipment may publications. Refer to Guidelines for Reusable
also require service when the engine overhaul is Parts and Salvage Operations, SEBF8029, “Index
performed. of Publications on Reusability or Salvage of Used
Parts”. The guidelines were developed in order to
Top End Overhaul Information help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
A top end overhaul involves servicing the cylinder required if the existing parts can still be used,
heads and turbochargers. Also, some other engine reconditioned, or repaired. If the components are
components are inspected. not in the reusability guidelines, refer to the Service
Manual, “Specifications” module.
Top end overhauls require more tools than preventive
maintenance. The following tools are needed for Rebuild – The component can be reconditioned in
restoring the engine to factory specifications: order to comply with reusability guidelines.

• Torque wrenches
• Dial indicators
• Accurate measurement tools
116 SEBU7563-09
Maintenance Section
Overhaul Considerations

Replace – The service life of the part is exhausted. • Costly unplanned downtime can be avoided.
The part may fail before the next maintenance
interval. The part must be replaced with a part that • Many original parts can be reused according to the
meets functional specifications. The replacement guidelines for reusable parts.
part may be a new part, a Cat remanufactured part, a
rebuilt part, or a used part. Some worn components • The service life of the engine can be extended
may be exchanged with your Caterpillar dealer. without the risk of a major catastrophe due to
Consult your Caterpillar dealer about repair options engine failure.
for your engine.
• Achieve the best cost/value relationship per hour
Table 42 of extended service life.
Top End Overhaul
Procedure Component
Overhaul Intervals
Inspect/Replace Seals for the gas admission Top end overhauls are determined by the projection
valve of exhaust valve stems. In-frame overhauls are
Precombustion chambers determined by cylinder compression, crankcase
Drive coupling blowby, and oil consumption. Major overhauls are
Rebuild Gas pressure regulator determined by the in-frame tests, and by results of
Starting motor S·O·S oil analysis.
Turbochargers
Some other factors that are important for determining
Replace Connecting rod bearings
Cylinder heads and
the overhaul intervals include the following
gaskets considerations:
Oil temperature regulators
Spark plug extenders • Performance of preventive maintenance
Water temperature
regulators • Use of recommended lubricants
• Use of recommended coolants
i02250409
• Use of recommended fuels
Overhaul Considerations
• Proper installation
SMCS Code: 7595-043
• Operating conditions
Overhaul Information
• Operation within acceptable limits
An overhaul is replacing the major worn components
of the engine. An overhaul is a maintenance interval • Engine load
that is planned. The engine is rebuilt with certain
rebuilt parts or new parts that replace the worn parts. • Engine speed
An overhaul also includes the following maintenance: Note: To avoid oil problems, engines that are
turbocharged and aftercooled must be operated at a
• Inspection of all the parts that are visible during minimum of 60 percent of rated load.
the disassembly
Generally, engines that are operated at a reduced
• Replacement of the seals and gaskets that are load and/or speed achieve more service life before
removed an overhaul. However, this is for engines that are
properly operated and maintained.
• Cleaning of the internal passages of the engine
and the engine block

Most owners will save money by overhauling the


engine at the intervals that are recommended in
the Operation and Maintenance Manual. It is not
practical to wait until the engine exhibits symptoms
of excessive wear or failure. It is not less costly to
wait. A planned overhaul before failure may be the
best value for the following reasons:
SEBU7563-09 117
Maintenance Section
Overhaul Considerations

Bio-Gas • Crankshafts
The overhaul intervals for engines that use bio-gas • Cylinder heads
depend on the concentration of contaminants in the
fuel. Although silicon is the primary contaminant • Oil Pumps
in bio-gas, other contaminants may cause further
reductions in the overhaul intervals. For more • Starting motors
information, refer to Gas Engines Application and
Installation Guide, LEKQ7260, “G3600 - G3300 Low • Turbochargers
Energy Fuels”.
• Water pumps
Overhaul Inspection
Consult your Caterpillar dealer for details and for a
Refer to the Service Manual for the disassembly and list of the remanufactured parts that are available.
assembly procedures that are necessary in order
to perform the required maintenance on the items Your Caterpillar dealer may be offering a variety of
that are listed. Consult your Caterpillar dealer for overhaul options.
assistance.
A Flat Rate Overhaul guarantees the maximum price
To determine the reusability publications that are that you will pay for an overhaul. Flat rate prices on
needed to inspect the engine, refer to Guidelines for preventive maintenance programs or major repair
Reusable Parts and Salvage Operations, SEBF8029, options are available from many servicing dealers
“Index of Publications on Reusability or Salvage of for all Caterpillar Engines. Consult your Caterpillar
Used Parts”. dealer in order to schedule a before failure overhaul.

The Guidelines For Reusable Parts and Salvage Overhaul Recommendation


Operations is part of an established Caterpillar
parts reusability program. These guidelines were Caterpillar recommends a scheduled overhaul in
developed in order to assist Caterpillar dealers and order to minimize downtime. A scheduled overhaul
customers reduce costs by avoiding unnecessary will provide the lowest cost and the greatest value.
expenditures for new parts. If the engine parts comply Schedule an overhaul with your Caterpillar dealer.
with the established inspection specifications, the
parts can be reused. New parts are not necessary if Overhaul programs vary between dealers. To obtain
the old parts can be reused, repaired, or salvaged. specific information about the types of overhaul
programs and services, consult your Caterpillar
If the parts are not within the inspection specifications, dealer.
the parts should be salvaged, repaired, replaced,
or exchanged. The use of out-of-spec parts could
result in unscheduled downtime and/or costly repairs.
The use of out-of-spec parts can also contribute to
increased fuel consumption and reduction of engine
efficiency.

Your Caterpillar dealer can provide the parts that are


needed to rebuild the engine at the least possible
cost.

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

• Alternators
• Connecting rods
118 SEBU7563-09
Maintenance Section
Prechamber - Clean/Inspect

i02602727 i02602093

Prechamber - Clean/Inspect Prechamber Check Valves -


SMCS Code: 1106-571 Clean
SMCS Code: 1550-070

g00789869
Illustration 100
(1) Plug
(2) O-ring seal
(3) Check valve assembly
(4) O-ring seal
g01302648 (5) Gasket
Illustration 99

Note: Use of a platform may be necessary to reach


1. Remove the ignition body assembly. Remove the prechamber check valves.
prechamber cup (1) from the ignition body. Refer
to the engine's Disassembly and Assembly Note: Refer to the engine's Disassembly and
manual for instructions. Assembly manual for instructions on removal and
installation of the check valves.
2. Clean the deposits from the prechamber cup.
1. Remove check valve assembly (3) and gasket (5).
3. Inspect the sealing flange for damage and debris.
Replace any prechamber cup that has a damaged 2. Discard gasket (5) and O-ring (4). Disassemble
flange. Replace any prechamber cup that has the check valve by unscrewing the end cap.
eroded holes. Replace any prechamber cup that
has cracks that are extending from the holes. a. Clean all parts with a non-chlorinated solvent.
4. Clean the prechamber gasket set in the cylinder b. Reassemble the check valve and torque the
head by using the 9U-5156 Cleaning Tool Group. cap to 2 N·m (1.5 lb ft).
Wipe the surface with a clean cloth and solvent.
3. Install a new gasket and a new O-ring. Install the
5. Install new prechamber gaskets and O-rings. clean, dry check valve assembly and torque to
115 N·m (85 lb ft).
6. Install the ignition body assembly in cylinder head.
Refer to the engine's Specifications manual for the 4. Do NOT overtighten the plug for the check valve.
proper torque procedure. Tighten to 15 N·m (11 lb ft).
SEBU7563-09 119
Maintenance Section
Prechamber Check Valves - Replace

i02602222 Inspect the prelube pump for leaks. Replace all of the
seals if a leak is observed.
Prechamber Check Valves -
Replace Inspect the wiring for the following conditions:

SMCS Code: 1550-510 • Damage


• Fraying
Ensure that the wiring is in good condition.

Inspect the electrical connections. Ensure that the


electrical connections are secure.

If repair or replacement is necessary, refer to the


engine's Disassembly and Assembly manual. Consult
your Caterpillar dealer for assistance.

Air Prelube Pump


g00789869 Inspect all of the components in the air circuit for
Illustration 101
the prelube pump. Inspect all of the air lines and
(1) Plug connections for leaks. Ensure that the components in
(2) O-ring seal
(3) Check valve assembly
the air circuit are in good condition.
(4) O-ring seal
(5) Gasket
Electric Prelube Pump
Note: Use of a platform may be necessary to reach Inspect the brushes. Replace the brushes, if
the prechamber check valves. necessary.
Note: Refer to the engine's Disassembly and
Assembly manual for instructions on removal and i01113939
installation of the check valves.
Starting Motor - Inspect
1. Remove check valve assembly (3) and gasket (5).
SMCS Code: 1451-040; 1453-040
2. Keep plug (1) for reassembly. Discard the other
parts. Obtain new parts for reassembly. If the starting motor fails, the engine may not start in
an emergency situation. A scheduled inspection of
3. Install a new gasket and a new O-ring. Install the the starting motor is recommended.
clean, dry check valve assembly and torque to
115 N·m (85 lb ft). The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine
4. Do NOT overtighten the plug for the check valve. to start properly. The engine will not start if the
Tighten to 15 N·m (11 lb ft). 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
i01612991 irregular engagement.
Prelube Pump - Inspect Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
SMCS Code: 1319-040 teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth. Look
Inspect the prelube pump for the following conditions: for teeth that are broken or chipped. If damaged teeth
are found, the starting motor pinion and the flywheel
• Cracks ring gear must be replaced.
• Pin holes
• Proper operation
• Wear
120 SEBU7563-09
Maintenance Section
Turbocharger - Clean

Electric Starting Motor i01765784

Note: Problems with the electric starting motor can Turbocharger - Clean
be caused by the following conditions: malfunction of (Cleaning with Dry Particles)
the solenoid and malfunction of the electric starting
system. SMCS Code: 1052-070
Inspect the electrical system for the following Note: Use of a platform may be necessary to reach
conditions: the turbocharger.

• Loose connections If the engine has more than one turbocharger, each
turbocharger requires cleaning.
• Corrosion
Note: The drain openings in the exhaust housing
• Wires that are worn or frayed of the turbocharger are closed during the cleaning
procedure. Some of the particles will be expelled
• Cleanliness through the exhaust stack. The particles that are
expelled will be burned.
Make repairs, if necessary.
The materials that are listed in Table 43 are
Air Starting Motor recommended for use with this cleaning procedure.

Table 43
Materials for Cleaning 3600 Engine Turbochargers

Personal injury or death can result from improp- Material Particle Size
erly checking for a leak. Nut shell 1.7 mm
(1/16 inch)
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure, Formed carbon 1 mm (1/32 inch)
even a pin-hole size leak, can penetrate body tis- Granulated carbon (70% hardness) 1.2 to 2 mm
sue causing serious injury, and possible death. (3/64 to 5/64 inch)

If fluid is injected into your skin, it must be treated Granulated dry rice 1.7 mm
(1/16 inch)
immediately by a doctor familiar with this type of
injury.

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
g00833073
Illustration 102
Refer to the Service Manual, “Disassembly and
(1) Air valve
Assembly” module for information on removing the (2) Purge valve
starting motor and installing the starting motor. (3) Cap
(4) Gate valve
Consult your Caterpillar dealer for assistance.
Note: During normal engine operation, air valve (1),
purge valve (2), and gate valve (4) are closed.

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


cap (3) is secure. Open gate valve (4).
SEBU7563-09 121
Maintenance Section
Turbocharger - Inspect

2. Open air valve (1) in order to remove deposits


that may be in the connecting pipe. After three NOTICE
minutes, close air valve (1). Close gate valve (4). Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems.
3. Open purge valve (2) in order to relieve any Loss of engine lubricant can result in serious engine
pressure from the container. Close purge valve damage.
(2).
Minor leakage of a turbocharger housing under ex-
4. Remove cap (3). Pour 0.5 L (0.5 qt) of the particles tended low idle operation should not cause problems
into the container. Tighten cap (3). as long as a turbocharger bearing failure has not oc-
curred.
5. Ensure that purge valve (2) is closed. Reduce
the output of the engine so that the exhaust When a turbocharger bearing failure is accompanied
temperature before the turbine is less than 577 °C by a significant engine performance loss (exhaust
(1070 °F). smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
6. Open gate valve (4). Open air valve (1). replaced.

7. After 60 to 90 seconds, close air valve (1). Close


gate valve (4). An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
8. Open purge valve (2) in order to relieve any turbocharger can also reduce the chance for potential
pressure from the container. Close purge valve damage to other engine parts.
(2).
Note: Turbocharger components require clearances
that are precise. The turbocharger cartridge must be
i00908991 balanced due to high rpm.
Turbocharger - Inspect The following conditions can cause the turbocharger
to be out-of-balance:
SMCS Code: 1052-040

Periodic inspection and cleaning is recommended


• The buildup of deposits
for the turbocharger.
• Chipping and/or flaking of deposits
Fouling of the turbine wheels can contribute to loss of If the turbocharger must be removed for inspection,
engine power and overall loss of engine efficiency. use caution. Do not break deposits from the turbine
wheel. Do not attempt to clean the turbine wheel. For
If the turbocharger fails during engine operation, options regarding removal, installation, repair and
damage to the turbocharger compressor wheel replacement, see the Service Manual or consult your
and/or to the engine may occur. Damage to the Caterpillar dealer.
turbocharger compressor wheel could allow parts
from the compressor wheel to enter an engine 1. Remove the exhaust outlet piping and remove
cylinder. This can cause additional damage to the the air inlet piping from the turbocharger. Visually
pistons, the valves, and the cylinder head. inspect the piping for the presence of oil.

2. Turn the compressor wheel and the turbine wheel


by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned.
122 SEBU7563-09
Maintenance Section
Turbocharger Cleaner Tube - Replace

3. Check the compressor wheel for cleanliness. i01765785


If only the blade side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering Turbocharger Cleaner Tube -
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
Replace
oil seal. SMCS Code: 1052-510
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the
turbocharger to slobber.

Note: Deposits of ash and silicon can accumulate


on the turbine wheel. Turbine wheel will become
unbalanced when the deposits flake off. The
turbocharger cartridge must be replaced when this
occurs. However, remove deposits from the housing.
This will prevent wear on the blades of the turbine
wheel.
g00790542
4. Inspect the turbine wheel and the nozzle for Illustration 103
deposits of ash and silicon. If deposits of 1 mm (1) Air valve
(1/32 inch) thickness are found, the turbocharger (2) Purge valve
must be disassembled and cleaned at an (3) Gate valve
ABBrepair facility. (4) Tube

5. Inspect the bore of the turbine housing for Note: Use of a platform may be necessary in order to
corrosion. reach the cleaner tube.

6. Clean the turbocharger housing with standard 1. Stop the engine.


shop solvents and a soft bristle brush.
2. Ensure that air valve (1) and gate valve (3) are
7. Check the clearances of the turbocharger bearing. closed.
Compare the clearances to the Service Manual,
“Specifications”. If the clearances are not within 3. Open purge valve (2) in order to relieve any
the specifications, the turbocharger must be pressure from the container.
repaired.
4. Remove tube (4). Discard the used tube.
8. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing. 5. Install a new tube.

6. Close purge valve (2).

i00682053

Valve Stem Projection -


Measure/Record
SMCS Code: 1105-082

Valve Recession – The valves and the valve seats


are worn over time. This causes the valves to recede
into the cylinder head. This condition is called “valve
recession”.

The exhaust valves and valve seats show the


greatest wear due to high operating temperatures.
The top end overhaul interval is normally scheduled
according to exhaust valve recession.
SEBU7563-09 123
Maintenance Section
Walk-Around Inspection

The actual measurement of the valve recession i01492446


inside of the cylinder head is difficult to obtain.
Two simpler methods are used to determine valve Walk-Around Inspection
recession:
SMCS Code: 1000-040
• Measure the projection of the valve stem above
the cylinder head. It is necessary to remove the Inspect the Engine for Leaks and
rocker arms in order to obtain this measurement.
This method is more accurate than measuring the for Loose Connections
projection of the exhaust valve rotators. Measure
the projection of the exhaust valve stems with the A walk-around inspection should only take a few
4C-2980 Cylinder Head Valve Projection Group. minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
• Measure the projection of the valve rotator above For maximum engine service life, thoroughly inspect
the cylinder head. It is not necessary to remove the
rocker arms in order to obtain this measurement. the engine room before starting the engine. Look for
Measure the projection of the exhaust valve items such as leaks, loose bolts, loose connections
rotators with the 148-2997 Valve Recession Tool and trash buildup. Make repairs, as needed.
Group.
• The guards must be in the proper place. Repair
Make several copies of this Operation and damaged guards or replace missing guards.
Maintenance Manual, “Valve Data Sheet” (Reference
Materials Section). Record the measurements on • Wipe all caps and plugs before the engine is
the sheets. serviced in order to reduce the chance of system
contamination.
• Measure the projection of the inlet and exhaust
valve stems and the exhaust valve rotators at NOTICE
the first 1000 service hours. This measurement For any type of leak, clean up the fluid. If leaking is ob-
is the baseline. The baseline is a reference for served, find the source and correct the leak. If leaking
subsequent measurements. is suspected, check the fluid levels more often than
recommended until the leak is found or fixed, or until
• Measure the projection of the inlet and exhaust the suspicion of a leak is proved to be unwarranted.
valve rotators when the engine valve lash is
checked. Continue this periodic measurement until
the projection of the valve rotator has increased by NOTICE
a total of 1.6 mm (.063 inch). This is 70 percent of Accumulated grease and/or oil on an engine or deck is
the maximum limit. Measure the projection of the a fire hazard. Remove this debris with steam cleaning
valve stems when this occurs. This measurement or high pressure water.
will determine the actual wear of both the valves
and the valve seats. • Ensure that cooling lines are properly clamped.
Check for leaks. Check the condition of all pipes.
• After 70 percent of the maximum limit has been
reached, measure the projection of the exhaust • Inspect the water pumps for coolant leaks.
valve stems at every 500 hours of operation.
Note: The water pump seal is lubricated by coolant
• Plan for the top end overhaul as the valve in the cooling system. It is normal for a small amount
stem projection approaches the maximum limit. of leakage to occur when the engine cools and the
Perform the top end overhaul when the valve stem parts contract.
projection has increased by a total of 2.3 mm
(.09 inch). Do not allow the valve recession Excessive coolant leakage may indicate the need
to exceed this limit. The valve head can break. to replace the water pump seal. For instructions
This will cause severe damage in the combustion on removal and installation of water pumps and/or
chamber and the turbocharger. seals, refer to the Service Manual, “Disassembly and
Assembly” module for the engine or consult your
Consult your Caterpillar dealer for assistance. Caterpillar dealer.

• Inspect the lubrication system for leaks at the front


crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve covers.
124 SEBU7563-09
Maintenance Section
Water Pump - Inspect

NEVER use a flame to check for gas leaks. Use a


gas detector.

An open flame can ignite mixtures of air and fuel.


This will cause explosion and/or fire which could
result in severe personal injury or death.

• Check the fuel system for leaks. Look for loose fuel
line clamps.

• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.

• Inspect the wiring and the wiring harnesses for


loose connections and for worn wires or frayed
wires.

• Inspect the ground straps for good connections


and for good condition.

• Check the condition of the gauges. Replace any


gauge that is damaged. Replace any gauge that
can not be calibrated.

• Inspect the exhaust system for leaks. If a leak is


found, make repairs.

i02624237

Water Pump - Inspect


SMCS Code: 1361-040

A failed water pump might cause severe engine


overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential
damage to the engine.

Visually inspect the water pump for leaks. If leaking


of the water pump seals is observed, replace all of
the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump
- Disassemble and Water Pump - Assemble” for
the disassembly and assembly procedure. If it is
necessary to remove the water pump, refer to two
articles in the Disassembly and Assembly Manual,
“Water Pump - Remove and Water Pump - Install”.

Inspect the water pump for wear, cracks, pin holes


and proper operation. Refer to the Parts Manual
for the correct part numbers for your engine or
consult your Caterpillar dealer if repair is needed or
replacement is needed.
SEBU7563-09 125
Reference Information Section
Customer Service

Reference Information Latin America, Mexico, Carribean


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

Europe, Africa, and Middle East


i03910306
Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000; 4450 CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
USA and Canada Fax: 22-849-4544
When a problem arises concerning the operation or Far East
the service of an engine, the problem will normally be Caterpillar Asia Pte. Ltd.
managed by the dealer in your area. 7 Tractor Road
Jurong, Singapore 627968
Your satisfaction is a primary concern to Caterpillar Republic of Singapore
and to Caterpillar dealers. If you have a problem that Phone: 65-662-8333
has not been handled to your complete satisfaction, Fax: 65-662-8302
follow these steps:
China
1. Discuss your problem with a manager from the Caterpillar China Ltd.
dealership. 37/F., The Lee Gardens
33 Hysan Avenue
2. If your problem cannot be resolved at the dealer Causeway Bay
level, use the phone number that is listed below to G.P.O. Box 3069
talk with a Field Service Coordinator: Hong Kong
Phone: 852-2848-0333
1-800-447-4986 Fax: 852-2848-0440
The normal hours are from 8:00 to 4:30 Monday Japan
through Friday Central Standard Time. Shin Caterpillar Mitsubishi Ltd.
SBS Tower
3. If your needs have not been met still, submit the 10-1, Yoga 4-Chome
matter in writing to the following address: Setagaya-Ku, Tokyo 158-8530
Japan
Caterpillar Inc. Phone: 81-3-5717-1150
Manager, Customer Service, Engine Division Fax: 81-3-5717-1177
Mossville Bldg AC
P.O. Box 610 Japan
Mossville, Illinois 61552-0610 Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
Please keep in mind: probably, your problem will 4-10-1, Yoga
ultimately be solved at the dealership, using the Setagaya-Ku, Tokyo 158-0097
dealership facilities, equipment, and personnel. Phone: 81-3-5797-4300
Therefore, follow the steps in sequence when a Fax: 81-3-5797-4359
problem is experienced.
Australia and New Zealand
Outside of the USA and of Canada Caterpillar of Australia Ltd.
1 Caterpillar Drive
If a problem arises outside the USA and outside Private Mail Bag 4
Canada, and if the problem cannot be resolved at the Tullamarine, Victoria 3043
dealer level, consult the appropriate Caterpillar office. Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
126 SEBU7563-09
Reference Information Section
Customer Service

i01028392

Ordering Replacement Parts


SMCS Code: 4450; 7567

When replacement parts are required for this


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

Failure to heed this warning can lead to prema-


ture failures, product damage, personal injury or
death.

Quality Caterpillar replacement parts are available


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

When you order parts, please specify the following


information:

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

When a Caterpillar engine requires maintenance


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

Discuss the problem with the dealer. Inform the


dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
SEBU7563-09 127
Reference Information Section
Reference Materials

Reference Materials • Maintenance log

i00912149

Maintenance Records
SMCS Code: 1000; 4450

Caterpillar Inc. recommends the retention of accurate


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

• Determine operating costs.


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

• Show compliance with the required maintenance


practices and maintenance intervals.

Maintenance records can be used for a variety of


other business decisions that are related to engine
maintenance.

Maintenance records are a key element of a


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

Records should be kept for the following items:

Fuel Consumption – A record of fuel consumption


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

Service Hours – A record of service hours is


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

Documents – These items should be easy to


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

Keep the following types of documents as proof of


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

• Dealer work orders and itemized bills


• Owner's repair costs
• Owner's receipts
128 SEBU7563-09
Reference Information Section
Reference Materials

i03905196

Maintenance Log
SMCS Code: 1000; 4450

Table 44
Engine Model Customer Identifier
Serial Number Arrangement Number
Service
Service Item Date Authorization
Hours
SEBU7563-09 129
Reference Information Section
Reference Materials

i00769479

Valve Data Sheet


SMCS Code: 1000

Table 45
Engine Model Serial Number Service Hours Authorization
Cylinder Valve Location Current Stem Rotator
Cylinder Wear
Pressure Measure Baseline Baseline
1 Pushrod Side
Exhaust Manifold
2 Pushrod Side
Exhaust Manifold
3 Pushrod Side
Exhaust Manifold
4 Pushrod Side
Exhaust Manifold
5 Pushrod Side
Exhaust Manifold
6 Pushrod Side
Exhaust Manifold
7 Pushrod Side
Exhaust Manifold
8 Pushrod Side
Exhaust Manifold
9 Pushrod Side
Exhaust Manifold
10 Pushrod Side
Exhaust Manifold
11 Pushrod Side
Exhaust Manifold
12 Pushrod Side
Exhaust Manifold
13 Pushrod Side
Exhaust Manifold
14 Pushrod Side
Exhaust Manifold
15 Pushrod Side
Exhaust Manifold
16 Pushrod Side
Exhaust Manifold
130 SEBU7563-09
Reference Information Section
Reference Materials

i02602385 • Application and Installation Guide, LEBW4977,


“Gaseous Fuels”
Reference Material
• Application and Installation Guide, LEBW5336,
SMCS Code: 1000; 4450 “Gaseous Fuel Systems”
The following literature can be obtained through any • Application and Installation Guide, LEKQ7260,
Caterpillar dealer. “Low Energy Fuels”

Lubricants • Special Publication, LEKQ9360, “Internal


Combustion Engine Fuel Gases” (Only available
through www.cat.com)
Oils
• Special Publication, PEDP7036, “S·O·S Fluid • Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel, and Coolant
Analysis”
Recommendations”
• Special Publication, PEHP6001, “How To Take A
Good Oil Sample” • Special Instruction, SEHS9298, “Installation and
Maintenance of Gaseous Fuel Filters”
• Data Sheet, PEHP0004, “Cat NGEO”
Coolants
• Data Sheet, PEHJ0006, “Cat NGEO EL350”
• Special Publication, PEDP7036, “S·O·S Fluid
• Special Publication, SEBD0640, “Oil and Your Analysis”
Engine”
• Data Sheet, PEHJ0040, “Cat NGEC (Premix)”
• Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel, and Coolant • Special Instruction, PEHP7057, “Coolant Analysis”
Recommendations”
• Data Sheet, PEHP9554, “Cat DEAC (Concentrate)”
Grease
• Special Publication, SEBD0518, “Know Your
• Data Sheet, NEHP6010, “Cat Ultra 5Moly Grease” Cooling System”
(NLGI grades 1 and 2)
• Special Publication, SEBD0970, “Coolant and Your
• Data Sheet, NEHP6015, “Cat High Speed Ball Engine”
Bearing Grease” (NLGI grade 2)
• Special Publication, SEBU6400, “Caterpillar
• Special Publication, PEGJ0035, “Grease Selection Gas Engine Lubricant, Fuel, and Coolant
Guide” Recommendations”

• Data Sheet, PEHJ0088, “Cat Multipurpose Grease” Miscellaneous


(NLGI grade 2)
• Special Instruction, GMG00694, “Analyzing
• Data Sheet, PEHP0002, “Cat Advanced 3Moly Cylinder Condition By Measuring Air Flow”
Grease” (NLGI grade 2)
• Data Sheet, LEKQ2364, “US Stationary Engine
• Special Publication, SEBU6400, “Caterpillar Regulations/Spark Ignited Emissions”
Gas Engine Lubricant, Fuel, and Coolant
Recommendations” • Application and Installation Guide, LEBW4969, “Air
Intake System”
Fuels
• Application and Installation Guide, LEBW4970,
• Special Publication, LEKQ5404, “Fuels “Exhaust Systems”
Specifications Changes” (Only available through
www.cat.com) • Application and Installation Guide, LEBW4971,
“Engine Room Ventilation”
• Software Program, LEKQ6378, “Methane Number
Program” • Application and Installation Guide, LEBW4958,
“Crankcase Ventilation”
SEBU7563-09 131
Reference Information Section
Reference Materials

• Application and Installation Guide, LEBW4974, Engine Manufacturers Associaton


“Mounting” Two North LaSalle Street, Suite 2200
Chicago, IL, USA 60602
• Application and Installation Guide, LEBW4975, E-mail: ema@enginemanufacturers.org
“Alignment” Telephone: (312) 827-8700
Facsimile: (312) 827-8737
• Application and Installation Guide, LEBW4978,
“Cooling Systems” The “Society of Automotive Engineers (SAE)
Specifications” can be found in your SAE handbook.
• Application and Installation Guide, LEBW4957, This publication can also be obtained from the
“Lubrication Systems” following locations: local technological society, local
library, and local college. If necessary, consult SAE
• Special Publication, NEHS0526, “Service at the following address:
Technician Application Guide”
SAE International
• Special Publication, NENG2500, “Caterpillar 400 Commonwealth Drive
Dealer Service Tools Catalog” Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841
• Special Publication, PECP9067, “One Safe
Source” The “American Petroleum Institute Publication No.
1509” can be obtained from the following locations:
• Service Manual, RENR5905, “G3600 Engines” local technological society, local library, and local
college. If necessary, consult API at the following
• Special Publication, SEBF8029, “Index to address:
Guidelines for Reusable Parts and Salvage
Operations” American Petroleum Institute
1220 L St. N.W.
• Special Publication, SEBF8062, “Procedure to Washington, DC, USA 20005
Inspect and Clean Air Filters” Telephone: (202) 682-8000

• Special Instruction, SEHS7332, “Do Not Operate The International Organization for Standardization
Tag” (ISO) offers information and customer service
regarding international standards and standardizing
• Special Instruction, SEHS7633, “Battery Test activities. ISO can also supply information on the
Procedure” following subjects that are not controlled by ISO:
national standards, local standards, regulations,
• Special Instruction, SEHS8622, “Using the FT1984 certification, and related activities. Consult the
Air-To-Air Aftercooler Leak Test Group” member of ISO in your country.

• Special Instruction, SEHS8712, “Using the International Organization for Standardization


8T-2700 Blowby/Airflow Indicator Group” (ISO)
1, rue de Varembé
• Special Instruction, SEHS8984, “Using the Case postale 56
1U-8860 Large Engine Blowby Pickup Group” CH-1211 Genève 20
Switzerland
• Special Instruction, SEHS9031, “Storage Telephone: +41 22 749 01 11
Procedure for Caterpillar Products” Facsimile: +41 22 733 34 30
E-mail: central@iso.ch
• Special Instruction, SEHS9162, “Spring Isolator Web site: http://www.iso.ch
Group Installation and Adjustment Procedure”
European classifications are established by the
• Specifications, SENR3130, “Torque Specifications” Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).
Additional Reference Material
CIMAC Central Secretariat
The “Engine Fluids Data Book” can be obtained from
Lyoner Strasse 18
the following locations: local technological society,
local library, and local college. If necessary, consult 60528 Frankfurt
Germany
EMA at the following address:
Telephone: +49 69 6603 1567
Facsimile: +49 69 6603 1566
132 SEBU7563-09
Reference Information Section
Reference Materials

i00382622

Warranty Information
SMCS Code: 1000

Engine Protection Plans


Extended Warranties and Service
Contracts
A wide variety of protection plans are available for
Caterpillar Engines. Consult your Caterpillar dealer
for detailed information on the specific programs and
coverages that are available.

Consult your Caterpillar dealer for information on a


plan that is tailored in order to fit your requirements.
SEBU7563-09 133
Index Section

Index
A Control Panel......................................................... 38
Advisor II ........................................................... 38
Actuator Control Linkage - Lubricate (If “DESIRED SPEED” Potentiometer .................... 43
applicable) ........................................................... 66 “EMERGENCY STOP” Button ........................... 41
Hydraulic Actuators............................................ 66 Indicators ........................................................... 41
Actuator Control Linkage - Replace....................... 66 “MANUAL PRELUBE” Switch and “PRELUBE
Removal and Installation.................................... 66 ACTIVE” Indicator ............................................ 42
Additional Messages ............................................. 10 Mode Control Switch.......................................... 42
After Starting Engine ............................................. 49 Control Panel - Inspect .......................................... 74
Engaging the Driven Equipment ........................ 49 Record the Data and Review the Data .............. 74
After Stopping Engine............................................ 53 Cooling System Coolant (NGEC) - Change .......... 74
Aftercooler Condensation - Drain .......................... 67 Clean the Cooling System ................................. 75
Air Starting Motor Lines Screen - Clean ................ 67 Cleaning a Cooling System that has Heavy
Air Starting Motor Lubricator Bowl - Clean ............ 67 Deposits or Plugging ........................................ 75
Air Starting Motor Lubricator Oil Level - Check ..... 68 Drain the Cooling System .................................. 74
Adjust the Lubricator .......................................... 69 Fill the Cooling System ...................................... 75
Air Tank Moisture and Sediment - Drain................ 69 Cooling System Coolant Level - Check ................. 76
Alternator - Inspect ................................................ 69 Add Coolant ....................................................... 76
Engines That Are Equipped With a Sight
Gauge .............................................................. 76
B Engines That Are Not Equipped With a Sight
Gauge .............................................................. 76
Barring Device - Lubricate ..................................... 69 Cooling System Coolant Sample (Level 1) -
Electric Barring Device....................................... 70 Obtain .................................................................. 77
Manual Barring Device....................................... 70 Cooling System Coolant Sample (Level 2) -
Battery Electrolyte Level - Check .......................... 71 Obtain .................................................................. 77
Before Starting Engine .................................... 17, 45 Cooling System Level Switch - Inspect ................. 77
Air Inlet System.................................................. 45 Cooling System Supplemental Coolant Additive
Cooling System.................................................. 45 (SCA) - Test/Add.................................................. 78
Driven Equipment .............................................. 45 Add the SCA, If Necessary ................................ 79
Electrical System ............................................... 45 Test the Concentration of the SCA..................... 78
Fuel System ....................................................... 46 Cooling System Water Temperature Regulator -
Hydraulic Actuator System................................. 46 Replace................................................................ 79
Lubrication System ............................................ 46 Crankcase Blowby - Measure/Record ................... 80
Starting System.................................................. 46 Crankshaft Vibration Damper - Inspect ................. 80
Walk-Around Inspection..................................... 45 Removal and Installation.................................... 81
Belts - Inspect/Adjust/Replace............................... 71 Crushing Prevention and Cutting Prevention ........ 16
Adjusting the Alternator Belt .............................. 71 Customer Assistance........................................... 125
Adjusting the Fan Drive Belt .............................. 72 Outside of the USA and of Canada.................. 125
Inspection........................................................... 71 USA and Canada ............................................. 125
Replacement...................................................... 72 Customer Service ................................................ 125
Burn Prevention..................................................... 14 Cylinder Pressure - Measure/Record .................... 81
Batteries............................................................. 14 Cylinders - Inspect (Inspect the Combustion
Coolant............................................................... 14 Chamber)............................................................. 82
Oils..................................................................... 14

D
C
Driven Equipment - Check..................................... 82
Cold Weather Starting ........................................... 46 Check the Alignment.......................................... 83
Jacket Water Heaters ........................................ 47 Every 10,000 Service Hours .............................. 83
Lubricating Oil Heaters ...................................... 47 Every 5000 Service Hours ................................. 82
Requirements for Starting with Air ..................... 47 Driven Equipment - Inspect/Replace/Lubricate ..... 83
Combustion Sensor - Clean/Inspect/Replace........ 72
Configuration Parameters...................................... 44
134 SEBU7563-09
Index Section

E F

Electrical System ................................................... 18 Features and Controls ........................................... 32


Grounding Practices .......................................... 18 Fire Prevention and Explosion Prevention ............ 14
Electrohydraulic Actuator - Inspect........................ 83 Fire Extinguisher ................................................ 15
Electrohydraulic Actuator - Recondition ................ 84 Lines, Tubes and Hoses .................................... 16
Electrohydraulic System - Check/Adjust................ 85 Foreword ................................................................. 5
Check the Pressure Relief Valve ....................... 85 California Proposition 65 Warning ....................... 4
Electrohydraulic System - Inspect ......................... 86 Literature Information........................................... 4
Check the Oil Level............................................ 86 Maintenance ........................................................ 4
Inspect the Lines, Connections, and Maintenance Intervals.......................................... 4
Components..................................................... 86 Operation ............................................................. 4
Electrohydraulic System Oil - Change................... 86 Overhaul .............................................................. 5
Electrohydraulic System Oil Filter - Change.......... 87 Safety................................................................... 4
Emergency Stopping ............................................. 52 Fuel System Fuel Filter Differential Pressure -
Emergency Stop Button ..................................... 52 Check................................................................. 103
Engine Air Cleaner Element (Single Element) -
Clean/Replace ..................................................... 87
Cleaning the Air Cleaner Elements.................... 88 G
Crankcase Air Cleaner....................................... 89
Servicing the Air Cleaner Elements ................... 87 Gas Admission Valve - Recondition .................... 103
Engine Air Cleaner Service Indicator - Inspect...... 90 Gas Admission Valve Seals - Inspect/Replace.... 104
Test the Service Indicator................................... 90 Gas Pressure Regulator - Inspect/Replace ......... 104
Engine Air Precleaner - Clean ............................... 91 Gas Shutoff Valve - Inspect ................................. 105
Engine Crankcase Breather - Clean...................... 91 General Hazard Information .................................. 12
Engine Diagnostics................................................ 44 Asbestos Information ......................................... 13
Engine Mounts - Check ......................................... 92 Containing Fluid Spillage ................................... 13
Engine Oil - Change .............................................. 92 Dispose of Waste Properly ................................ 14
Change the Engine Oil....................................... 92 Fluid Penetration................................................ 13
Oil Change Interval ............................................ 92 Pressurized Air and Water ................................. 13
Engine Oil Filter - Change ..................................... 93
Inspect the Used Oil Filter Elements.................. 96
Replacing the Engine Oil Filters During Engine H
Operation ......................................................... 95
Replacing the Engine Oil Filters With the Engine Hoses and Clamps - Inspect/Replace ................. 105
Stopped............................................................ 94 Inspect the Hoses and the Clamps .................. 105
Engine Oil Level - Check ....................................... 96 Replace the Hoses and the Clamps ................ 106
Engine Oil Sample - Obtain ................................... 97
Obtain the Sample and the Analysis.................. 97
Engine Oil Temperature Regulator - Replace........ 98 I
Engine Operation................................................... 50
Oil Consumption ................................................ 50 Ignition System Spark Plugs - Check/Adjust ....... 108
Operating the Engine and the Driven Cleaning the Spark Plug ................................... 110
Equipment ........................................................ 50 Inspecting the Spark Plug ................................ 109
Partial Load Operation ....................................... 50 Installing the Spark Plug ................................... 110
Engine Protective Device Connections - Inspect... 98 Removing the Spark Plug ................................ 108
Engine Protective Devices - Check ..................... 100 Ignition System Spark Plugs - Replace ................ 111
Visual Inspection.............................................. 100 Ignition Systems .................................................... 16
Engine Speed/Timing Sensor - Clean/Inspect..... 100 Important Safety Information ................................... 2
Engine Starting ................................................ 17, 45 Inlet Air System - Inspect...................................... 111
Engine Stopping .............................................. 17, 52 Inlet Gas Manifold and Piping - Inspect/Replace .. 111
Engine Valve Lash - Inspect/Adjust ..................... 101
Check the Timing of the Crankshaft and
Camshaft........................................................ 101 L
Engine Valve Lash ........................................... 101
Gas Admission Valve ....................................... 102 Lifting and Storage ................................................ 30
Valve Bridge..................................................... 101
Engine Valve Rotators - Inspect .......................... 102
Exhaust Bypass - Recondition............................. 102
Exhaust Shields - Inspect .................................... 102
SEBU7563-09 135
Index Section

M R

Maintenance Interval Schedule (G3600 Engines That Reference Information ........................................... 28


use Bio-Gas)........................................................ 64 Reference Information Section ............................ 125
Maintenance Interval Schedule (G3600 Engines That Reference Material .............................................. 130
Use Natural Gas and Have a Compression Ratio of Additional Reference Material.......................... 131
10.5:1 or 11:1)...................................................... 62 Coolants........................................................... 130
Maintenance Interval Schedule (G3600 Engines Fuels ................................................................ 130
That Use Wellhead or Natural Gas and Have a Lubricants ........................................................ 130
Compression Ratio of 9.2:1) ................................ 60 Miscellaneous .................................................. 130
Maintenance Log ................................................. 128 Reference Materials ............................................ 127
Maintenance Recommendations ........................... 58 Refill Capacities..................................................... 54
Maintenance Records.......................................... 127 Refill Capacities and Recommendations............... 54
Maintenance Section ............................................. 54 Cooling System.................................................. 56
Manual Stop Procedure......................................... 52 Fuel .................................................................... 55
Model View Illustrations......................................... 19 Hydraulic Actuator System................................. 54
Model Views and Specifications ............................ 19 Lubrication System ............................................ 54
Monitoring System................................................. 32
Integrated Combustion Sensing Module
(ICSM).............................................................. 36 S
Mounting and Dismounting.................................... 16
Safety Messages ..................................................... 6
Safety Section ......................................................... 6
O Specifications ........................................................ 23
Drives and Gear Trains ...................................... 24
Operation Section.................................................. 30 Engine Specifications......................................... 23
Ordering Replacement Parts ............................... 126 Reference Weights ............................................ 27
Overhaul (In-Frame) ............................................. 112 Starting Motor - Inspect ........................................ 119
In-Frame Overhaul Information......................... 112 Air Starting Motor ............................................. 120
Scheduling an In-Frame Overhaul .................... 112 Electric Starting Motor...................................... 120
Overhaul (Major)................................................... 113 Removal and Installation of the Starting
Major Overhaul Information .............................. 114 Motor .............................................................. 120
Scheduling a Major Overhaul............................ 113 Starting the Engine ................................................ 47
Overhaul (Top End) .............................................. 114 Automatic Starting.............................................. 48
Scheduling a Top End Overhaul ....................... 114 Manual Starting.................................................. 48
Top End Overhaul Information .......................... 115 Purging Unburned Gas ...................................... 47
Overhaul Considerations ...................................... 116 System Pressure Release ..................................... 58
Overhaul Information ........................................ 116 Coolant System.................................................. 58
Engine Oil .......................................................... 58
Fuel System ....................................................... 58
P

Plate Locations and Film Locations....................... 28 T


Engine Identification........................................... 28
Information Plate................................................ 28 Table of Contents..................................................... 3
Serial Number Plate........................................... 28 Turbocharger - Clean (Cleaning with Dry
Prechamber - Clean/Inspect................................. 118 Particles)............................................................ 120
Prechamber Check Valves - Clean....................... 118 Turbocharger - Inspect ........................................ 121
Prechamber Check Valves - Replace................... 119 Turbocharger Cleaner Tube - Replace ................ 122
Prelube Pump - Inspect ........................................ 119
Air Prelube Pump.............................................. 119
Electric Prelube Pump ...................................... 119 V
Product Description ............................................... 21
Engine Service Life ............................................ 22 Valve Data Sheet................................................. 129
Product Identification Information .......................... 28 Valve Stem Projection - Measure/Record............ 122
Product Information Section .................................. 19
Product Lifting........................................................ 30
Engine Lifting with a Generator.......................... 30
Product Storage..................................................... 31
Generator Storage ............................................. 31
136 SEBU7563-09
Index Section

Walk-Around Inspection ...................................... 123


Inspect the Engine for Leaks and for Loose
Connections ................................................... 123
Warranty Information ........................................... 132
Engine Protection Plans................................... 132
Water Pump - Inspect.......................................... 124
Welding on Engines with Electronic Controls ........ 58
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
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All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
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