Operation and Maintenance Manual: G3600 Engines [PDF]

Zitiervorschau

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

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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 Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature 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.

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Table of Contents Foreword ................................................................. 4

Safety Section

3 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 Maintenance Interval Schedule (G3600 Engines That use Bio-Gas) ....................................................... 64

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 Foreword

Foreword Literature Information This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information. English is the primary language for all Caterpillar publications. The English used facilitates translation and consistency in electronic media delivery. Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Caterpillar dealer for the latest available information.

Safety This safety section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.

Operation Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities. The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.

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

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Use service hours to determine intervals. Calendar intervals shown (daily, annually, etc) may be used instead of service meter intervals if they provide more convenient schedules and approximate the indicated service meter reading. Recommended service should always be performed at the service hour interval. The actual operating environment of the engine also governs the maintenance schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the maintenance schedule may be necessary. The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.

Maintenance Intervals Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in each level should be shifted ahead or back depending upon your specific maintenance practices, operation and application. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine's permanent record. See the section in the Operation and Maintenance Manual, “Maintenance Records” for information regarding documents that are generally accepted as proof of maintenance or repair. Your authorized Caterpillar dealer can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.

California Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

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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.

5 Foreword

6 Safety Section Safety Messages

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Safety Section i02602825

Safety Messages SMCS Code: 1000; 7405

Illustration 1 Right side view

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Illustration 2

7 Safety Section Safety Messages

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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 this section. Please become familiar with all safety messages. Ensure that all of the safety messages are legible. Clean the safety messages or replace the safety messages if the words cannot be read or if the 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. Solvents, gasoline, or harsh 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.

Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. The safety messages that may be attached on the engine are illustrated and described below.

8 Safety Section Safety Messages

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(1) Pinch Point (Linkage) The safety messages for the pinch point (linkage) are located on the covers of the fuel control actuator, the air choke actuator, and the bracket of the exhaust bypass actuator .

(3) Engine Lifting (Label On the Number Three Camshaft Cover and On the Number Four Camshaft Cover) 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.

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During operation, the linkage of the electrohydraulic 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 causing 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.

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Flash fire may result in personal injury, if crankcase covers are removed within fifteen minutes after emergency shut down. Do not restart engine until cause for shutdown has been corrected.

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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.

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Improper lift rigging can allow unit to tumble causing 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 Safety Section Additional Messages

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Additional Messages SMCS Code: 1000; 7405

Illustration 3 Right side view

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Illustration 4

11 Safety Section Additional Messages

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Left side view

There may be several specific messages on the engine. The exact location of the messages and the description of the messages are reviewed in this section. Please become familiar with all messages. 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. Replace any damaged messages or missing messages. If a message is attached to a part of the package that is replaced, install a new message on the replacement part. Any Caterpillar dealer can provide new messages.

(1) Removal of the Prechamber Assembly The notices for the removal of the prechamber assemblies are located on each valve cover.

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Before the prechamber assembly is removed, drain the coolant and remove the spark plugs in order to prevent damage. Tighten the nuts that are located on the wire assembly for the combustion sensor to 9.5 ± .5 N·m (85 ± 5 lb in). Do not overtighten the nuts.

12 Safety Section General Hazard Information

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General Hazard Information SMCS Code: 1000; 4450; 7405

Illustration 6

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• Wear a hard hat, protective glasses, and other protective equipment, as required.

Illustration 5

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Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer. Attach the warning tags to the engine and to each operator control station. When it is appropriate, disconnect the starting controls. Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced. Engine exhaust contains products of combustion which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is in an enclosed area, vent the engine exhaust to the outside. Cautiously remove the following parts. To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed.

• Filler caps • Grease fittings • Pressure taps • Breathers • Drain plugs Use caution when cover plates are removed. Gradually loosen, but do not remove the last two bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last two bolts or nuts, pry the cover loose in order to relieve any spring pressure or other pressure.

• When work is performed around an engine that is

operating, wear protective devices for ears in order to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers are secured in place on the engine.

• Never put maintenance fluids into glass containers. Glass containers can break.

• Use all cleaning solutions with care. • Report all necessary repairs. Unless other instructions are provided, perform the maintenance under the following conditions:

• The engine is stopped. Ensure that the engine cannot be started.

• Disconnect the batteries when maintenance

is performed or when the electrical system is serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks.

• Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.

California Proposition 65 Warning Some engine exhaust constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

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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). Illustration 8

Fluid Penetration

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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.

Illustration 7

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Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated. If dust that may contain asbestos is present, there are several guidelines that should be followed:

• Never use compressed air for cleaning. • Avoid brushing materials that contain asbestos.

Containing Fluid Spillage

• Avoid grinding materials that contain asbestos.

Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the engine. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids.

• Use a wet method in order to clean up asbestos

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tools Catalog” for the following items:

• Use exhaust ventilation on permanent machining

• Tools that are suitable for collecting fluids and

• Wear an approved respirator if there is no other

equipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids and equipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

materials.

• A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be used. jobs.

way to control the dust.

14 Safety Section Burn Prevention

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• Comply with applicable rules and regulations

for the work place. In the United States, use Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposal of asbestos.

• Stay away from areas that might have asbestos particles in the air.

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. Check the coolant level after the engine has stopped and the engine has been allowed to cool. Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch with a bare hand. Remove the filler cap slowly in order to relieve pressure. Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

Dispose of Waste Properly

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

Illustration 9

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Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations. Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.

Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended. i01372262

Fire Prevention and Explosion Prevention SMCS Code: 1000; 4450; 7405

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Burn Prevention SMCS Code: 1000; 4450; 7405 Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the air system, in the hydraulic system, in the lubrication system, in the fuel system, or in the cooling system before any lines, fittings or related items are disconnected.

Coolant When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant.

Illustration 10

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All fuels, most lubricants, and some coolant mixtures are flammable.

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Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. Fire may cause personal injury and property damage. A flash fire may result if the covers for the engine crankcase are removed within fifteen minutes after an emergency shutdown. 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.

15 Safety Section Fire Prevention and Explosion Prevention

Inspect all lines and hoses for wear or for deterioration. The hoses must be properly routed. The lines and hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause fires. Oil filters and fuel filters must be properly installed. The filter housings must be tightened to the proper torque.

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. Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a hose, or a seal failure. Exhaust shields must be installed correctly. Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines that contain flammable fluid. Clean any such lines thoroughly with a nonflammable solvent prior to welding or flame cutting. Wiring must be kept in good condition. All electrical wires must be properly routed and securely attached. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections. Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers. Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly maintained battery cables will help to prevent arcing or sparking.

Illustration 11

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Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas. Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer. Improper jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions. Do not charge a frozen battery. This may cause an explosion. The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated.

Fire Extinguisher Make sure that a fire extinguisher is available. Be 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 Safety Section Crushing Prevention and Cutting Prevention

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Lines, Tubes and Hoses Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged.

Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris. i01372247

Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Caterpillar dealer for repair or for replacement parts.

Mounting and Dismounting

Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque.

Inspect the steps, the handholds, and the work area before mounting the engine. Keep these items clean and keep these items in good repair.

Replace the parts if any of the following conditions are present:

Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine.

• End fittings are damaged or leaking.

SMCS Code: 1000; 4450; 7405

Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds.

• Outer coverings are chafed or cut. • Wires are exposed. • Outer coverings are ballooning.

Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.

• Flexible part of the hoses are kinked. • Outer covers have embedded armoring. • End fittings are displaced. Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this will help to prevent vibration, rubbing against other parts, and excessive heat. i01359666

Crushing Prevention and Cutting Prevention SMCS Code: 1000; 4450; 7405 Support the component properly when work beneath the component is performed. Unless other maintenance instructions are provided, never attempt adjustments while the engine is running. Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstall the guards. Keep objects away from moving fan blades. The fan blades will throw objects or cut objects. When objects are struck, wear protective glasses in order to avoid injury to the eyes.

Do not carry tools or supplies when you mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies. i01519141

Ignition Systems SMCS Code: 1550 Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not inspect the valve mechanism or the transformers while the engine is operating. Personal injury or death may result. If the mode control switch is in the AUTOMATIC or START position and the wiring harness is connected, the ignition system may discharge and a spark plug will ignite. The spark plug will ignite any gas that has accumulated in that cylinder. The crankshaft and the driven equipment can move. Personal injury may result. The driven equipment could be damaged. Gas that has accumulated in the exhaust system can also be ignited.

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17 Safety Section Before Starting Engine

Turn the mode control switch to the STOP or OFF/RESET position before connecting the wiring harness. When the mode control switch is in the STOP or OFF/RESET position, the ignition system is disabled. i00659904

Before Starting Engine SMCS Code: 1000 Inspect the engine for potential hazards. Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel. Ensure that the engine is equipped with a lighting system that is suitable for the conditions. Ensure that all lights work properly. All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully. Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage. On the initial start-up of a new engine or an engine that has been serviced, be prepared to stop the engine if an overspeed condition occurs. This may be accomplished by shutting off the fuel supply to the engine, or shutting off the ignition system. See the Service Manual for repairs and for adjustments. i02136012

Engine Starting SMCS Code: 1000 If a warning tag is attached to the engine start switch or to the controls, DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started. All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.

If there is a possibility that unburned gas remains in the exhaust system, refer to the purge procedure in this Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Start the engine from the operator's compartment or from the engine start switch. Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Knowing the correct procedure will help to prevent major damage to the engine components. Knowing the procedure will also help to prevent personal injury. To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working properly, check the water temperature and the oil temperature during heater operation. Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside. i00659907

Engine Stopping SMCS Code: 1000 To avoid overheating of the engine and accelerated wear of the engine components, stop the engine according to the instructions in this Operation and Maintenance Manual, “Engine Stopping” topic (Operation Section). Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected. On the initial start-up of a new engine or an engine that has been serviced, make provisions to stop the engine if an overspeed occurs. This may be accomplished by shutting off the fuel supply to the engine, or shutting off the ignition system.

18 Safety Section Electrical System

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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.

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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.

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Illustration 12 Right hand view (in-line engine) (1) Gas shutoff valve (2) Fuel actuator (3) Ignition transformer

(4) Integrated Combustion Sensing Module (ICSM) (5) Engine oil filter (6) Junction box

(7) Crankcase pressure sensor (8) Engine oil level gauge (9) Engine oil filler

20 Product Information Section Model Views and Specifications

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Illustration 13 Left hand view (in-line engine) (1) Exhaust bypass actuator (2) Air choke actuator

(3) Hydraulic oil tank (4) Hydraulic oil pump

(5) Hydraulic oil filter

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Illustration 14 Right hand view (vee engine) (1) Gas shutoff valve (2) Exhaust bypass actuator (3) Fuel actuator (4) Integrated Combustion Sensing Module (ICSM)

(5) (6) (7) (8) (9)

Engine oil filter Junction box Ignition rail Crankcase pressure sensor Engine oil level gauge

(10) Engine oil filler

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21 Product Information Section Model Views and Specifications

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Illustration 15 Left hand view (vee engine) (1) Ignition transformer (2) Integrated Combustion Sensing Module (ICSM)

(3) Air choke actuator (4) Ignition rail (5) Hydraulic oil tank

(6) Hydraulic oil pump (7) Hydraulic oil filter

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The ECM monitors the actual engine speed. The ECM calculates the difference between the actual engine speed and the desired engine speed. The ECM controls the fuel actuator in order to maintain the desired engine speed.

The G3600 Family of Engines is designed to provide power for the following applications:

The fuel, the inlet air, and the exhaust bypass are regulated by the ECM through control of three electrohydraulic actuators. The actuators are electronically controlled and hydraulically actuated. The hydraulic oil is in a circuit that is separate from the engine oil. The hydraulic oil is circulated by a gear-driven pump.

Product Description SMCS Code: 1000; 4450

• Electrical power generation • Gas compression • Industrial air compression • Petroleum The engines incorporate advanced technology that is essential for obtaining high output, low emissions, and thermal efficiency. Precise control of the engine parameters enable optimum engine performance. The engines are capable of using a variety of fuels in various ambient conditions. The Engine Control Module (ECM) controls most of the functions of the engine. The module is an environmentally sealed unit that is mounted in a junction box on the engine. The ECM monitors various inputs from sensors in order to activate relays, solenoids, etc at the appropriate levels.

The ECM operates the fuel actuator in order to allow fuel to enter the gas manifold. Fuel flows from the manifold through an orifice. Some of the gas is routed through an adjustable needle valve and into a precombustion chamber. The rest of the gas is routed through a gas admission valve that is actuated by the camshaft. This allows fuel to enter the inlet port in the cylinder head. Air for combustion flows from the turbocharger to an air inlet choke. The ECM operates the air choke actuator in order to allow air to enter the inlet air manifold. The air flows through the aftercooler to the air plenum and into the cylinder head inlet port. The air is mixed with gas in the cylinder head. The rich fuel in the precombustion chamber is ignited by the spark plug. This provides the ignition for the air/fuel mixture in the cylinder.

22 Product Information Section Model Views and Specifications

The inlet manifold air pressure is controlled by the air inlet choke and the exhaust bypass valve. The ECM determines the air pressure that is required to maintain the correct air/fuel ratio. Each cylinder has an ignition transformer. To initiate combustion, the ECM sends a pulse of approximately 108 volts to the primary coil of each ignition transformer at the appropriate time and for the appropriate duration. The transformer increases the voltage which creates a spark across the spark plug electrode. The electronic control system controls the ignition timing. The control system monitors changes in the load. The control system modifies the timing in response to the change in the load. The timing can also be modified in order to compensate for detonation that is detected. The fuel flow is the main factor in the calculation of the engine load. Zero fuel flow is zero load. A fuel flow that is greater than zero is used to calculate a percentage of the indicated load. At loads that are less than 40 percent, the air/fuel ratio is controlled by the air choke actuator which is trimmed by the exhaust port temperatures. The engine has an Integrated Combustion Sensing Module (ICSM) for each bank of cylinders. Each cylinder exhaust port has a thermocouple that is monitored by an ICSM. The ICSM monitors the actual exhaust port temperatures for one bank of cylinders. The ICSM calculates an average exhaust port temperature for the bank of cylinders. The ECM sends a map of the desired exhaust port temperature to the ICSM. The ICSM calculates the difference between the average exhaust port temperature and the desired exhaust port temperature. The ICSM communicates the information to the ECM. The ECM controls the air choke actuator in order to maintain the desired exhaust temperature. When the load reaches approximately 40 percent, the air/fuel ratio is controlled by the exhaust bypass actuator which is trimmed by the combustion burn time. Each ICSM calculates an average combustion burn time for all of the cylinders in one bank. The ECM sends a map of the desired combustion burn time to the ICSM. The ICSM calculates the difference between the average combustion burn time and the desired combustion burn time. The ICSM sends a fuel correction factor to the ECM. The ECM controls the exhaust bypass actuator in order to maintain the desired combustion burn time.

SEBU7563-09

For more detailed information on the control system, refer to Systems Operation, “Electronic Control System Operation”. The engine has two cooling circuits: a jacket water circuit and a separate circuit for the aftercooler and engine oil cooler. Water temperature regulators are used in both circuits in order to maintain the correct operating temperatures. Water temperature regulators can be installed in order to regulate the inlet or outlet temperature of the water. A gear-driven centrifugal pump circulates the jacket water coolant from an external source. The coolant is circulated through the water jacket to the cylinder heads. The coolant flows through water manifolds to the outlet. The coolant flows through a remote water temperature regulator and to a heat exchanger. The coolant is returned to the engine. The engine oil and the combustion air are cooled in a separate circuit. A gear-driven pump pulls the coolant from the heat exchanger. Some of the coolant goes to the engine oil cooler. Most of the coolant goes to the aftercooler. The coolant returns to the heat exchanger. A gear-driven pump pumps the engine oil. The temperature of the engine oil is regulated. The engine oil is filtered prior to circulation in the cylinder block.

Engine Service Life Engine efficiency and maximum utilization of engine performance depend on the adherence to proper operation and maintenance recommendations. This includes use of the recommended lubricants, fuels, and coolant/antifreezes. For additional information about coolant analysis, see the Special Publication, “Caterpillar Gas Engine Lubricant, Fuel and Coolant Recommendations” or consult your Caterpillar dealer. For the engine maintenance that is required, see this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section).

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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 cylinders

In-line 6

In-line 8

50 degree V-12

50 degree V-16

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 10.5:1

9:1 10.5:1

Displacement per cylinder

21.2 L (1294 in3)

21.2 L (1294 in3)

21.2 L (1294 in3)

21.2 L (1294 in3)

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 pistons at 900 rpm

9 m/s (1772 ft/min)

9 m/s (1772 ft/min)

9 m/s (1772 ft/min)

9 m/s (1772 ft/min)

Mean velocity of the pistons at 1000 rpm

10 m/s (1969 ft/min)

10 m/s (1969 ft/min)

10 m/s (1969 ft/min)

10 m/s (1969 ft/min)

Flywheel rotation (standard)

Counterclockwise

Counterclockwise

Counterclockwise

Counterclockwise

Fuel, Lubricant, and Coolant

See this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (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 cooling system

See the Application and Installation Guide.

See the Application and Installation Guide.

See the Application and Installation Guide.

See the Application and Installation Guide.

Maximum allowable exhaust back pressure

3 kPa (12 inches of H2O)

3 kPa (12 inches of H2O)

3 kPa (12 inches of H2O)

3 kPa (12 inches of H2O)

Maximum allowable inlet air restriction

3.7 kPa (15 inches of H2O)

3.7 kPa (15 inches of H2O)

3.7 kPa (15 inches of H2O)

3.7 kPa (15 inches of H2O)

Air cleaners

Remote

Remote

Remote

Remote

24 Product Information Section Model Views and Specifications

Illustration 16

SEBU7563-09

g00891513

Illustration 19

G3606 Engine design

G3616 Engine design

(A) Gas admission valves (B) Inlet valves (C) Exhaust valves

(A) Gas admission valves (B) Inlet valves (C) Exhaust valves

g00790805

Drives and Gear Trains Front Drives

Illustration 17

g00891514

G3608 Engine design (A) Gas admission valves (B) Inlet valves (C) Exhaust valves

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

Illustration 18 G3612 Engine design (A) Gas admission valves (B) Inlet valves (C) Exhaust valves

g00790801

g00790861

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25 Product Information Section Model Views and Specifications

Engine Front Gear Train

g00790864

Illustration 21

g00891685

SAE standard engine crankshaft rotation

Illustration 22

In-line engines and vee engines

SAE standard engine crankshaft rotation

(4) (5) (6) (7)

In-line engines and vee engines

Water outlet Water inlet Oil outlet Oil inlet

(1) (2) (3) (4) (5) (6) (7)

Table 2

Front Drives Component

Speed(1)

Jacket water pump

2522

Aftercooler and oil cooler pump

2522

Oil pump

1524

(1)

Crankshaft Idler Idler Jacket water pump Aftercooler and oil cooler pump Auxiliary pump Oil pump

The speed of the component is listed for an engine that is operating at 1000 rpm. For an engine that is operating at 900 rpm, multiply the speed of the component by .9. For an engine that is operating at 800 rpm, multiply the speed of the component by .8.

Table 3

Front Gear Train Gear

Number Of Teeth

(1) Crankshaft

96

(2) Idler

68

(3) Idler

67

(4) Jacket water pump

38

(5) Aftercooler and oil cooler Pump

38

(6) Auxiliary pump

43

(7) Oil pump

63

26 Product Information Section Model Views and Specifications

SEBU7563-09

Engine Rear Gear Train

g01056736

Illustration 23 SAE standard engine crankshaft rotation In-line engines (1) (2) (3) (4)

Crankshaft Large cluster idler Small cluster idler Camshaft

g00891688

Illustration 24 SAE standard engine crankshaft rotation Vee engines (1) (2) (3) (4) (5)

Crankshaft Large cluster idler Small cluster idler Camshaft 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 Engine(1)

G3606 Engine

G3608 Engine

G3612 Engine

G3616 Engine

15 680 kg (34 568 lb)

19 000 kg (41 888 lb)

25 084 kg (55 300 lb)

29 892 kg (65 900 lb)

8300 kg (18 298 lb)

9400 kg (20 723 lb)

15 855 kg (34 954 lb)

15 855 kg (34 954 lb)

1360 kg (2998 lb)

1410 kg (3109 lb)

1650 kg (3638 lb)

1650 kg (3638 lb)

7820 kg (17 240 lb)(2) 8170 kg (18 012 lb)(3)

8640 kg (19 048 lb)

12 700 kg (28 000 lb)

12 700 kg (28 000 lb)

590 kg (1300 lb)

590 kg (1300 lb)

977 kg (2154 lb)

977 kg (2154 lb)

39 040 kg (86 068 lb)

56 266 kg (124 045 lb)

61 074 kg (134 645 lb)

Generator

(2)

8270 kg (18 232 lb) (3)

Module Mounting base Coupling Total (1) (2) (3)

lb)(2)

33 750 kg (74 406 34 070 kg (75 111 lb)(3)

The weights of the engines that are listed includes attachments that are mounted on the engines. The engine weights are dry weights. Single bearing generator Double bearing generator

Table 6

Approximate Weights Of Serviceable Parts Component

G3606 Engine

G3608 Engine

G3612 Engine

G3616 Engine

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)

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)

29 kg (64 lb)

29 kg (64 lb)

29 kg (64 lb)

29 kg (64 lb)

Cylinder block

Aftercooler

core(1)

Used air cleaner element (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 Product Information Section Product Identification Information

SEBU7563-09

Product Identification Information

Information Plate

i01519197

Plate Locations and Film Locations SMCS Code: 1000; 4450

Engine Identification Caterpillar engines are identified with serial numbers, with performance specification numbers, and with arrangement numbers. In some of the cases, modification numbers are used. These numbers are shown on the Serial Number Plate and the Information Plate that are mounted on the engine. Caterpillar dealers need these numbers in order to determine the components that were included with the engine. This permits accurate identification of replacement part numbers.

Illustration 26

g00361974

The Information Plate is on the side of the cylinder block above one of the crankshaft inspection covers. The following information is stamped on the Information Plate: engine's maximum altitude, horsepower, high idle, full load rpm, fuel settings, and other information. 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.

Illustration 25

g00123229

The Serial Number Plate is on the side of the cylinder block above one of the crankshaft inspection covers. The following information is stamped on the Serial Number Plate: engine serial number, model, and arrangement number.

The top level part numbers in the Parts Manual for the engine are listed with the engine arrangement number. The performance specification can be used by your Caterpillar dealer with the Technical Marketing Information system. Before the engine leaves the factory, the engine performance is tested. Detailed performance data is recorded. The performance specification number can be used for obtaining the data.

SEBU7563-09

29 Product Information Section Product Identification Information

Table 7

Record Of Reference Numbers Item 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

Identification

30 Operation Section Lifting and Storage

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Operation Section

Engine Lifting with a Generator

Lifting and Storage

NOTICE Do not use the engine lifting eyes to remove the engine and generator together. i01536259

Product Lifting SMCS Code: 7000; 7002

A lifting plate is provided with the package generator set. Instructions for lifting the package generator set are stamped on the lifting plate. 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.

Illustration 27

g00103219

NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes 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.

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 package is lifted. This may cause the locking nuts to loosen. This could cause the lifting eye to swivel. Ensure that the lifting eye is correctly oriented on the packaged generator set. Ensure that the lifting eye is tightened to the correct torque before you lift the packaged generator set.

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 Operation Section Features and Controls

SEBU7563-09

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 Parameter

Low System Voltage

Event Code

System Response

E043

Warning (1)

E042

Engine Shutdown (3)

State

Always On (1)

Trip Point

Delay Time (Seconds)

20 volts

20

18 volts

10

Security Level

Trip Point Range

Delay Time Range (Seconds)

This item is not programmable.

(continued)

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33 Operation Section Features and Controls

(Table 8, contd)

Engine ECM Monitoring Delay Time (Seconds)

Event Code

System Response

State

Trip Point

E017

Warning (1)

On

92°C

E016

Engine Shutdown (3)

Always On(1)

98°C

E017

Warning (1)

On

105°C

E016

Engine Shutdown (3)

Always On(1)

110°C

E017

Warning (1)

On

115°C

E016

Engine Shutdown (3)

Always On(1)

120°C

Low Engine Coolant Temperature

E038

Warning (1)

On

25°C

High Pump Outlet Pressure(2)

E224

Engine Shutdown (3)

Always On(1)

462 kPa

Warning (1)

Always On(1)

124 kPa

Engine Shutdown (3)

Always On(1)

103 kPa

Always On(1)

1017 rpm or 1130 rpm

0

Parameter

High Engine Coolant Temperature (88° C Jacket Water Rating) High Engine Coolant Temperature (99° C Jacket Water Rating) High Engine Coolant Temperature (110° C Jacket Water Rating)

Low Jacket Water Outlet Pressure(2)

E228

Security Level

Trip Point Range

80° to 129°C 20

Customer

1 to 60

5° to 80°C

10

This item is not programmable.

Engine Overspeed

E004

Engine Shutdown (3)

Engine Overload

E242

Warning (1)

Always On(1)

110%

0

E020

Warning (1)

On

88°C

5

Customer

85° to 102°C

E019

Engine Shutdown (3)

Always On(1)

90°C

1

Factory

85° to 104°C

High Engine Oil Temperature

Delay Time Range (Seconds)

Factory

800 to 1300 rpm

0

This item is not programmable.

1 to 60

(continued)

34 Operation Section Features and Controls

SEBU7563-09

(Table 8, contd)

Engine ECM Monitoring Parameter

Low Engine Oil Pressure(2) (Under 600 RPM)

Low Engine Oil Pressure(2) (Over 600 RPM)

High Engine Oil Pressure

High Oil Filter Differential Pressure

Low Oil Filter Differential Pressure

Event Code

System Response

State

Trip Point

Delay Time (Seconds)

E100

Warning (1)

Always On(1)

175 kPa

5

E040

Engine Shutdown (3)

Always On(1)

100 kPa

0

E100

Warning (1)

Always On(1)

400 kPa

5

E040

Engine Shutdown (3)

Always On(1)

350 kPa

0

E125

Warning (1)

On

650 kPa

E126

Engine Shutdown (3)

Always On(1)

1000 kPa

E129

Warning (1)

Off

100 kPa

E130

Engine Shutdown (3)

Always On(1)

300 kPa

E127

Warning (1)

Off

5 kPa

E128

Engine Shutdown (3)

High Fuel Temperature

E223

Warning (1)

Low Fuel Differential Pressure

E864

Warning (1)

High Fuel Differential Pressure

E865

Warning (1)

High System Voltage

E050

Warning (1)

Security Level

Delay Time Range (Seconds)

This item is not programmable.

25

Customer

15

Customer

600 to 1200 kPa

0 to 350 kPa 25

Factory Customer

10 Off

Trip Point Range

3 kPa

1 to 60 0 to 150 kPa

Factory

60°C

20

5 kPa

60

Always On(1)

160 kPa

30

On

34 volts

20

0° to 60°C

On Customer

0 to 100 kPa

0 to 195 kPa This item is not programmable. (continued)

SEBU7563-09

35 Operation Section Features and Controls

(Table 8, contd)

Engine ECM Monitoring Parameter

High Inlet Air Temperature at Low Engine Load 54° C SCAC Rating High Inlet Air Temperature at Low Engine Load 43° C SCAC Rating High Inlet Air Temperature at Low Engine Load 32° C SCAC Rating High Inlet Air Temperature at High Engine Load 54° C SCAC Rating High Inlet Air Temperature at High Engine Load 43° C SCAC Rating High Inlet Air Temperature at High Engine Load 32° C SCAC Rating High Engine Load(2) High Engine Oil to Engine Coolant Differential Temperature

Event Code

System Response

State

Trip Point

E027

Warning (1)

On

82°C

E026

Engine Shutdown (3)

Always On(1)

85°C

E027

Warning (1)

On

77°C

E026

Engine Shutdown (3)

Always On(1)

80°C

E027

Warning (1)

On

72°C

E026

Engine Shutdown (3)

Always On(1)

75°C

E027

Warning (1)

On

72°C

E026

Engine Shutdown (3)

Always On(1)

75°C

E027

Warning (1)

On

65°C

E026

Engine Shutdown (3)

Always On(1)

68°C

E027

Warning (1)

On

57°C

E026

Engine Shutdown (3)

Always On(1)

60°C

E242

Warning (1)

Always On(1)

110%

E123

Warning (1)

On

10°C

E124

Engine Shutdown (3)

Always On(1)

15°C

Delay Time (Seconds)

Security Level

Trip Point Range

Delay Time Range (Seconds)

20

Factory

Default -20°C to +5°C

1 to 60

0

This item is not programmable. Customer

60

0° to 80°C

1 to 60

Factory (continued)

36 Operation Section Features and Controls

SEBU7563-09

(Table 8, contd)

Engine ECM Monitoring Parameter

High Inlet Air Restriction (Right)

High Inlet Air Restriction (Left)

(1) (2)

Event Code

E385

E384

Trip Point

Delay Time (Seconds)

System Response

State

Warning (1)

Always On(1)

20

Engine Shutdown (3)

Off

0

Warning (1)

Always On(1)

Engine Shutdown (3)

Off

5.23 kPa

This parameter is permanently active. This parameter cannot be turned off. 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.

20 0

Security Level

Trip Point Range

Delay Time Range (Seconds)

This item is not programmable. Customer

This item is not programmable.

0 to 65

This item is not programmable. Customer

This item is not programmable.

0 to 65

SEBU7563-09

37 Operation Section Features and Controls

Table 9

ICSM Monitoring Description High Exhaust Temperature (Port)

Exhaust Port Temperature High Deviation

Exhaust Port Temperature Low Deviation

High Turbo Turbine Inlet Temperature

High Turbo Turbine Outlet Temperature

Event Code

System Response

State

Warning (1) E801 through E816

E821 through E836

Trip Point

Delay Time (Seconds)

Off

Warning (1)

On

50°C

240

Engine Shutdown (3)

Off

100°C

600

650°C

Warning (1)

On

120°C

E841 through E856

Engine Shutdown (3)

Off

400°C

E245 (Right Bank) E246 (Left Bank)

Warning (1)

E243 (Left Bank) E244 (Right Bank)

Warning (1) Engine Shutdown (3)

Trip Point Range

Delay Range (Seconds)

600°C

Engine Shutdown (3)

Engine Shutdown (3)

Security Level Password

100° to 1000°C

10

10° to 500°C 300

Customer

1 to 1200

600°C 400 to 700 °C

650°C On

570°C 600°C

10 400 to 650°C

38 Operation Section Features and Controls

SEBU7563-09

i02600163

Control Panel SMCS Code: 7451

Illustration 29

g00799615

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. Illustration 28

g00824832

Control panel (1) (2) (3) (4) (5) (6) (7)

Advisor II display Keypad for the Advisor II “EMERGENCY STOP” button “ENGINE ON” indicator “ACTIVE ALARM” indicator “ENGINE FAILURE” indicator “MANUAL PRELUBE” switch and “PRELUBE ACTIVE” indicator (8) Mode control switch (9) “DESIRED SPEED” potentiometer

When the control panel is powered up, the screen becomes active. To view the options for the display, press the “?” key. Table 10 lists the menu. Table 10

Menu 1

Status Screen Mode

2

Detonation Levels

3

Ignition Times

The features of the control panel are described below.

4

Burn Times

Advisor II

5

Temperatures

6

Secondary Voltages

7

Not Used

8

Events and Diagnostics

9

Display Setup

?

Menu

Advisor II is a device which enables the operator to monitor engine operation. The Advisor II receives information from the Electronic Control Module (ECM). The device cannot be used for programming. A screen display and a keypad provide the interface for the operator.

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.

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39 Operation Section Features and Controls

Status Screen Mode

Speed Status

Table 11

The “Speed Status” screen displays parameters that pertain to the engine speed and some additional parameters. Table 14 lists the information that is displayed.

Status Screen Mode 1

Status Screen Menu

2

Engine Status

3

Air/Fuel Ratio Status

4

Speed Status

5

Pressure Status

6

Temperature Status

7

Misc Status

8

Relay Status

9

Not Used

?

Menu

Table 14

Speed Status Engine Speed

Desired Engine Speed

Percent Load

Speed Control

Droop Setting

Governor Type

Wastegate Command

Choke command

Fuel Command

Pressure Status

Status Screen Menu

The “Pressure Status” screen displays parameters that pertain to the engine pressures. Table 15 lists the information that is displayed.

Pressing “1” returns the user to the “Menu” screen.

Table 15

Pressure Status

Engine Status The “Engine Status” screen displays basic information about the condition of the engine. Table 12 lists the information that is displayed. Table 12

Fuel Pressure

Air Pressure

Desired Air Pressure

Oil Pressure

Differential Oil Pressure

Crankcase pressure

Not Used

Jacket Water

Not Used

Engine Status Engine Speed RPM

Desired Engine Speed

Percent Load

Oil Pressure

Air Pressure

Air Temperature

Oil Temperature

Jacket Water Temperature

Fuel Correction

Temperature Status The “Temperature Status” screen displays parameters that pertain to the engine temperatures. Table 16 lists the information that is displayed. Table 16

Temperature Status

Air/Fuel Ratio Status The “Air/Fuel Ratio Status” screen displays the status of parameters that pertain to the air and fuel. The actual data is continuously updated. Table 13 lists the information that is displayed. Table 13

Air Temperature

Jacket Water

Oil Temperature

Fuel Temperature

Odd Bank

Even Bank

Not Used

Not Used

Not Used

Miscellaneous Status

Air/Fuel Ratio Status A/F Ratio

Desired A/F Ratio

Fuel Quality

Air Pressure

Desired Air Pressure

Specific Gravity

Air Flow

Fuel Flow

Feedback Status

The “Miscellaneous Status” screen displays the parameters that are listed in Table 17. Table 17

Miscellaneous Status Detonation Level

Service Hours

Battery Voltage

Engine Configuration

Multi Strike Feature

Engine Cylinders

Multi Strike Mode

Multi Strike Switch

Multi Strike Status

40 Operation Section Features and Controls

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Relay Status

Table 20

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

Ignition Timing Even Bank

Odd Bank

Actual Timing Base Timing

Table 18

Relay Status Speed Status

Burn Times

Mode Status

The “Burn Times” screen can display either the “Filtered Burn Times” or the “Unfiltered Burn Times”. “Filtered Burn Times” displays an average of the combustion burn time for each bank of cylinders. The desired combustion burn time and the time for each individual cylinder are also displayed. “Unfiltered Burn Times” displays the actual instantaneous combustion burn time for each individual cylinder. The desired combustion burn time and the average combustion burn time for each bank of cylinders are also displayed.

E-Stop Status Driven Equipment Prelube Solenoid Prelube Oil Pressure Switch Initiate Contact Start Solenoid Fuel Control Solenoid Hydrax Oil Pressure Switch

Table 21

Normal Stop

Burn Times Filtered

Not Used Option 9 of this screen is not used at this time. Menu Pressing “?” returns the user to the “Menu” screen.

Detonation Levels The “Detonation Levels” screen displays the level of detonation for each cylinder as bars on the screen. The average detonation level for all of the cylinders is also displayed. Table 19

Detonation Levels Even Bank

Odd Bank

Engine Average Detonation Level

Ignition Timing The “Ignition Timing” screen displays the current degrees before top center for the timing of each cylinder. The values for the programmable desired timing are listed. The current active selected timing is indicated.

Unfiltered

Even Bank

Odd Bank

Even Bank

Odd Bank

Desired Burn

Fuel Correction

Temperatures The “Temperatures” screen can display either “Exhaust Temperatures” or “Turbo Temperatures”. “Exhaust Temperatures” displays the actual exhaust port temperature for each cylinder. The average temperature for all of the exhaust ports in each bank is also displayed. If the engine is operating at a load that is less than 40 percent, the desired exhaust temperature is displayed. If the engine load is greater than 40 percent, the desired exhaust temperature is not a factor. “Turbo Temperatures” displays the temperatures of the exhaust at the inlet and outlet of each turbocharger. The average temperature for each bank is also displayed. Table 22

Temperatures Exhaust

Turbo

Even Bank

Odd Bank

Even Bank

Odd Bank

Desired Temp

Fuel Correction

Secondary Voltages The “Secondary Voltages” screen display the voltage drop across the spark plugs as a percent.

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41 Operation Section Features and Controls

“EMERGENCY STOP” Button

Table 23

Secondary Voltage Even Bank

NOTICE Only use the “Emergency Stop” button in order to stop the engine in an emergency situation. Do not use the “Emergency Stop” button for normal engine stopping.

Odd Bank

Actual Timing Base Timing

To prevent damage to the engine, use the mode control switch or use the remote start/stop initiate contact for normal engine stopping.

Not Used 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

Illustration 30

g00824884

The fuel and the ignition are immediately shut off when the “EMERGENCY STOP” button is pressed. No postlube cycle occurs.

Display Setup The “Display Setup” screen enables the operator to adjust the display. The contrast and back lighting can be adjusted. Metric units or English units can also be selected for the display. Use the left arrow or the right arrow to navigate the options. Use the up arrow or the down arrow to select the preference.

Note: The engine mounted junction box also has an “EMERGENCY STOP” button.

Indicators

Table 25

Display Setup LCD Contrast Offset

The “EMERGENCY STOP” button and the mode control switch must be reset before the engine will start. To reset the “EMERGENCY STOP” button, turn the button clockwise. To reset the mode control switch, turn the switch to the OFF/RESET position.

The remote panel has three indicators for the status of the engine operation. Backlighting Lights On

Metric English Imperial Units

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

42 Operation Section Features and Controls

Illustration 31

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g00824980

(1) “ENGINE ON” indicator (2) “ACTIVE ALARM” indicator (3) “ENGINE FAILURE” indicator

Illumination of green “ENGINE ON” indicator (1) indicates normal operation. Yellow “ACTIVE ALARM” indicator (2) illuminates if the control system initiates a warning for an event or a diagnostic condition. Red “ENGINE FAILURE” indicator (3) illuminates if the control system shuts down the engine due to an event or a diagnostic condition. The “ENGINE FAILURE” indicator also illuminates if an emergency stop is performed.

“MANUAL PRELUBE” Switch and “PRELUBE ACTIVE” Indicator

Illustration 32

g00825028

“MANUAL PRELUBE” switch and “PRELUBE ACTIVE” indicator

The “MANUAL PRELUBE” switch enables the operator to prelube the engine by pressing the switch. A lamp behind the switch illuminates when the prelube is active. This is the “PRELUBE ACTIVE” indicator. If the mode control switch is in the “AUTO” position and the remote start/stop initiate contact closes, the prelube system will operate and the lamp will illuminate. The lamp will also illuminate during the postlube. Note: The ECM is programmed to provide engine lubrication after the engine is shut off. The typical duration of the postlube is 180 seconds.

Mode Control Switch

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.

Illustration 33

g00825037

Mode control switch in the “AUTO” position

The mode control switch has four positions: “AUTO”, “START”, “STOP”, and “OFF/RESET”

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“AUTO” – When the mode control switch is in 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 operate until the ECM receives a shutdown signal.

43 Operation Section Features and Controls

“DESIRED SPEED” Potentiometer

Illustration 34

g00825039

“DESIRED SPEED” potentiometer

The following methods cause a shutdown signal:

• The remote start/stop initiate contact opens when

the mode control switch is in the “AUTO” position.

• The mode control switch is turned to the “STOP” position.

• The mode control switch is turned to the “OFF/RESET” position.

• The “EMERGENCY STOP” button is pressed. • An undesirable operating condition is sensed and an engine shutdown is initiated by the ECM.

“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.

The “DESIRED SPEED” potentiometer allows the operator to adjust the desired engine speed. This is achieved by providing a 0 to 5 volt input to the ECM. The desired speed can be viewed on the Advisor panel or by using Cat ET.

44 Operation Section Engine Diagnostics

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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.

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45 Operation Section Engine Starting

Engine Starting

Cooling System • Inspect the cooling system for leaks or loose i02601065

Before Starting Engine

connections. Inspect the condition of all the pipes for the cooling system. Ensure that the connections are properly clamped.

SMCS Code: 1000; 1400; 1450

• Inspect the water pumps for evidence of leaks.

Perform the required daily maintenance and other periodic maintenance before starting the engine. This can prevent major repairs at a later date. Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section).

• Check the coolant level. Add coolant, if necessary.

Walk-Around Inspection

Driven Equipment

NOTICE For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted.

• If necessary, check the oil levels of the driven

To obtain maximum service life for your engine, make a thorough inspection before starting the engine. Make a walk-around inspection of the installation. Look for items such as oil or coolant leaks, loose bolts and trash buildup. Remove any trash. Make repairs, if necessary.

• For generator set engines, ensure that the main

• The guards must be in the proper place. Repair damaged guards or replace missing guards.

For information on the proper coolant to use, refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section).

equipment. Perform any maintenance that is required for the driven equipment. Refer to the literature that is provided by the OEM of the driven equipment.

• If the engine is equipped with a clutch, ensure that the clutch is disengaged. circuit breaker is open.

Electrical System Inspect the wiring for the following conditions:

• Loose connections

• Ensure that the areas around the rotating parts are

• Wiring that is worn or frayed

Air Inlet System

Inspect the gauge panel and the control panel for good condition. Reset any shutoff or alarm components.

clear.

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 unburned 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 Operation Section Engine Starting

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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 Illustration 35

g01140341

Engine oil level gauge (1) “ADD” mark (2) “RUNNING FULL” mark (3) “STOPPED FULL OIL COLD NO PRELUBE” mark

• Check the engine 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. For information on the proper engine oil to use, refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section).

• Check for leaks at the following components:

crankshaft seals, crankcase, engine oil filters, plugs for the engine oil gallery, sensors, and valve covers.

• Inspect the tubes, tee pieces, and clamps on the crankcase breathers.

from any other air piping.

• Check the oil level in the lubricator for the air

starting motor. Keep the lubricator at least half full. Add oil, if necessary. Use nondetergent “10W” oil for temperatures that are greater than 0 °C (32 °F). Use air tool oil for temperatures that are below 0 °C (32 °F).

• Check the air pressure before starting. Starting

motors with vanes require air pressure in a range of 620 to 1550 kPa (90 to 225 psi). Air turbines require air pressure in a range of 414 to 620 kPa (60 to 90 psi) or 690 to 1034 kPa (100 to 150 psi).

• Open the air supply valve for the air starting motor. Note: If the engine is equipped with a system for external support, prepare the system before starting the engine. Ensure that all of the systems for engine support are enabled. Perform all prestart checks for the control system.

• If the engine has an air cleaner for crankcase

ventilation, inspect the air cleaner service indicator. Service the air cleaner filter element when the yellow diaphragm enters the red zone, or the red piston locks in the visible position.

Fuel System • Inspect the fuel lines for loose fittings and leaks. Ensure that the fuel lines are properly clamped.

• Ensure that the fuel is supplied to the engine at the correct pressure for the application.

G3600 engines use a fuel pressure of 310 ± 14 kPa (45 ± 2 psi).

i02601106

Cold Weather Starting SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900 See Gas Engines Application and Installation Guide, LEBW4980 for more information on the following topics:

• Recommendations for the size and installation of jacket water heaters and oil heaters

• Requirements for cranking torque and air starting motors at various temperatures

Consult your Caterpillar dealer for more information on the starting aids that are available for cold weather starting.

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47 Operation Section Engine Starting

Jacket Water Heaters Jacket water heaters are available as optional equipment. Jacket water heaters are recommended for improving startability in ambient temperatures below 21 °C (70 °F). These heaters are recommended for all installations that have automatic starting.

Lubricating Oil Heaters Note: Oil pan immersion heaters are not recommended for heating the lube oil. To ensure the compatibility of the components, only use equipment that is recommended by Caterpillar. NOTICE Heating elements that are in direct contact with the lubricating oil can cause coking of the oil. To aviod coking of the oil when the oil is heated, follow these recommendations: The temperature of the heating surface must not exceed 150 °C (300 °F). The maximum heat density of the heating surface must not exceed 1.24 w/cm2 (8W/in2).

i02601115

Starting the Engine SMCS Code: 1000; 1450

Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside. NOTICE For initial start-up of a new or rebuilt engine, and for start-up of an engine that has been serviced, make provision to shut the engine off should an overspeed occur. This may be accomplished by shutting off the fuel supply and/or the ignition to the engine.

Unburned gas in the air inlet and exhaust system 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 below 10 °C (50 °F) require cranking torque that is excessive. Oil heaters are recommended for heating the lube oil to 10 °C (50 °F) when the ambient conditions are below this temperature.

Before starting an engine that may contain unburned 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.

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 is necessary. Ensure a sufficient supply of air pressure for cold weather starting. Do not exceed the maximum air pressure for the starting motor.

Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls.

Water Separator

Ensure that no one will be endangered before the engine is started and when the engine is started.

Condensation of vapor in the air supply can freeze in cold weather. This can enable the following problems to occur:

Perform the procedures that are described in this Operation and Maintenance Manual, “Before Starting 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 in the air inlet and in the exhaust manifold:

A water separator removes vapor from compressed air prior to the air storage tank. Dry air is required for cold weather in order to help prevent ice from forming in the supply lines.

• Emergency stop

motor, the starting motor can be damaged.

• Engine overspeed

48 Operation Section Engine Starting

• The engine control is set to the STOP mode and the gas shutoff valve does not close.

• Unsuccessful successive attempts to start the engine

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b. For industrial engines, unload the compressor or pump. Disengage the clutch (if equipped). Place the transmission and/or other attachments for the power take-off in NEUTRAL.

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” parameter is equal to ten seconds less than the value of the “Crank Cycle” parameter.

Illustration 36

3. Set the engine control to the START mode. The engine will crank for the “Engine Purge Cycle” time. Then, the gas shutoff valve will be energized and the ignition will be enabled. The engine will start.

3. Verify that “DESIRED SPEED” potentiometer (2) is set to an rpm that is appropriate. Verify that the “IDLE/RATED” display (if equipped) indicates “IDLE”.

4. Continue with your previous procedure.

Automatic Starting

g00791099

(1) Engine control switch in the “START” position (2) “DESIRED SPEED” potentiometer

4. Observe the “Configuration” screen on Caterpillar Electronic Technician (ET) or on the Advisor panel. Verify that the “FUEL ENERGY CONTENT” 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 injury, always remain clear of the the engine when the engine is in the AUTOMATIC mode. If the engine control switch is in the “AUTO” position, the engine will automatically start when the remote start/stop initiate contact closes. The engine will accelerate to rated rpm when the oil pressure is sufficient.

Manual Starting 1. Ensure that fuel is supplied to the engine. Ensure that no gas is leaking. 2. Ensure that the driven equipment is unloaded. a. For generator set engines, open the main circuit breaker.

NOTICE The engine must be prelubed before the crankshaft is rotated. Damage can result if the crankshaft is rotated on dry bearing surfaces. Note: The prelube oil pump will operate until the pressure switch is made for 30 seconds. The Electronic Control Module (ECM) will initiate the engine start-up after the prelube pressure switch detects 1 psi of oil pressure. If the module detects a signal for preventing the start-up, the corresponding diagnostic code will be generated. 6. Allow the engine to idle for three to five minutes. The engine speed should stabilize at low idle rpm. Perform these checks during the warm-up:

• Check all of the pressure gauges. • Inspect the engine for leaks. • Listen for unusual noises.

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49 Operation Section Engine Starting

When all systems are normal, the rpm may be increased. Ensure that the oil pressure and the fuel pressure are in the normal ranges. After the engine has started and the warm-up is complete, the engine can be operated at rated rpm and low load. The engine will reach normal operating temperature faster if the engine is operated at low rpm and with a low power demand. This procedure is more effective than idling the engine with no load. The engine should reach normal operating temperature in a few minutes. i02606873

After Starting Engine SMCS Code: 1000 Note: For new installations and engines that are recently rebuilt, carefully monitor the engine in order to detect any unusual engine performance. 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.

Apply the load according to the requirements for temperatures: Before you apply a load up to 49 percent of the rated load, the minimum temperature of the jacket water is 38 °C (100 °F). The minimum engine oil temperature is 10 °C (50 °F). Before you apply a load between 50 and 100 percent of the rated load, the minimum temperature of the jacket water is 50 °C (122 °F). The minimum engine oil temperature is 50 °C (122 °F). Continue to check the gauges and the driven equipment. For information on partial load operation, refer to this Operation and Maintenance Manual, “Engine Operation” topic (Operation Section). 3. Adjust the load, as needed.

50 Operation Section Engine Operation

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Engine Operation

Partial Load Operation

Engine Operation

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

SMCS Code: 1000

• Accelerated wear of components

Proper operation and maintenance are key factors in attaining the maximum service life and economy for the engine. Follow the instructions in this Operation and Maintenance Manual in order to minimize operating costs and maximize the service life of the engine.

• Loss of control of the exhaust emissions

i03679822

Observe the Advisor display or the Caterpillar Electronic Technician (ET) frequently while the engine is operating. Record the data from the gauges in a log. Average the data that is recorded during operation and record the average values for each day. Compare the data to the specifications for normal engine operation. Comparing the data over time will help to detect trends in engine performance. Investigate any significant change in the readings. Monitor the engine operation and take action when discrepancies are found.

Operating the Engine and the Driven Equipment Apply the load according to the following requirements for temperatures. Lack of compliance could result in scuffing of the piston skirt or seizure in some applications.

• Narrow margin for detonation • Poor performance • Power loss Caterpillar Engines can be operated at very light loads for limited times with no harmful effects. Table 26 lists the limits for hours of operation at various loads. After the time limit for reduced load operation has expired, operate the engine for a minimum of two hours at a load that is more than 70 percent of the rated load. For example, an engine is operating at 20 percent of the rated load. The engine may be operated at this load factor for a maximum of one-half hour. After the one-half hour, operate this engine for at least two hours at a load factor of more than 70 percent. To keep engine maintenance at a minimum, follow the guidelines that are listed in Table 26. 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 water is 38 °C (100 °F). The minimum engine oil temperature is 10 °C (50 °F).

• Before you apply a load between 50 and 100

percent of the rated load, the minimum temperature of the jacket water is 50 °C (122 °F). The minimum engine oil temperature is 50 °C (122 °F).

The minimum rpm for operating an engine with a load is 750 rpm. The maximum rpm for operating an engine with a load is 1000 rpm. Check the Advisor display and the driven equipment frequently while the engine is operating under a load. The engine can be operated continuously at full load.

(1)

Engine Load

Time Limit

0 to 30 percent

1/2 hour

31 to 50 percent

2 hours

51 to 100 percent

Continuous

(1)

For continuous operation, the manifold air pressure must be greater than the atmospheric pressure.

Oil Consumption The rate of oil consumption is called Brake Specific Oil Consumption (BSOC). The unit of measure is grams per brake kilowatt hour or pounds per brake horsepower hour. The BSOC depends on the engine 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

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• 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)

51 Operation Section Engine Operation

52 Operation Section Engine Stopping

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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. Pressing the emergency stop button may cause unburned gas to remain in the air inlet and in the exhaust manifold.

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 unburned 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.

Illustration 37

g00792865

(1) Emergency stop button (2) Mode control switch in the “OFF/RESET” position

The emergency stop button is in the OUT position for normal engine operation. For an emergency stop, push emergency stop button (2). The engine will not start when the button is locked. To reset the button, turn the button clockwise or pull the button. The spring-loaded button will return to the OUT position. The control panel must also be reset before the engine will start. To reset the control panel, turn mode control switch (1) to the “OFF/RESET” position. Another emergency stop button is located on the ECM junction box on the rear of the engine. 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 accelerated wear of engine components. Excessive temperatures in the turbocharger centerhousing 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.

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53 Operation Section Engine Stopping

1. Disengage or unload the driven equipment. a. For generator set engines, open the main circuit breaker. b. For industrial engines, unload the compressor or pump. Disengage the clutch (if equipped). Place the transmission and/or other attachments for the power take-off in NEUTRAL.

The engine will coast to a stop. Ensure that any system that provides external support to the engine is secured after the engine is stopped. Turn off the auxiliary systems for engine operation after the engine is stopped. The power to the control panel will be maintained until the engine control switch is turned to the “OFF/RESET” position. i02508920

Note: Extended idling can cause excessive oil consumption and related problems. See this Operation and Maintenance Manual, “Engine Operation” topic (Operation Section).

After Stopping Engine

2. Reduce the engine rpm to low idle.

• Check the engine crankcase oil level. Maintain the

Note: If the cooldown feature is not utilized, operate the engine at low idle rpm for a cooldown period of approximately one to two minutes before stopping the engine. 3. Use one of the following methods in order to stop the engine:

SMCS Code: 1000 oil level between the “ADD” and “FULL” marks on the “ENGINE STOPPED” side of the oil level gauge.

• If necessary, perform minor adjustments. Repair any leaks and tighten loose bolts.

• Note the service hour 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 damage.

• Allow the engine to cool. Check the coolant level. • If freezing temperatures are expected, check the Illustration 38

g00825057

Engine control switch in the “STOP” position

a. Turn the engine control switch to the “STOP” position. b. If the engine control switch is in the “AUTO” position, the engine will stop when the remote start/stop initiate contact opens. If the cooldown feature is utilized, the engine will operate for a programmed period of time before the engine stops. Otherwise, the engine will immediately shut off. When the engine rpm is reduced to approximately 100 rpm, the postlube cycle will operate for approximately 180 seconds.

coolant for protection against freezing. The cooling system must be protected against freezing to the lowest expected outside temperature. Add the proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all

driven equipment. Refer to the instructions that are provided by the OEM of the driven equipment.

54 Maintenance Section Refill Capacities

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Maintenance Section

Lubricant Capacities

Refill Capacities

The capacity of the engine crankcase includes the capacity of the oil filters that are installed at the factory. Table 28 i03679347

Refill Capacities and Recommendations SMCS Code: 1348; 1395; 7560 NOTICE 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 omissions. The information that is provided are the latest recommendations for Cat gas engines. This information supersedes all previous recommendations which have been published for Cat gas engines. Special fluids 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 Manual. NOTICE These recommendations are subject to change without notice. Consult your local Caterpillar dealer for the most up to date recommendations. Refer to Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations” for further information.

Lubrication System Note: Instructions for the installation of the filter are printed on the side of each Cat spin-on filter. For non-Cat filters, refer to the installation instructions that are provided by the supplier of the filter.

Lubricant Recommendations Due to the significant variations in the quality and in the performance of commercially available oils, Caterpillar makes the following recommendations, in order of oil performance:

Approximate Refill Capacity of Crankcase Liters

US Gallons

G3606

708

187

G3608

912

241

G3612

1030

272

G3616

1325

351

Sales Model

Hydraulic Actuator System Hydraulic Oil Caterpillar offers two hydraulic oil products:

• Cat HYDO Advanced 10 • Cat Bio HYDO Advanced Cat HYDO Advanced 10 (Hydraulic Oil) CatHYDO Advanced 10 fully replaced CatHYDO oil. CatHYDO is no longer available. CatHYDO Advanced 10 is preferred in most hydraulic systems and in most hydrostatic systems when ambient temperature is between −20 °C (−4 °F) and 40 °C (104 °F). If a different viscosity is required due to ambient temperatures, the following Caterpillar oils can be used:

• Cat DEO ULS Multigrade • Cat DEO Multigrade • Cat DEO ULS SYN • Cat Arctic DEO SYN • 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

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55 Maintenance Section Refill Capacities

Cat Bio HYDO Advanced (Hydraulic Oil) Cat Bio HYDO Advanced is biodegradable non-toxic hydraulic oil that is recommended for use in hydraulic systems when environmental compliance is required or desired. Cat Bio HYDO Advanced has a renewable content that exceeds 90% and complies with the European Eco-Label. Consult Federal, state, or local authorities for guidance on hydraulic oils environmental requirements in your area.

Permissible fuels must be analyzed in order to determine the following characteristics:

• Composition • Contaminants • Heat value • 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 g00103844

Illustration 39

Machines with this symbol are filled with biodegradable hydraulic oil. This symbol is located on the hydraulic tank.

Capacity of the Electrohydraulic Actuator's System G3600 Electrohydraulic Actuator System Approximate Refill Capacity

Hydraulic Oil Tank

• Methane values below 30 are not recommended

for use in a Cat engine. Fuels with a methane number that is below 30 must first be processed in order to remove harmful impurities in the fuel and raising the methane number into the acceptable range.

• If necessary, use an engine that is configured for a

Table 29

Compartment or System

level of Caterpillar Methane Number Program, LEKQ6378.

Liters

US Gallons

19

5

Fuel Gaseous fuels consist primarily of hydrocarbons (combinations of hydrogen and carbon) and some inert gases. Pipeline natural gas has been used for many years. Other types of fuels such as wellhead gas, bio-gas, and manufactured gas need to be reviewed for acceptability. Each commercial fuel gas is a mixture of gases. Some of the gases are combustible and some of the gases are inert. The compositions of these gas mixtures have extreme variations. Cat gas engines will operate successfully on a broad 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.

fuel that has a high energy. Consult the appropriate manual for the engine in order to determine the recommended engine timing.

• Reduce the oil change interval according to the results of the oil analysis.

Before the engine arrangement is ordered, use the methane number in order to determine the following characteristics for the new engine:

• Compression ratio • Fuel system components • Ignition timing • Rated load For a detailed explanation of methane numbers, refer to the most current revision level of Special Publication, LEBW4977, “Gaseous Fuels Application and Installation Guide”.

56 Maintenance Section Refill Capacities

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Cooling System

• Caterpillar dealer

Coolant Recommendations

• Local water utility company

During shipping and storage, the engine must be protected from damage that can be caused by freezing of the cooling system. If the engine is shipped to a site with freezing temperatures and/or if the engine is stored in a location with freezing temperatures, the cooling system must contain antifreeze that will withstand the lowest ambient temperature. Frequently check the concentration of glycol in the coolant/antifreeze. Make sure that the concentration is adequate in order to prevent freezing. Otherwise, the cooling system must be completely drained and all of the drain plugs must be removed.

• Agricultural agent

Coolant/antifreeze is normally composed of three elements: water, glycol, and additives. Each element must meet specific guidelines. Water Deionized water or distilled water is recommended for use in engine cooling systems. If distilled water or deionized water is not available, use water with the properties that are listed in Table 30. Table 30

Caterpillar Minimum Acceptable Water Requirements Property

Maximum Limit

ASTM Test

Chloride (Cl)

40 mg/L (2.4 grains per US gal)

“D512”, “D4327”

Sulfate (SO4)

100 mg/L (5.9 grains per US gal)

“D516”

Total Hardness

170 mg/L (10 grains per US gal)

“D1126”

Total Solids

340 mg/L (20 grains per US gal)

“D1888”

Acidity

pH of 5.5 to 9.0

“D1293”

NOTICE Use of water that does not meet the recommendations for the cooling system will damage the cooling system. Do not use these types of water in the cooling system: sea water, softened water that has been conditioned with salt, hard water, and tap water. Only use water that meets the recommendations for the cooling system. If you are not sure about the properties of your water, consult one of the following sources for a water analysis:

• Independent laboratory Glycol NOTICE Do not use Extended Life Coolant (ELC) with Cat Gas Engines. ELC was not formulated for use in Cat Gas Engines. Do not use heat transfer fluids in Cat Gas Engines. Use only the coolant/antifreeze that is recommended. Preferred – Cat NGEC (Natural Gas Engine Coolant) Alternatively, use Cat DEAC (Diesel Engine Antifreeze/Coolant) or a commercial heavy-duty antifreeze/coolant that meets “ASTM D6210” or “ASTM D4985” specifications. NOTICE Do not use a commercial coolant/antifreeze that only meets the ASTM “D3306” specification. This type of coolant/antifreeze is made for light duty automotive applications. Use only the coolant/antifreeze that is recommended. Acceptable – In applications that do not require protection from boiling or from freezing, a mixture of Caterpillar SCA and water that meets the properties that are listed in Table 30 is acceptable. Note: The preferred coolant/antifreeze and the acceptable mixture of SCA and water require different concentrations of SCA. Refer to the Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations”, “Supplemental Coolant Additive (SCA)” topic. Table 31 is a list of the coolant/antifreeze that is recommended for Caterpillar Gas Engines. The service life of the coolant/antifreeze that is used in Caterpillar Gas Engines is also listed. To achieve this service life, the coolants must be properly maintained. The maintenance program includes S·O·S coolant analysis.

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57 Maintenance Section Refill Capacities

Table 31

Table 32

Recommended Coolant/Antifreeze and Service Life of the Coolant/Antifreeze Coolant/Antifreeze Cat NGEC Cat DEAC Commercial Heavy-Duty Antifreeze/Coolant that meets “ASTM D6210”

Service Life

Compartment or System

Liters

US Gallons

Jacket Water

340

90

Aftercooler

61

16

Accessory Module

345

91

Three Years

Two Years

External System Total Cooling System

Commercial Heavy-Duty Antifreeze/Coolant that meets “ASTM D4985”

One Year

Cat SCA and Water

Two Years

Commercial SCA and Water

One Year

(1)

(1)

G3606 Engine Cooling System Approximate Refill Capacities

Table 33

G3608 Engine Cooling System Approximate Refill Capacities Compartment or System

Liters

US Gallons

Jacket Water

469

124

Aftercooler

61

16

Accessory Module

345

91

The service life of coolant is also limited by use (service hours). Refer to the specific engine's Operation and Maintenance Manual, “Maintenance Interval Schedule”.

Additives Preferred – Cat SCA (Supplemental Coolant Additive) Acceptable – A commercial SCA that provides 1400 mg/L (82 grains per US gal) or 1400 ppm of nitrites in the final mixture of coolant/antifreeze Note: A 50/50 concentration of Cat NGEC or of Cat DEAC does not require a treatment with an SCA at the initial fill. Commercial heavy-duty antifreeze/coolant that meets “ASTM D6210” or “ASTM D4985” specifications may require a treatment with an SCA at the initial fill. Read the label or the instructions that are provided by the OEM of the product. To ensure that the correct amount of SCA is in the cooling system, the concentration of SCA must be tested on a scheduled basis. Obtain an S·O·S coolant analysis (Level 1) or use a test kit to check the concentration of the SCA according to this Operation and Maintenance Manual, “Maintenance Interval Schedule”.

Coolant Capacities To properly maintain the cooling system, the total cooling system capacity must be determined. The total cooling system capacity will vary between individual installations. The external system capacity includes the following components: 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:

External System Total Cooling System Table 34

G3612 Engine Cooling System Approximate Refill Capacity Compartment or System

Liters

US Gallons

Jacket Water

669

177

Aftercooler

64

17

Accessory Module

345

91

External System Total Cooling System Table 35

G3616 Engine Cooling System Approximate Refill Capacity Compartment or System

Liters

US Gallons

Jacket Water

900

238

Aftercooler

72

19

Accessory Module

345

91

External System Total Cooling System

58 Maintenance Section Maintenance Recommendations

SEBU7563-09

Maintenance Recommendations

1. Stop the engine. 2. Wait for ten minutes. i02909163

System Pressure Release SMCS Code: 1250; 1300; 1350; 5050

Coolant System

Do not loosen the high pressure fuel lines in order to remove air pressure from the fuel system.

Engine Oil To relieve pressure from the lubricating system, turn off the engine. i03681563

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. To relieve the pressure from the coolant system, turn off the engine. Allow the cooling system pressure cap to cool. Remove the cooling system pressure cap slowly in order to relieve pressure.

Fuel System To relieve the pressure from the fuel system, turn off the engine.

High Pressure Fuel Lines (If Equipped)

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel systems. This is because of the following differences:

• The high pressure fuel lines are constantly charged with high pressure.

Welding on Engines with Electronic Controls SMCS Code: 1000 NOTICE Because the strength of the frame may decrease, some manufacturers do not recommend welding onto a chassis frame or rail. Consult the OEM of the equipment or your Caterpillar dealer regarding welding on a chassis frame or rail. Proper welding procedures are necessary in order to avoid damage to the engine's electronic control module (ECM), sensors, and associated components. When possible, remove the component 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 the safest procedure to weld on a component. This procedure should provide a minimum risk of damage to electronic components. NOTICE Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic components, electrical components, and other components. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. This will help reduce the possibility of damage.

• The internal pressures of the high pressure fuel

1. Stop the engine. Turn the switched power to the OFF position.

Before any service or repair is performed on the engine fuel lines, perform the following tasks:

2. Disconnect the negative battery cable from the battery. If a battery disconnect switch is provided, open the switch.

lines are higher than other types of fuel system.

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59 Maintenance Section Maintenance Recommendations

3. Disconnect the J1/P1 and J2/P2 connectors from the ECM. Move the harness to a position that will not allow the harness to accidentally move back and make contact with any of the ECM pins.

Illustration 40

g01075639

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) (2) (3) (4) (5) (6) (7) (8)

Engine Welding rod Keyswitch in the OFF position Battery disconnect switch in the open position Disconnected battery cables Battery Electrical/Electronic component 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.

5. Protect the wiring harness from welding debris and spatter. 6. Use standard welding practices to weld the materials.

60 Maintenance Section Maintenance Interval Schedule

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i03915129

Maintenance Interval Schedule (G3600 Engines That Use Wellhead or Natural Gas and Have a Compression Ratio of 9.2:1) SMCS Code: 1000; 4450; 7500 Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of all maintenance including the following procedures: all adjustments, the use of proper lubricants, fluids, filters, and the installation of new components due to normal wear and aging . The performance of this product may be diminished if proper maintenance intervals and procedures are not followed. Components may experience accelerated wear if proper maintenance intervals and procedures are not followed. Note: Use whichever of the following that occurs first in order to determine the maintenance intervals: fuel consumption, service hours, and calendar time . Before each consecutive interval is performed, all maintenance from the previous intervals must be performed. Products that operate in severe operating conditions may require more frequent maintenance.

When Required Actuator Control Linkage - Replace ...................... 66 Barring Device - Lubricate .................................... 69 Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77 Engine Air Cleaner Element (Single Element) Clean/Replace .................................................... 87 Engine Air Precleaner - Clean .............................. 91 Overhaul Considerations ..................................... 116 Valve Stem Projection - Measure/Record ........... 122

Daily Air Starting Motor Lubricator Oil Level - Check .... 68 Air Tank Moisture and Sediment - Drain ............... 69 Control Panel - Inspect ......................................... 74 Cooling System Coolant Level - Check ................ 76 Driven Equipment - Inspect/Replace/Lubricate ... 83 Electrohydraulic System - Inspect ........................ 86 Engine Oil Level - Check ...................................... 96 Fuel System Fuel Filter Differential Pressure Check ................................................................ 103 Walk-Around Inspection ...................................... 123

Every 250 Service Hours Battery Electrolyte Level - Check .......................... Cooling System Coolant Sample (Level 1) Obtain ................................................................. Cooling System Supplemental Coolant Additive (SCA) - Test/Add ................................................. Engine Oil Sample - Obtain ..................................

71 77 78 97

Initial 1000 Service Hours Air Starting Motor Lines Screen - Clean ............... 67 Air Starting Motor Lubricator Bowl - Clean ........... 67 Crankcase Blowby - Measure/Record .................. 80 Cylinder Pressure - Measure/Record ................... 81 Electrohydraulic System Oil Filter - Change ......... 87 Engine Crankcase Breather - Clean ..................... 91 Engine Protective Device Connections - Inspect .. 98 Engine Speed/Timing Sensor - Clean/Inspect .... 100 Engine Valve Lash - Inspect/Adjust .................... 101 Engine Valve Rotators - Inspect ......................... 102 Valve Stem Projection - Measure/Record ........... 122

Every 1000 Service Hours Actuator Control Linkage - Lubricate .................... 66 Belts - Inspect/Adjust/Replace .............................. 71 Hoses and Clamps - Inspect/Replace ................ 105 Ignition System Spark Plugs - Check/Adjust ...... 108

Every 2000 Service Hours Aftercooler Condensation - Drain ......................... 67 Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77 Crankshaft Vibration Damper - Inspect ................. 80 Engine Crankcase Breather - Clean ..................... 91 Engine Mounts - Check ........................................ 92 Engine Valve Lash - Inspect/Adjust .................... 101 Engine Valve Rotators - Inspect ......................... 102 Valve Stem Projection - Measure/Record ........... 122

Every 5000 Service Hours Air Starting Motor Lines Screen - Clean ............... 67 Air Starting Motor Lubricator Bowl - Clean ........... 67 Combustion Sensor - Clean/Inspect/Replace ....... 72 Cooling System Level Switch - Inspect ................. 77 Crankcase Blowby - Measure/Record .................. 80 Cylinder Pressure - Measure/Record ................... 81 Driven Equipment - Check .................................... 82 Electrohydraulic System - Check/Adjust ............... 85 Electrohydraulic System Oil - Change .................. 86 Electrohydraulic System Oil Filter - Change ......... 87 Engine Oil - Change ............................................. 92 Engine Oil Filter - Change .................................... 93 Engine Protective Device Connections - Inspect .. 98 Engine Protective Devices - Check .................... 100 Exhaust Bypass - Recondition ............................ 102 Gas Shutoff Valve - Inspect ................................ 105 Ignition System Spark Plugs - Replace ............... 111 Inlet Air System - Inspect ..................................... 111

SEBU7563-09

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

61 Maintenance Section Maintenance Interval Schedule

62 Maintenance Section Maintenance Interval Schedule

SEBU7563-09

i03915106

Maintenance Interval Schedule (G3600 Engines That Use Natural Gas and Have a Compression Ratio of 10.5:1 or 11:1) SMCS Code: 1000; 4450; 7500 Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of all maintenance including the following procedures: all adjustments, the use of proper lubricants, fluids, filters, and the installation of new components due to normal wear and aging . The performance of this product may be diminished if proper maintenance intervals and procedures are not followed. Components may experience accelerated wear if proper maintenance intervals and procedures are not followed. Note: Use whichever of the following that occurs first in order to determine the maintenance intervals: fuel consumption, service hours, and calendar time . Before each consecutive interval is performed, all maintenance from the previous intervals must be performed. Products that operate in severe operating conditions may require more frequent maintenance.

When Required Actuator Control Linkage - Replace ...................... 66 Barring Device - Lubricate .................................... 69 Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77 Engine Air Cleaner Element (Single Element) Clean/Replace .................................................... 87 Engine Air Precleaner - Clean .............................. 91 Overhaul Considerations ..................................... 116 Valve Stem Projection - Measure/Record ........... 122

Daily Air Starting Motor Lubricator Oil Level - Check .... 68 Air Tank Moisture and Sediment - Drain ............... 69 Control Panel - Inspect ......................................... 74 Cooling System Coolant Level - Check ................ 76 Driven Equipment - Inspect/Replace/Lubricate ... 83 Electrohydraulic System - Inspect ........................ 86 Engine Oil Level - Check ...................................... 96 Fuel System Fuel Filter Differential Pressure Check ................................................................ 103 Walk-Around Inspection ...................................... 123

Every 250 Service Hours Battery Electrolyte Level - Check .......................... Cooling System Coolant Sample (Level 1) Obtain ................................................................. Cooling System Supplemental Coolant Additive (SCA) - Test/Add ................................................. Engine Oil Sample - Obtain ..................................

71 77 78 97

Initial 1000 Service Hours Air Starting Motor Lines Screen - Clean ............... 67 Air Starting Motor Lubricator Bowl - Clean ........... 67 Crankcase Blowby - Measure/Record .................. 80 Cylinder Pressure - Measure/Record ................... 81 Electrohydraulic System Oil Filter - Change ......... 87 Engine Crankcase Breather - Clean ..................... 91 Engine Protective Device Connections - Inspect .. 98 Engine Speed/Timing Sensor - Clean/Inspect .... 100 Engine Valve Lash - Inspect/Adjust .................... 101 Engine Valve Rotators - Inspect ......................... 102 Valve Stem Projection - Measure/Record ........... 122

Every 1000 Service Hours Actuator Control Linkage - Lubricate .................... 66 Belts - Inspect/Adjust/Replace .............................. 71 Hoses and Clamps - Inspect/Replace ................ 105 Ignition System Spark Plugs - Replace ............... 111

Every 2000 Service Hours Aftercooler Condensation - Drain ......................... 67 Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77 Crankshaft Vibration Damper - Inspect ................. 80 Engine Crankcase Breather - Clean ..................... 91 Engine Mounts - Check ........................................ 92 Engine Valve Lash - Inspect/Adjust .................... 101 Engine Valve Rotators - Inspect ......................... 102 Valve Stem Projection - Measure/Record ........... 122

Every 5000 Service Hours Air Starting Motor Lines Screen - Clean ............... 67 Air Starting Motor Lubricator Bowl - Clean ........... 67 Combustion Sensor - Clean/Inspect/Replace ....... 72 Cooling System Level Switch - Inspect ................. 77 Crankcase Blowby - Measure/Record .................. 80 Cylinder Pressure - Measure/Record ................... 81 Driven Equipment - Check .................................... 82 Electrohydraulic System - Check/Adjust ............... 85 Electrohydraulic System Oil - Change .................. 86 Electrohydraulic System Oil Filter - Change ......... 87 Engine Oil - Change ............................................. 92 Engine Oil Filter - Change .................................... 93 Engine Protective Device Connections - Inspect .. 98 Engine Protective Devices - Check .................... 100 Exhaust Bypass - Recondition ............................ 102 Gas Shutoff Valve - Inspect ................................ 105 Inlet Air System - Inspect ..................................... 111 Inlet Gas Manifold and Piping - Inspect/Replace .. 111

SEBU7563-09

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

63 Maintenance Section Maintenance Interval Schedule

64 Maintenance Section Maintenance Interval Schedule

SEBU7563-09

i03915101

Maintenance Interval Schedule (G3600 Engines That use Bio-Gas) SMCS Code: 1000; 4450; 7500 Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of all maintenance including the following procedures: all adjustments, the use of proper lubricants, fluids, filters, and the installation of new components due to normal wear and aging . The performance of this product may be diminished if proper maintenance intervals and procedures are not followed. Components may experience accelerated wear if proper maintenance intervals and procedures are not followed. Note: Use whichever of the following that occurs first in order to determine the maintenance intervals: fuel consumption, service hours, and calendar time . Before each consecutive interval is performed, all maintenance from the previous intervals must be performed. Products that operate in severe operating conditions may require more frequent maintenance.

When Required

Every 125 Service Hours Engine Oil Sample - Obtain .................................. 97

Every 250 Service Hours Battery Electrolyte Level - Check .......................... 71 Cooling System Coolant Sample (Level 1) Obtain ................................................................. 77 Cooling System Supplemental Coolant Additive (SCA) - Test/Add ................................................. 78

Initial 1000 Service Hours Air Starting Motor Lines Screen - Clean ............... 67 Air Starting Motor Lubricator Bowl - Clean ........... 67 Crankcase Blowby - Measure/Record .................. 80 Cylinder Pressure - Measure/Record ................... 81 Electrohydraulic System Oil Filter - Change ......... 87 Engine Crankcase Breather - Clean ..................... 91 Engine Protective Device Connections - Inspect .. 98 Engine Speed/Timing Sensor - Clean/Inspect .... 100 Engine Valve Lash - Inspect/Adjust .................... 101 Engine Valve Rotators - Inspect ......................... 102 Valve Stem Projection - Measure/Record ........... 122

Every 1000 Service Hours Actuator Control Linkage - Lubricate .................... 66 Belts - Inspect/Adjust/Replace .............................. 71 Combustion Sensor - Clean/Inspect/Replace ....... 72 Hoses and Clamps - Inspect/Replace ................ 105 Ignition System Spark Plugs - Replace ............... 111 Prechamber Check Valves - Clean ...................... 118

Actuator Control Linkage - Replace ...................... 66 Barring Device - Lubricate .................................... 69 Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77 Engine Air Cleaner Element (Single Element) Clean/Replace .................................................... 87 Engine Air Precleaner - Clean .............................. 91 Engine Oil - Change ............................................. 92 Engine Oil Filter - Change .................................... 93 Overhaul Considerations ..................................... 116 Valve Stem Projection - Measure/Record ........... 122

Every 2000 Service Hours

Daily

Every 5000 Service Hours

Air Starting Motor Lubricator Oil Level - Check .... 68 Air Tank Moisture and Sediment - Drain ............... 69 Control Panel - Inspect ......................................... 74 Cooling System Coolant Level - Check ................ 76 Driven Equipment - Inspect/Replace/Lubricate ... 83 Electrohydraulic System - Inspect ........................ 86 Engine Air Cleaner Service Indicator - Inspect ..... 90 Engine Oil Level - Check ...................................... 96 Fuel System Fuel Filter Differential Pressure Check ................................................................ 103 Turbocharger - Clean .......................................... 120 Walk-Around Inspection ...................................... 123

Air Starting Motor Lines Screen - Clean ............... 67 Air Starting Motor Lubricator Bowl - Clean ........... 67 Cooling System Level Switch - Inspect ................. 77 Crankcase Blowby - Measure/Record .................. 80 Cylinder Pressure - Measure/Record ................... 81 Driven Equipment - Check .................................... 82 Electrohydraulic System - Check/Adjust ............... 85 Electrohydraulic System Oil - Change .................. 86 Electrohydraulic System Oil Filter - Change ......... 87 Engine Protective Device Connections - Inspect .. 98 Engine Protective Devices - Check .................... 100 Exhaust Bypass - Recondition ............................ 102 Gas Shutoff Valve - Inspect ................................ 105

Aftercooler Condensation - Drain ......................... 67 Cooling System Coolant Sample (Level 2) Obtain ................................................................. 77 Crankshaft Vibration Damper - Inspect ................. 80 Cylinders - Inspect ................................................ 82 Engine Crankcase Breather - Clean ..................... 91 Engine Mounts - Check ........................................ 92 Engine Valve Lash - Inspect/Adjust .................... 101 Engine Valve Rotators - Inspect ......................... 102 Valve Stem Projection - Measure/Record ........... 122

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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

65 Maintenance Section Maintenance Interval Schedule

66 Maintenance Section Actuator Control Linkage - Lubricate

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i02236400

Actuator Control Linkage Lubricate (If applicable)

Actuator Control Linkage Replace

SMCS Code: 1265-086

Inspect the rod ends of the following components for wear:

The linkage can move and form a pinch point which can cause personal injury. Keep hands away from the linkage. Before performing this procedure, ensure that the linkage is meant to be lubricated. If the linkage is meant to be lubricated, this article applies to the following: air choke actuator, fuel control actuator, and exhaust bypass actuator. Apply Dow Corning 41 Extreme High Temperature Bearing Grease to the rod ends (bearings) of the control linkage for the actuator. For more information on grease, see the Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations”.

SMCS Code: 1265-510

Note: Use of a platform may be necessary to reach the linkages.

• Air choke actuator • Exhaust bypass actuator • Fuel control actuator • Linkages If necessary, replace the rod ends.

Removal and Installation

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

Illustration 42

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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.

Illustration 41 Typical locations of grease fittings

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67 Maintenance Section Aftercooler Condensation - Drain

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Aftercooler Condensation Drain

Air Starting Motor Lines 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.

Illustration 45

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(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). Illustration 43

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

3. Carefully remove screen (2). Clean the screen with nonflammable solvent. Inspect the screen for damage. If the screen is damaged, replace the damaged screen with a new screen. 4. Install clean, dry screen (2). Clean plug (1). Install the plug. i02654935

Air Starting Motor Lubricator Bowl - Clean SMCS Code: 1451-070

Illustration 44

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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.

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

68 Maintenance Section Air Starting Motor Lubricator Oil Level - Check

Personal injury can result from removing hoses or fittings in a pressure system. Failure to relieve pressure can cause personal injury. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.

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5. Dry the bowl. Inspect the bowl for cracks. If the bowl is cracked, replace the damaged bowl with a new bowl. Inspect the gasket. If the gasket is damaged, replace the gasket. 6. Install the bowl. 7. Make sure that drain valve (3) is closed. 8. For instructions on filling the lubricator, see this 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 lubrication. Ensure that sufficient oil is in the lubricator bowl.

Illustration 46

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(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, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. 3. Place a suitable container under bowl (2) and open drain valve (3) in order to drain the oil from the bowl. 4. Remove bowl (2). Clean the bowl with warm water.

Illustration 47

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1. Observe the oil level in sight gauge (3). If the oil level is less than 1/2, add oil to the lubricator bowl.

Personal injury can result from removing hoses or fittings in a pressure system. Failure to relieve pressure can cause personal injury. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved. 2. Ensure that the air supply to the lubricator is OFF. Slowly loosen filler plug (4) in order to release pressure from the lubricator bowl.

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69 Maintenance Section Air Tank Moisture and Sediment - Drain

3. Remove filler plug (4). Pour oil into the lubricator bowl. Use nondetergent SAE 10W oil for temperatures that are greater than 0 °C (32 °F). Use air tool oil for temperatures that are below 0 °C (32 °F).

1. Open the drain valve that is on the bottom of the air tank. Allow the moisture and sediment to drain. 2. Close the drain valve. 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 oil in proportion to variations of the air flow. 1. Ensure that the fuel supply to the engine is OFF. NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again. 2. Operate the air starting motor. Observe the drops of oil that are released in dome (1). Note: Some lubricators have an adjustment screw rather than a knob. 3. If necessary, adjust the lubricator in order to release from one to three drops of oil per second. To increase the rate, turn knob (2) counterclockwise. To decrease the rate, turn the knob clockwise. i00351324

Air Tank Moisture and Sediment - Drain

Inspect the alternator for the following conditions:

• Proper connections • Clean ports for cooling airflow • Proper charging of the battery Observe battery voltage on the Advisor panel or Cat ET during engine operation to evaluate the performance of the alternator. Make repairs, if necessary. See the Service Manual for service procedures. Consult your Caterpillar dealer for assistance. i02601741

Barring Device - Lubricate SMCS Code: 1235-086 NOTICE Do not use an impact wrench to operate the barring device. The use of an impact wrench will cause gear tooth failure.

SMCS Code: 1466-543-M&S Moisture and sediment in the air starting system can cause the following conditions:

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

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

Guards must be in place prior to operating barring device motor. Remove all hand tools prior to operating barring device motor. Note: Prelube of the engine is required before the crankshaft is rotated for normal maintenance. The barring device provides a means for slowly turning the flywheel in order to service the engine. When the barring device is in the engaged position, the engine starting system is disabled. When the barring device is not used, the barring device must be fully disengaged from the flywheel and secured in the disengaged position. Refer to the Service Manual for information on operation of the barring device.

70 Maintenance Section Barring Device - Lubricate

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

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

Illustration 50

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1. Ensure that the barring device is locked in the disengaged position. 2. Remove level plugs (2) and check the lubricant level.

Illustration 48

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3. If necessary, remove cap (1) and add Caterpillar 4C-6767 Synthetic Oil until the oil is visible at the level plugs.

Rear view of an electrically driven barring device

4. Reinstall the level plugs and reinstall the cap.

Lubricating the Pinion

Manual Barring Device

Illustration 49

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Section view of a barring device without the electric motor (1) Grease fitting (2) Vent

1. Ensure that the barring device is locked in the disengaged position. 2. Lubricate grease fitting (1) with Cat Advanced 3Moly Grease until the grease is visible at vent (2).

Illustration 51

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(1) Grease fitting (2) Gear end

1. Ensure that the barring device is locked in the disengaged position. 2. Lubricate grease fitting (1) with Cat Advanced 3Moly Grease until the grease is visible at gear end (2).

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71 Maintenance Section Battery Electrolyte Level - Check

i02601752

Battery Electrolyte Level Check SMCS Code: 1401-535-FLV When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing.

i02601764

Belts - Inspect/Adjust/Replace SMCS Code: 1357-025; 1357-040; 1357-510

Inspection Inspect the alternator belt and the fan drive belts for wear and for cracking. Replace the belts if the belts 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 can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries.

Slippage of loose belts can reduce the efficiency of the driven components. Vibration of loose belts can cause unnecessary wear on the following components:

1. Remove the filler caps. Maintain the electrolyte level to the “FULL” mark on the battery.

• Belts

If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use artificially softened water. 2. Check the condition of the electrolyte with the 245-5829 Coolant Battery Tester Refractometer. 3. Keep the batteries clean.

• Pulleys • Bearings If the belts are too tight, unnecessary stress is placed on the components. This reduces the service life of the components.

Adjusting the Alternator Belt

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

1. Remove the drive belt guard.

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72 Maintenance Section Combustion Sensor - Clean/Inspect/Replace

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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 drive belt to carry more load because the older drive belts are stretched. The additional load on the new drive belt could cause the new drive belt to fail. i02601781

Combustion Sensor Clean/Inspect/Replace SMCS Code: 1900; 1905 To provide a signal without interference to the engine control module, the sensor must be in good condition. The connections must be clean.

Illustration 53

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Section view of a cylinder head with a combustion sensor (1) (2) (3) (4) (5) (6)

Harness connector Connector Extension Sensor Gasket Discs

Note: Use of a platform may be necessary to reach the combustion sensor. Note: Clean the connections and polish the connections with a clean, dry cloth. Always install a new O-ring seal in connector (1) when the 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.

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73 Maintenance Section Combustion Sensor - Clean/Inspect/Replace

Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes. Note: The maximum air pressure for cleaning purposes must be below 207 kPa (30 psi). 4. The area around sensor (4) may have debris. Thoroughly remove any debris. Use compressed air. Ensure that the area around the sensor is clean and free of debris. 5. Loosen sensor (4) with a 15.9 mm (5/8 inch) spark plug socket and an extension. After the sensor has been loosened, remove the sensor by hand in order to detect problems with the threads. If the sensor resists removal by hand, apply penetrating oil to the threads. Use the wrench and apply steady pressure to the sensor until the sensor is loose.

Light brown deposits or beige deposits around the electrode is produced by normal operation. White deposits or gray deposits may be caused by the following substances:

• Excessive oil • Use of the wrong oil • A substance that is introduced through the fuel system or the air system

A buildup of ash on the electrode reduces the efficiency of the sensor. 8. Measure the resistance between terminal post (6) and electrode (10). The sensor must pass a low voltage check for continuity between the terminal post and the electrode. The resistance must not exceed five ohms. 9. Thoroughly clean the sensor. Clean the shell and the electrode that is inside of the shell. Do not use a wire brush. Glass beads are the preferred method for cleaning. Follow these guidelines for the use of glass beads:

• Always use clean glass beads. Illustration 54

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Combustion sensor (6) Terminal post (7) Insulator (8) Shell (9) Gasket (10) Electrode

6. After the sensor is removed, discard gasket (9). 7. Inspect the sensor closely for damage. Terminal post (6) must not move. If the terminal post can be moved by hand, discard the sensor. Inspect insulator (7) for cracks. If a crack is found, discard the sensor. Inspect shell (8) for damage. Cracks can be caused by overtightening the sensor. Overtightening can also loosen the shell. Discard any sensor that has a shell that is cracked or loose. Inspect electrode (10) for excessive wear.

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

• Do not use glass beads on the outside of the shell or on the upper part of the insulator.

Ensure that the sensor is clean and free of dirt and oil. Note: Do not use anti-seize compound on the sensor. Most of the heat is transferred through the threads and the seat area of the sensor. The surfaces must be in contact in order to provide the heat transfer that is required. 10. Place a new 108-3515 Plug Gasket on the sensor. Install the sensor by hand until the sensor bottoms out. Tighten the sensor to 38 ± 2 N·m (28 ± 2 lb ft). 11. Install extension (3). Make sure that discs (5) are positioned in order to align the extension's connectors with sensor (4) and connector (2). 12. Make sure that the O-ring seal on connector (2) is in good condition. Install the connector. 13. Attach harness connector (1) to connector (2).

74 Maintenance Section Control Panel - Inspect

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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 Data If equipped, check the gauges and check the indicators frequently during normal operation. Record the data in a log. Compare the new data to the data that was previously recorded. Comparing the new data to the recorded data will establish the normal gauge readings for the engine. A gauge reading that is abnormal may indicate a problem with operation or with the gauge.

Illustration 55

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Location of cooling system drain valves or drain plugs on the water pumps (1) Jacket water pump (2) Aftercooler and oil cooler pump

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Cooling System Coolant (NGEC) - Change SMCS Code: 1350-044 g00901833

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

Illustration 56

• The engine overheats frequently.

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

• Foaming is observed. • The oil has entered the cooling system and the coolant is contaminated.

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

Drain the Cooling System 1. Stop the engine and allow the engine to cool. Ensure that the engine will not start when the cooling system is drained. 2. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.

Location of drain plug for the jacket water system

NOTICE Dispose of used engine coolant properly or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant. For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools Group: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL

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Clean the Cooling System 1. Flush the cooling system with clean water in order to remove any debris.

75 Maintenance Section Cooling System Coolant (NGEC) - Change

2. Close the cooling system drain valves (if equipped). Clean the cooling system drain plugs and install the cooling system drain plugs.

2. Close the cooling system drain valves (if equipped). Clean the cooling system drain plugs and install the cooling system drain plugs.

3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L (1 to 2 US gal) of the cooling system capacity. Install the cooling system filler cap.

NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute in order to avoid air locks. Proper venting of the cooling system is essential to fill at this rate.

4. Start the engine. Operate the engine for a minimum of 90 minutes with a coolant temperature of at least 82 °C (180 °F).

3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Add .5 L (1 pint) of cleaner per 15 L (4 US gal) of the cooling system capacity. Install the cooling system filler cap.

5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the cooling system drain valves (if equipped). Remove the cooling system drain plugs. Allow the water to drain.

4. Start the engine. Operate the engine for a minimum of 30 minutes with a coolant temperature of at least 82 °C (180 °F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the cooling system drain valves (if equipped). Remove the cooling system drain plugs. Allow the water to drain. NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone. 6. Flush the cooling system with clean water until the water that drains is clean. Close the cooling system drain valves (if equipped). Clean the cooling system drain plugs and install the cooling system drain plugs.

Cleaning a Cooling System that has Heavy Deposits or Plugging Note: For the following procedure to be effective, there must be an active flow through the cooling system components. 1. Flush the cooling system with clean water in order to remove any debris.

NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone. 6. Flush the cooling system with clean water until the water that drains is clean. Close the cooling system drain valves (if equipped). Clean the cooling system drain plugs and install the cooling system drain plugs.

Fill the Cooling System NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute in order to avoid air locks. Proper venting of the cooling system is essential to fill at this rate. Note: For information about the proper coolant to use, and the capacity of the cooling system, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section). 1. Fill the cooling system with coolant/antifreeze. Do not install the cooling system filler cap. 2. Start the engine. Operate the engine in order to purge the air from the cavities of the engine block. Allow the coolant to warm and allow the coolant level to stabilize. Stop the engine.

76 Maintenance Section Cooling System Coolant Level - Check

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3. Check the coolant level. Maintain the coolant to the proper level on the sight gauge (if equipped). If a sight gauge is not equipped, maintain the coolant to the level that is specified by the OEM of the cooling system.

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

4. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets of the cooling system filler cap are damaged, discard the old cooling system filler cap and install a new cooling system filler cap. If the gaskets of the cooling system filler cap are not damaged, use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system filler cap. The correct pressure is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not retain the correct pressure, install a new cooling system filler cap.

Engines That Are Not Equipped With a Sight Gauge

5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature. i02062976

Cooling System Coolant Level - Check SMCS Code: 1350-535-FLV

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Check the coolant level when the engine is stopped and cool. Check the coolant level only after the engine has been stopped and the cooling system filler cap is cool enough to touch with your bare hand. Remove the cooling system filler cap slowly in order to relieve any pressure. Maintain the coolant within 13 mm (0.5 inch) below the bottom of the filler pipe.

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

Note: For the proper coolant mixture to use, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section). 1. Stop the engine. Allow the engine to cool.

Engines That Are Equipped With a Sight Gauge

Illustration 57 (1) Filler cap (2) Sight gauge

2. Remove the cooling system filler cap slowly in order to relieve any pressure. Pour the proper coolant mixture into the filler pipe.

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Illustration 58 Gaskets

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77 Maintenance Section Cooling System Coolant Sample (Level 1) - Obtain

3. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets are damaged, replace the old cooling system filler cap with a new cooling system filler cap. Install the cooling system filler cap. 4. Start the engine. Inspect the cooling system for leaks. i02064894

Cooling System Coolant Sample (Level 1) - Obtain SMCS Code: 1350-008; 1395-008; 1395-554; 7542 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. For conventional heavy-duty coolant/antifreeze, check the concentration of supplemental coolant additive (SCA) regularly. The concentration of SCA can be checked with an S·O·S coolant analysis (Level 1). Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for proper sampling of the coolant:

• Never collect samples from expansion bottles. • Never collect samples from the drain for a system. • Keep the unused sampling bottles stored in plastic bags.

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

• Complete the information on the label for the sampling bottle before you begin to take the samples. • Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location.

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

Submit the sample for Level 1 analysis. Note: Level 1 results may indicate a need for Level 2 Analysis. For additional information about coolant analysis, see the Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel and Coolant Recommendations” or consult your Caterpillar dealer. i02168823

Cooling System Coolant Sample (Level 2) - Obtain SMCS Code: 1350-008; 1395-008; 1395-554; 7542 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Obtain the sample of the coolant as close as possible to the recommended sampling interval. Supplies for collecting samples can be obtained from your Caterpillar dealer. Refer to this Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) - Obtain” (Maintenance Section) for the guidelines for proper sampling of the coolant. Submit the sample for Level 2 analysis. For additional information about coolant analysis, see the Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations” or consult your Caterpillar dealer. i01519993

Cooling System Level Switch - Inspect SMCS Code: 7422-040 The low coolant level switch actuates an alarm or a shutoff if the coolant level is low. A low coolant level could cause the engine to overheat. This could result in damage to the engine.

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

If the coolant level is low, coolant must be added to the expansion tank or the heat exchanger.

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

Test the Concentration of the SCA Coolant/Antifreeze and SCA NOTICE Do not exceed the recommended six percent supplemental coolant additive concentration. Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. Follow the instructions that are provided in the kit. Illustration 59

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(1) Switch (2) Lines

For proper operation of the switch, the lines and the switch must be clean. 1. Drain the coolant to a level below lower line (2). Drain the coolant into a clean container so that the coolant can be reused. 2. Remove switch (1). Inspect the openings of the inlet and the outlet for plugging. If an opening is plugged, clean the switch. 3. Inspect lines (2) for plugging. Clean the lines, if necessary. Pressure air or a flexible wire can be used to clean the lines. 4. Install switch (1). 5. Pour the coolant into the cooling system. Verify that the low coolant level switch is operating properly. A switch that is operating properly will activate an alarm until a sufficient amount of coolant is added. i02017557

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

Water and SCA NOTICE Do not exceed the recommended eight percent supplemental coolant additive concentration. Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. Use the instructions that follow: 1. Fill the syringe to the “1.0 ml” mark with the coolant. 2. Dispense the 1.0 mL coolant sample from the syringe into the empty mixing bottle. 3. Add tap water to the mixing bottle in order to bring the level up to the “10 ml” mark. Place the cap on the bottle and shake the bottle. 4. Add 2 to 3 drops of the “NITRITE INDICATOR SOLUTION B” to the mixing bottle. Move the bottle in a circular motion in order to mix the solution. 5. Add 1 drop of “NITRITE TEST SOLUTION A” to the mixing bottle. Move the bottle in a circular motion in order to mix the solution. 6. Repeat 5 until the solution changes color from red to light gray, green, or blue. Record the number of drops of “NITRITE TEST SOLUTION A” that were required to cause the color change. 7. Use Table 36 to interpret the results.

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79 Maintenance Section Cooling System Water Temperature Regulator - Replace

Table 36

Number of Drops

Concentration of SCA

Maintenance Required

Less than 25

Less than the recommended concentration of SCA

Add SCA. Retest the coolant.

The recommended concentration of SCA

None

More than the recommended concentration of SCA

Remove the coolant. Replace with water only Retest the coolant.

25 to 30

More than 30

4. Clean the cooling system filler cap. Install the cooling system filler cap. i02168842

Cooling System Water Temperature Regulator Replace SMCS Code: 1355-510

Add the SCA, If Necessary

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Remove the cooling system filler cap slowly. Note: Always dispose of fluids according to local regulations. 2. If necessary, drain some coolant in order to allow space for the addition of the SCA. NOTICE Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine's heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger, overheating, and/or accelerated wear of the water pump seal. Do not exceed the recommended amount of supplemental coolant additive concentration. 3. Add the proper amount of SCA. The concentration of the SCA depends on the type of coolant that is used. To determine the proper amount, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic.

Replace the water temperature regulators for these systems:

• Jacket water • Oil cooler • Aftercooler Replace the water temperature regulators before the water temperature regulators fail. This is a recommended preventive maintenance practice. Replacing the water temperature regulators reduces the chances for unscheduled downtime. A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine. A water temperature regulator that fails in the closed position can cause excessive overheating. Excessive overheating could result in cracking of the cylinder head or a seizure of the pistons. A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation. Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders. This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner. Also, a low temperature can allow moisture to condense in the oil. This can form damaging acids. NOTICE Failure to replace the water temperature regulator on a regularly scheduled basis could cause severe engine damage. Never operate an engine without the water temperature regulator installed. If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head damage. Ensure that the new water temperature regulator is installed in the original position.

80 Maintenance Section Crankcase Blowby - Measure/Record

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Note: If only the water temperature regulators are replaced, drain the coolant from the cooling system to a level that is below the water temperature regulator housing.

Excessive crankcase blowby may indicate the need for an overhaul. By keeping a record of the results, a gradual increase in the amount of the crankcase blowby will be noted until the amount of crankcase blowby has become excessive.

i02602965

Use the 1U-8860 Large Engine Blowby Pickup Group to measure the blowby. Refer to Special Instruction, SEHS8984, “1U-8860 Large Engine Blowby Pickup Group” that is provided with the tool.

Crankcase Blowby Measure/Record SMCS Code: 1317 Note: The typical crankcase blowby on a new engine is approximately 0.02 m3/bkW h (.50 ft3/bhp h). Measure the crankcase blowby of new engines. Record the data. Continue to periodically measure the crankcase blowby. Comparing the recorded data to the new data provides information about the condition of the engine. Note: Crankcase blowby is one of the three factors that help to determine the in-frame overhaul interval. For more information, see the Operation and Maintenance manual, “Overhaul (In-Frame)” topic in the Maintenance Section. After a new engine is used for a short time, the crankcase blowby can decrease as the piston rings are seated. The crankcase blowby will gradually increase as the following components show wear:

• piston rings • cylinder liners Note: A problem with the piston rings causes the oil to deteriorate rapidly. Information regarding the condition of the piston rings can be obtained from the measurement of the crankcase blowby and the results of oil analysis. The crankcase blowby of a worn engine may exceed the crankcase blowby of a new engine by two times or more. A sudden increase in crankcase blowby could indicate a broken piston ring. The following conditions are other potential sources of crankcase blowby:

• Worn valve guides • A turbocharger seal that leaks A rebuilt engine can have a high crankcase blowby due to the following factors:

• The piston rings are not seated properly. • Worn parts such as valve guides were not replaced.

Record the crankcase blowby for the engine. Keep a record of the results. For more information, see the Service Manual, “Systems Operation/Testing and Adjusting”. For assistance, consult your Caterpillar dealer. i02062446

Crankshaft Vibration Damper - Inspect SMCS Code: 1205-040 The crankshaft vibration damper limits the torsional vibration of the crankshaft. The visconic damper has a weight that is located inside a fluid filled case. Damage to the crankshaft vibration damper or failure of the damper can increase torsional vibrations. This can result in damage to the crankshaft and to other engine components. A deteriorating damper can cause excessive gear train noise at variable points in the speed range. A damper that is hot is due to excessive torsional vibration. Monitor the temperature of the damper during operation. The 8T-2821 Temperature Indicator or the 8T-2822 Temperature Indicator are recommended for monitoring the temperature of the damper. Evenly space four of the adhesive indicators around the outer diameter of the damper. Note: If you use an infrared thermometer to monitor the temperature of the damper, use the thermometer during operation with similar loads and speeds. Keep a record of the data. If the temperature begins to rise, reduce the interval for inspecting the damper. It is important to regularly monitor the temperature of the damper. It is important to document the temperature of the damper when it increases and decreases. This will verify that damper service is necessary. If the temperature of the damper reaches 110 °C (230 °F), consult your Caterpillar dealer. Inspect the damper for evidence of dents, cracks, and leaks of the fluid.

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81 Maintenance Section Cylinder Pressure - Measure/Record

If a fluid leak is found, determine the type of fluid. The fluid in the damper is silicone. Silicone has the following characteristics: transparent, viscous, smooth, and sticky. If leaking silicone is found, repair the damper or replace the damper. If the fluid leak is oil, inspect the crankshaft seal for leaks. If a leak is observed, replace the seal. Inspect the damper and repair or replace the damper for any of the following reasons.

• Minimize the cranking time. This will enable a

maximum consistent cranking speed for the check. Also, the starting air or battery power will be conserved.

A loss of cylinder pressure or a change of pressure in one or more cylinders may indicate the following conditions. These conditions may indicate a problem with lubrication:

• Excessive deposits

• 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.

• An analysis of the oil has revealed that the front bearing of the crankshaft is badly worn.

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

Removal and Installation Refer to the Service Manual, “Disassembly and Assembly” or consult your Caterpillar dealer for information about damper replacement. i02602007

Cylinder Pressure Measure/Record SMCS Code: 1223-082-CC; 1223; 7450-082 Measure the cylinder pressure of new engines. Record the data. Continue to periodically measure the cylinder pressure. Comparing the recorded data to the new data provides information about the condition of the engine. Note: Cylinder pressure is one of the three factors that help to determine the in-frame overhaul interval. For more information, refer to this Operation and Maintenance manual, “Overhaul (In-Frame)” (Maintenance Section). Cylinder pressure can be measured during inspection of the spark plugs. Use the following guidelines for checking the cylinder pressure:

• Remove all of the spark plugs. • Verify that the choke is fully open.

• A broken piston ring • Worn piston rings • Worn cylinder liners If the cylinder pressure has risen by one or more compression ratios, the engine needs a top end overhaul in order to remove deposits. Failure to remove the deposits will increase the chance for detonation. Severe guttering of the valves will occur. To measure the cylinder pressure, refer to Special Instruction, GMG00694, “Analyzing Cylinder Condition By Measuring Air Flow”. Also, use the 146-2739 Cylinder Pressure Adapter. Illustration 60 is a graph of typical cylinder pressures for engines with different compression ratios.

82 Maintenance Section Cylinders - Inspect

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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 Illustration 60

g00789376

(Y) Cylinder pressure in kPa (psi) (X) Compression ratio (1) Normal range for cylinder pressure

Record the pressure for each cylinder. Use Operation and Maintenance Manual, “Valve Data Sheet” (Reference Materials Section). i01765658

Cylinders - Inspect (Inspect the Combustion Chamber) SMCS Code: 1223-040; 1223 Excessive deposits can accumulate in the combustion chambers of engines that use gas with a low BTU such as bio-gas fuel, landfill gas, etc. The deposits can affect the characteristics of combustion. Erratic operation can result. The rate of recession of the exhaust valves can increase. The risk of guttering of the exhaust valves can increase. Note: Use of a platform may be necessary to inspect the combustion chamber. Use a borescope to inspect the combustion chamber. The inspection will provide information about the internal condition of the engine. A borescope with a lens that can be rotated is recommended. This type of borescope provides a clear view of the combustion chamber and of the bottom deck of the cylinder head. Photographic documentation or video documentation is also recommended. Consult your Caterpillar dealer for information on available borescopes.

• Deposits on the cylinder walls that are above the upper limit of the piston stroke

Deposits that are on the valve face and the valve seat can cause guttering of the valve. Inspect the valve seat and the valve face for excessive deposits. If excessive deposits are found, replace the valve and the valve seat. Determine whether the exhaust valve face has erosion from pitting. This requires the exhaust valve to be in the open position. To obtain as much detail as possible, obtain a close up view of the valve face. Erosion of the exhaust valve face can lead to guttering of the valve. If erosion is found on the exhaust valve face, recondition the cylinder head as soon as possible. Note: Operation at loads that are less than 50 percent of the rated load can result in an excessive buildup of carbon deposits in the combustion chamber. The deposits can lead to detonation and premature ignition. This condition is more obvious at certain engine speeds and loads. i02602013

Driven Equipment - Check SMCS Code: 3279-535

Every 5000 Service Hours Engines That Are Not Attached To the Base with a Dowel If some engines are too rigidly mounted, excessive stress may affect the internal support of the cylinder block. This could cause the following problems:

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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 service life of the engine could be severely reduced.

• Damaged parts

For engines that are not attached to the base with a dowel, check the following:

• Check the alignment after every 5000 service hours.

• Inspect the drive coupling according to the

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

• Inspection • Lubricating grease and lubricating oil requirements

specifications of the OEM.

• Specifications for adjustment

Every 10,000 Service Hours

• Replacement of components

Engines That Are Attached To the Base with a Dowel Some engines must be more rigidly mounted. Due to thermal expansion, a cold engine will expand after the engine achieves operating temperature. Some engines are attached to the base with a dowel in the rear mounting support. This installation forces the thermal growth forward. The driven equipment is also attached with a dowel in order to maintain alignment with the engine.

• Requirements for ventilation i01610487

Electrohydraulic Actuator Inspect SMCS Code: 1716-040 Inspect the actuators for the fuel control, the wastegate, and the air choke.

For this type of installation, check the alignment after every 10,000 service hours.

Check the Alignment The alignment between the engine and the driven equipment must be maintained properly. Improper alignment will cause damage to the engine, the coupling, and the driven equipment.

During operation, the linkage of the electrohydraulic actuators can form pinch points which can cause personal injury. Shut down the engine before you service the electrohydraulic actuators.

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

• Caterpillar • OEM of the coupling • OEM of the driven equipment i00935098

Driven Equipment Inspect/Replace/Lubricate SMCS Code: 3279-040 Observe the driven equipment during operation. Look for the following items:

Illustration 61 (1) (2) (3) (4)

Receptacle for the wiring harness Solenoid Bolt Guards

g00833473

84 Maintenance Section Electrohydraulic Actuator - Recondition

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1. Disconnect the wiring harness from receptacle (1). Inspect the connectors for damage and corrosion. Make repairs, if necessary. 2. Inspect the joint between solenoid (2) and the housing for leaks. If a leak is found between the solenoid and the housing, replace the O-ring seal for the solenoid. For instructions, refer to this Operation and Maintenance Manual, “Electrohydraulic Actuator Recondition”. 3. Check the solenoid's mounting bolts (3) for tightness. 4. Remove guards (4).

10. Install guards (4). 11. Connect the wiring harness to receptacle (1). i01610640

Electrohydraulic Actuator Recondition SMCS Code: 1716-020 Recondition the actuators for the fuel control, the wastegate, and the air choke. The main components of each actuator include the housing, a piston assembly, and a solenoid which actuates the piston. The piston assembly and the solenoid can be serviced separately. Note: New parts or remanufactured parts may be used for reconditioning the actuators.

During operation, the linkage of the electrohydraulic actuators can form pinch points which can cause personal injury. Shut down the engine before you service the electrohydraulic actuators.

Illustration 62

g00833477

(5) Rod end (6) Clevis (7) Boot

5. Disconnect rod end (5) from clevis (6). 6. Remove clevis (6). 7. Remove rubber boot (7). Inspect the boot for damage. If the boot is damaged, obtain a new boot for assembly. There may be a small amount of hydraulic fluid inside of the boot. Wipe off the boot and reinstall the boot. If an excessive amount of hydraulic fluid is found inside the boot, the seal for the actuator's shaft is probably worn. If this is the case, replace the piston assembly. For instructions, refer to this Operation and Maintenance Manual, “Electrohydraulic Actuator - Recondition”. 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.

Illustration 63

g00833592

(1) Receptacle for the wiring harness (2) Guards

1. Disconnect the wiring harness from receptacle (1). Inspect the connectors for damage and corrosion. Make repairs, if necessary. 2. Remove guards (2). 3. Disconnect the supply line (not shown) and the return line (not shown) for the hydraulic oil.

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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. Illustration 64 (3) (4) (5) (6)

g00833594

Rod end Clevis Boot Nut

9. Remove bolts (10) in order to remove solenoid (11). Remove O-ring seal (12) from the joint between the solenoid and the housing. 10. Install a new O-ring seal (12) and solenoid (11). Install bolts (10). Tighten the bolts according to the engine's Specifications.

4. Disconnect rod end (3) from clevis (4). 5. Remove clevis (4) and rubber boot (5). Inspect the boot for damage. If the boot is damaged, obtain a new boot for assembly. Note: Handle the actuator carefully. Use care not to damage the actuator's shaft. Damage to the shaft can result in premature failure of the O-ring seal. This will cause hydraulic fluid to leak. 6. Remove nut (6) in order to remove the actuator from the bracket. Note: Do not allow debris to enter the actuator. Seal the openings with clean covers immediately after the solenoid and/or the piston assembly is removed.

11. Install the actuator in the bracket with nut (6). 12. Install boot (5). Make sure that the outer end of the boot folds inward when the actuator's shaft moves from the fully open position to the fully closed position. 13. Install clevis (4). Connect rod end (3) to the clevis. 14. Install guards (2). 15. Connect the supply line and the return line for the hydraulic oil. 16. Connect the wiring harness to receptacle (1). i01525261

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

Check the Pressure Relief Valve

Illustration 65

g00833595

(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.

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.

86 Maintenance Section Electrohydraulic System - Inspect

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i02214104

Electrohydraulic System Inspect

Inspect the hoses and lines for wear and leaks. Ensure that the hoses and lines are properly clamped. Inspect the connections for leaks. Ensure 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.

Illustration 66

g00792283

(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 and Maintenance Manual, “Refill Capacities and Recommendatons” topic (Maintenance Section).

Illustration 67

g00792335

(1) Oil filler cap (2) Valve

2. If necessary, remove the oil filler cap. Pour the correct oil into the oil filler.

1. Remove oil filler cap (1).

3. Clean the oil filler cap. Install the oil filler cap.

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

Inspect the Lines, Connections, and Components

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

The linkage can move and form a pinch point which can cause personal injury. Keep hands away from the linkage.

Note: For the proper oil to use, refer to the Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel and Coolant Recommendations” . 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.

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87 Maintenance Section Electrohydraulic System Oil Filter - Change

i02246458

Electrohydraulic System Oil Filter - Change

5. Start the engine. Check the oil level in sight gauge (2). The oil should be between the “ADD” and “FULL” marks on the tank. If necessary, remove 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

Illustration 68

g00792302

(1) Filter (2) Sight gauge (3) Filler cap

1. Remove filter (1) with a 1U-8760 Chain Wrench. 2. Clean the sealing surface of the filter mounting base. Ensure that all of the old filter gasket is removed.

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

Servicing the Air Cleaner Elements 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 Illustration 69

g00103713

accumulation of dirt and debris. Remove any dirt and debris, as needed.

Typical filter mounting base and gasket

• Operating conditions (dust, dirt and debris) may

Note: For the proper oil to use, refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic (Maintenance Section).

• The air cleaner element may be cleaned up to

3. Apply clean hydraulic oil to the new filter gasket. 4. Install the filter by hand. Tighten the filter until the gasket contacts the mounting base. Tighten the filter according to the instructions that are shown on the filter. Do not overtighten the filter.

require more frequent service of the air cleaner element.

six times if the element is properly cleaned and inspected.

• The air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings.

88 Maintenance Section Engine Air Cleaner Element (Single Element) - Clean/Replace

Replace the dirty paper air cleaner elements with clean air cleaner elements. Before installation, the air cleaner elements should be thoroughly checked for tears and/or holes in the filter material. Inspect the gasket or the seal of the air cleaner element for damage. Maintain a supply of suitable air cleaner elements for replacement purposes. 1. Remove the air cleaner cover. Remove the air cleaner element. Note: Refer to “Cleaning the Air Cleaner Elements”.

SEBU7563-09

Use clean air cleaner elements while dirty elements are being cleaned. NOTICE Do not clean the air cleaner elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine damage could result.

2. Cover the air inlet with tape in order to keep dirt out.

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

3. Clean the inside of the air cleaner cover and body with a clean, dry cloth.

There are two common methods that are used to clean air cleaner elements:

4. Remove the tape for the air inlet. Install an air cleaner element that is new or cleaned.

• Pressurized air

5. Install the air cleaner cover. 6. Reset the air cleaner service indicator.

Cleaning the Air Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning services that are available at Caterpillar dealers. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life.

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

Observe the following guidelines if you attempt to clean the filter element: Do not tap or strike the filter element in order to remove 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 pleats and down the pleats from the inside of the filter element. Take extreme care in order to avoid damage to the pleats. Do not use air filters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage to engine components. The air cleaner element can be used up to six times if the element is properly cleaned and inspected. When the air cleaner element is cleaned, check for rips or tears in the filter material. The air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings.

Illustration 70

g00281692

Note: When the air cleaner elements are cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats. Do not aim the stream of air directly at the air cleaner element. Dirt could be forced further into the pleats. Note: Refer to “Inspecting the Air Cleaner Elements”.

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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 Illustration 72

g00281694

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: Illustration 71

g00281693

Inspect the clean, dry air cleaner element. Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the air cleaner element. Rotate 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 material. If it is necessary in order to confirm the result, compare the air cleaner element to a new air cleaner element that has the same part number. Do not use an air cleaner element that has any tears and/or holes in the filter material. Do not use an air cleaner element with damaged pleats, gaskets or seals. Discard damaged air cleaner elements.

• Date of cleaning • Number of cleanings Store the box in a dry location.

Crankcase Air Cleaner Engines that are equipped with positive crankcase ventilation have an air cleaner for crankcase ventilation. Clean the air cleaner element or replace the air cleaner element when the following conditions occur:

• 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 not be used, the air cleaner element can be stored for future use.

• The air restriction reaches 0.25 kPa (1 inch of H2O).

90 Maintenance Section Engine Air Cleaner Service Indicator - Inspect

Illustration 73

g00294189

(1) Service indicator (2) Cover

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Illustration 74

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Service indicator

1. Remove cover (2). 2. Remove the used element and dispose of the element. 3. Clean the inside of cover (2) and clean the inside of the body.

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

• The yellow diaphragm enters the red zone. • The red piston locks in the visible position. • The air filter restriction reaches .25 kPa

4. Install a new element. Install cover (2).

(1 inch of H2O).

5. Reset service indicator (1), if necessary. i01520297

Engine Air Cleaner Service Indicator - Inspect

Inspect the service indicator daily for cracks, holes, or loose fittings. If any of these conditions are present, repair the service indicator or replace the service indicator.

Test the Service Indicator

SMCS Code: 7452-040

Service indicators are important instruments.

Some engines are equipped with an air cleaner for crankcase ventilation.

• Check for ease of resetting. The service indicator

This air cleaner filters air that is drawn into the crankcase. The air dilutes the harmful fumes that may accumulate in the crankcase. The air and the fumes are drawn away from the crankcase.

• Check the movement of the yellow core when the

should reset in less than three pushes.

engine is accelerated to the engine rated rpm. The yellow core should latch approximately at the greatest vacuum that is attained.

If the service indicator does not reset easily, or if the yellow core does not latch at the greatest vacuum, replace the service indicator. If the new service indicator will not reset, the fitting for the service indicator may be plugged.

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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 Illustration 75

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Porous filter

A porous filter is part of a fitting that is used for mounting of the service indicator. Inspect the filter for cleanliness. Clean the filter, if necessary. Use compressed air or a clean, nonflammable solvent. The service indicator may need to be replaced frequently in environments that are severely dusty. Replace the service indicator annually regardless of the operating conditions. Replace the service indicator when the engine is overhauled, and whenever major engine components are replaced.

If the crankcase breather is not maintained on a regular basis, the crankcase breather will become plugged. A plugged crankcase breather will cause excessive crankcase pressure that can shut down the engine. Leakage of the crankshaft seal can occur. Note: Use of a platform may be necessary to reach the engine crankcase breather. Perform this maintenance when the engine is stopped.

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

Illustration 77

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

(1) (2) (3) (4) (5)

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Breather assembly Tee Hose clamp O-ring seal 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). Illustration 76 (1) Clip (2) Cup

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92 Maintenance Section Engine Mounts - Check

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4. Allow the breather elements to dry before installation. Install the breather assemblies in the original position. Coat the rubber parts with clean engine oil or petroleum jelly in order to make installation easier. Tighten the retaining clamps and the hose clamps according to the engine's Specifications manual.

Engines That Use Bio-Gas The oil change interval is determined by the results of oil analysis. Change the lubrication oil when oil analysis determines that the oil has reached the condemning limit. Also, change the engine oil filters.

Change the Engine Oil i01612978

Engine Mounts - Check SMCS Code: 1152-535

Hot oil and components can cause personal injury.

Check the torque of the bolts for the mounting plates. For the proper torque, refer to Gas Engines Application and Installation Guide, LEKQ7252, “G3600 Mounting, Alignment”.

Do not allow hot oil or components to contact skin.

Engine vibration can be caused by the following conditions:

• Improper mounting of the engine • Deterioration of the isolators Settling of the isolators will result in misalignment between the engine and the driven equipment. Inspect the condition of isolators, if necessary. Keep the isolators clean and dry. Ensure that the isolators are free of oil and contamination. Inspect the isolators for deterioration. Replace any isolator that shows deterioration. For more information, refer to the literature that is provided by the OEM of the isolators. Also refer to the following publications:

• Gas Engines Application and Installation Guide, LEKQ7252, “G3600 Mounting, Alignment”

• Special Instruction, SEHS9162, “Spring Isolator

NOTICE Ensure that the engine is stopped before performing this procedure. Attach a DO NOT OPERATE tag to the starting controls. Do not drain the oil when the engine is cold. As the oil cools, suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed when the cold oil is drained. Drain the crankcase with the oil warm. This draining method allows the waste particles that are suspended in the oil to be drained properly. Failure to follow this recommended procedure will allow the waste particles to be recirculated through the engine lubrication system with the new oil. 1. After the engine has been operated at normal operating temperature, STOP the engine. Note: Drain the oil into a suitable container. Dispose of fluids according to local regulations.

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 established S·O·S oil analysis program enables used oil to be evaluated. The evaluation can be used to determine if this oil change interval is suitable for your specific engine.

Illustration 78

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(1) Drain valve

2. Open drain valve (1) in order to drain used oil. After the oil has drained, close drain valve (1).

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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 is clean. This will prevent dirt from entering the oil pan. Be careful not to strike the engine oil suction tubes or the piston cooling jets. 3. Clean the oil suction screen. Note: Approximately 1 L (1 qt) of oil will remain in the housing after the sump has been completely drained. This oil will pour out of the housing when the cover for the oil suction screen is removed. Prepare to catch the oil in a suitable container. Clean up any spilled oil with rags. DO NOT use absorbent particles to clean up the oil.

NOTICE Engine damage can occur if the crankcase is filled above the “FULL” mark on the oil level gauge (dipstick). An overfull crankcase can cause the crankshaft to dip into the oil. This will reduce the power that is developed and also force air bubbles into the oil. These bubbles (foam) can cause the following problems: reduction of the oil's ability to lubricate, reduction of oil pressure, inadequate cooling, oil blowing out of the crankcase breathers, and excessive oil consumption. Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber. Deposits in the combustion chamber lead to the following problems: guttering of the valves, packing of carbon under the piston rings, and wear of the cylinder liner. If the oil level is above the “FULL” mark on the oil level gauge, drain some of the oil immediately. Note: For the amount of oil to use, refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section).

Illustration 79

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(2) Screen assembly

a. Loosen the bolts of the cover for the oil suction screen. Remove the cover and the gasket. Discard the old gasket. Slide screen assembly (2) from the tube. b. Wash the screen assembly in clean nonflammable solvent. Allow the screen assembly to dry before installation. c. Install the screen assembly. Install a new gasket. Install the cover. 4. Change the engine oil filters. Refer to this Operation and Maintenance Manual, “Engine Oil Filter - Change” topic (Maintenance Section). NOTICE Only use oils that are recommended by Caterpillar. For the proper oil to use, refer to this Operation and Maintenance Manual, “Engine Oil” topic (Maintenance Section).

5. Remove the oil filler cap. Fill the crankcase through the oil filler tube only. Clean the oil filler cap. Install the oil filler cap. 6. Follow this Operation and Maintenance Manual, “Starting The Engine” procedure (Operation Section). Operate the engine at low idle for two minutes. Inspect the engine for oil leaks. Ensure that the oil level is at the “FULL” mark on the “LOW IDLE” side of the oil level gauge. 7. Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes. 8. Remove the oil level gauge and check the oil level. Maintain the oil level above the “ADD” mark. i01520518

Engine Oil Filter - Change SMCS Code: 1308-510; 1308 Replace the engine oil filters when the following conditions are met:

• Every oil change • The engine oil filter differential pressure reaches 100 kPa (15 psi).

94 Maintenance Section Engine Oil Filter - Change

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

Replacing the Engine Oil Filters With the Engine Stopped

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

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 3. Be alert to the spring force. The cover has a spring force up to 240 N (54 lb). Gradually loosen but do not remove the last two bolts or nuts that are located at opposite ends of covers (3). Before removing the last two bolts or nuts, pry the covers loose or tap the covers with a rubber mallet in order to relieve any spring pressure.

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.

Illustration 81

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

Illustration 80 (1) (2) (3) (4)

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Pressure gauge Drain Cover Control valve

1. Connect a hose from each drain valve (2) to a suitable container in order to catch the oil. 2. Open both drain valves (2). Allow the oil to drain. Note: Some oil will remain in the housing after the oil has been drained. This oil will pour out of the housing when cover (3) is removed. Prepare to catch the oil in a suitable container. Clean up any spilled oil with rags. DO NOT use absorbent particles to clean up the oil.

4. Elements (7) are mounted on wire racks (5) inside the housing. Use a pan to catch the oil that drips when wire racks (5) are removed. Remove wire racks (5). Remove used elements (7). Clean up any oil that is spilled. NOTICE Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubricating system. Only use oil filters recommended by Caterpillar. 5. Ensure that the new oil filter elements are in good condition. Place the elements on wire rack (5). Install the wire rack and the elements.

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95 Maintenance Section Engine Oil Filter - Change

6. Ensure that the surfaces for O-ring seals (6) are clean. Inspect the O-ring seals. If the old O-ring seals are damaged or deteriorated, replace the old O-ring seals with new O-ring seals. Install the O-ring seals. 7. Install covers (3). Ensure that the spring is seated properly between elements (7) and covers (3). Close drain valves (2). 8. Ensure that the crankcase is filled with oil. Operate the prelube pump and rotate the control valve (if equipped) to the “FILL” position for each housing. After both of the housings are full of oil, turn the control valve (if equipped) to the “RUN” position. 9. Start the engine. Check for oil leaks.

Replacing the Engine Oil Filters During Engine Operation

Filter contains hot pressurized fluid when engine is running. Follow instructions on control valve to avoid personal injury. If rapid air movement exists to blow fluid, Stop the engine to avoid fire.

3. Open drain valve (2) and drain the lower oil filter housing. Observe pressure gauge (1) until the pressure is “0”. Note: Some oil will remain in the housing after the oil has been drained. This oil will pour out of the housing when cover (3) is removed. Prepare to catch the oil in a suitable container. Clean up any spilled oil with rags. DO NOT use absorbent particles to clean up the oil.

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 4. After zero pressure has been reached, remove cover (3). Be alert to the spring force. The cover has a spring force up to 240 N (54 lb). Gradually loosen but do not remove the last two bolts or nuts that are located at opposite ends of cover (3). Before removing the last two bolts or nuts, pry the cover loose or tap the cover with a rubber mallet in order to relieve any spring pressure.

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

Illustration 83

g00789772

(5) Wire rack (6) O-ring seal (7) Element Illustration 82 (1) (2) (3) (4)

g00789754

Pressure gauge Drain Cover Control valve

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.

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

96 Maintenance Section Engine Oil Level - Check

NOTICE Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubricating system. Only use oil filters recommended by Caterpillar. 6. Ensure that the new oil filter elements are in good condition. Place the elements on wire rack (5). Install the wire rack and the elements. 7. Ensure that the surfaces for O-ring seal (6) are clean. Inspect the O-ring seal. If the old O-ring seal is damaged or deteriorated, replace the old O-ring seal with a new O-ring seal. Install the O-ring seal. 8. Install cover (3). Ensure that the spring is seated properly between element (8) and cover (3). Close drain valve (2).

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Aluminum debris may indicate problems with the bearings of the front gears. If aluminum is found in the filter, inspect the crankshaft vibration damper and the front idler gear bearing. Due to normal wear and friction, it is not uncommon to find small amounts of debris in the oil filter element. If an excessive amount of debris is found in the oil filter element, consult your Caterpillar dealer in order to arrange for further oil analysis. i02602034

Engine Oil Level - Check SMCS Code: 1348-535-FLV The most accurate check of the oil level is performed when the engine is stopped. Perform this maintenance on a surface that is as level as possible.

9. Rotate control valve (4) to the “LOWER FILL” position. Observe pressure gauge (1). Check cover (3) for leaks. Note: A hydraulic stop will limit the rotation of the control valve until the oil filter housing is full of oil. 10. After the pressure of the lower oil filter and the upper oil filter is equal, rotate control valve (4) to the “UPPER SERVICE” position. Repeat Step 1 through Step 9 for the upper oil filter. 11. After the oil filters have been serviced and after the pressure of the lower oil filter and the upper oil filter is equal, rotate control valve (4) to the “RUN” position.

Illustration 84

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(1) Oil level gauge (2) Oil filler

Inspect the Used Oil Filter Elements Cut the used oil filter element open with a utility knife. Remove the metal wrap. Cut the filter element free from the end caps. Spread apart the pleats and inspect the element for metal debris. An excessive amount of debris in the element may indicate early wear or a pending failure. Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the element. Ferrous metals may indicate wear on the steel and the cast iron parts of the engine. Nonferrous metals may indicate wear on the aluminum parts, the brass parts, or the bronze parts of the engine. Parts that may be affected include the following components: main bearings, rod bearings, turbocharger bearings, and cylinder heads.

Illustration 85

g01140702

(3) “ADD” mark (4) “RUNNING FULL” mark (5) “STOPPED FULL OIL COLD NO PRELUBE” mark

Note: For engines with powered crankcase ventilation, remove the oil filler cap. Allow the crankcase pressure to stabilize before checking the engine oil level.

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97 Maintenance Section Engine Oil Sample - Obtain

Obtain the Sample and the Analysis

1. Ensure that oil level gauge (1) is seated. 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. NOTICE Engine damage can occur if the crankcase is filled above the “FULL” mark on the oil level gauge (dipstick). An overfull crankcase can cause the crankshaft to dip into the oil. This will reduce the power that is developed and also force air bubbles into the oil. These bubbles (foam) can cause the following problems: reduction of the oil's ability to lubricate, reduction of oil pressure, inadequate cooling, oil blowing out of the crankcase breathers, and excessive oil consumption. Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber. Deposits in the combustion chamber lead to the following problems: guttering of the valves, packing of carbon under the piston rings, and wear of the cylinder liner. If the oil level is above the “FULL” mark on the oil level gauge, drain some of the oil immediately. 3. If necessary, remove oil filler cap (2) and add oil. For the correct oil to use, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic (Maintenance Section). Wipe off the oil level gauge and reinstall the oil level gauge. Clean the oil filler cap and reinstall the oil filler cap. 4. Record the amount of oil that is added. For the next oil sample and analysis, include the total amount of oil that has been added since the previous sample. This will help to provide the most accurate oil analysis. 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. i03542996

Engine Oil Sample - Obtain SMCS Code: 1348-554-SM In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine. S·O·S oil analysis provides infrared analysis, which is required for determining nitration and oxidation levels.

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Before you take the oil sample, complete the Label, PEEP5031 for identification of the sample. In order to help obtain the most accurate analysis, provide the following information:

• Engine model • Service hours on the engine • The number of hours that have accumulated since the last oil change

• The amount of oil that has been added since the last oil change

To ensure that the sample is representative of the oil in the crankcase, obtain a warm, well mixed oil sample. To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean. Caterpillar recommends using the sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when the sampling valve is used. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation. The 169-8373 Fluid Sampling Bottle is recommended for use with the sampling valve. The fluid sampling bottle includes the parts that are needed for obtaining oil samples. Instructions are also provided. NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. If the engine is not equipped with a sampling valve, use the 1U-5718 Vacuum Pump. The pump is designed to accept sampling bottles. Disposable tubing must be attached to the pump for insertion into the sump.

98 Maintenance Section Engine Oil Temperature Regulator - Replace

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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. Illustration 86 i02601497

Engine Protective Device Connections - Inspect SMCS Code: 7400-040 Inspect the wiring and the electrical connections for these components:

• Connectors • Control panel • Junction box • Sensors

g00449867

Typical examples of electrical connectors (A) Military Standard connector (1) Plug (2) Receptacle (B) Deutsch HD connector (C) Phoenix terminal strip

Note: Military Standard (MS), Caterpillar Environmental (CE), and Vehicle Environmental (VE) connectors are similar in design. However, the wiring is soldered to the pins and sockets of Military Standard connectors. In CE and VE connectors, the wiring is crimped into the pins and sockets. The wiring is crimped into the pins and sockets of Deutsch HD connectors also. 1. Turn the mode control switch to the “OFF/RESET” 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.

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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. Illustration 87

g01302112

Investigate the source of the corrosion. Correct the condition.

Inside of control panel (front)

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.

Illustration 88

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Inside of control panel (rear) (1) Terminal strips

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

• Connectors • Relays • Switches • Terminal strips

a. For wiring that is attached to a connector, hold the body of the connector with one hand. Pull each wire with approximately 45 N (10 lb) of force. Pull the wire firmly. b. Before testing the wiring of the sensors, ensure that the sensors are securely installed. Then pull each wire with approximately 45 N (10 lb) of force. If a wire is loose, repair the connection. For instructions on connecting wires, see the Service Manual, “Troubleshooting” module. 6. Disconnect the connectors at the following locations. Inspect the connectors.

• Engine sensors

100 Maintenance Section Engine Protective Devices - Check

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• Junction box • Modules of the control panel a. Inspect each pin and each socket for corrosion and damage. If corrosion is found, scrape large deposits. Use cotton swabs with isopropyl alcohol to clean any corrosion that remains. Investigate the source of the corrosion. Correct the condition. If damage is found, replace the part. 7. Reconnect the connectors. a. For Military Standard, CE, and VE connectors, ensure the following conditions:

NOTICE During testing, abnormal operating conditions must be simulated. The tests must be performed correctly in order to prevent possible damage to the engine. To prevent damage to the engine, only authorized service personnel or your Caterpillar dealer should perform the tests.

Visual Inspection Visually check the condition of all gauges, sensors and wiring. Look for wiring and components that are loose, broken, or damaged. Damaged wiring or components should be repaired or replaced immediately.

• The connection is threaded properly.

i01762818

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

b. For Deutsch HD connectors, ensure the following conditions:

• The index markings of the plug and the receptacle are aligned.

• The connection is turned fully.

Engine Speed/Timing Sensor Clean/Inspect SMCS Code: 1905-040; 1905-070; 1907-040; 1907-070 The engine speed/timing sensor is located at the right rear side of the engine.

• 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 provide timely warning to the operator. Shutoffs help to prevent damage to the engine. It is impossible to determine if the engine protective devices are in good working order during normal operation. Malfunctions must be simulated in order to test the engine protective devices. A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints. Ensure that the engine protective devices are functioning properly.

Illustration 89

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(1) Engine speed/timing sensor (2) Bolt

1. Disconnect the wiring harness from engine speed/timing sensor (1). 2. Remove bolt (2) in order to remove engine speed/timing sensor (1). 3. Inspect the sensor for damage. If the sensor is damaged, obtain a new sensor for installation.

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101 Maintenance Section Engine Valve Lash - Inspect/Adjust

4. Inspect the O-ring seal for the sensor. If the O-ring seal is damaged, obtain a new O-ring seal for installation. 5. Clean the tip of the sensor. Note: The engine speed/timing sensor does not require any special adjustments. 6. Install the sensor. Make sure that the sensor is properly seated. Tighten bolt (2). 7. Inspect the wiring harness. Make sure that the connector is in good condition. Attach the wiring harness to the sensor. Make sure that the mating of the connectors is proper.

NOTICE The prelube pump should not be operated continuously for extended periods of time. If, during repairs, the prelube pump has run continuously for a period of three hours or more, it will be necessary to remove any oil that may have collected in the cylinders and/or above the valves. Prelube of the engine is required before the crankshaft is rotated for normal maintenance. Activate the prelube pump for rotating the engine crankshaft. NOTICE 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 Inspect/Adjust SMCS Code: 1102-025 For instructions on the following procedures, refer to Systems Operation/Testing and Adjusting. Consult your Caterpillar dealer for assistance.

The barring device provides a means for slowly turning the flywheel in order to service the engine. The barring device can also be used to prevent rotation of the crankshaft.

Valve Bridge

Note: Use of a platform may be necessary for these procedures.

NOTICE Do NOT attempt to adjust the valves if the crankshaft and camshaft are not synchronized. Disregard for this can result in engine damage such as bent valves.

Check the Timing of the Crankshaft and Camshaft

Check the valve bridges. Perform the procedure for both valve bridges for each cylinder.

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

After the valve bridge is checked for each cylinder, check the valve lash for the exhaust valves, the inlet valves, and the gas admission valves.

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

Engine Valve Lash

NOTICE DO NOT use the starting motor to rotate the crankshaft. The lubrication oil can drain out from between the crankshaft and the engine bearings if the engine has not been operated for a period of time. Damage can result if the crankshaft is rotated on dry bearing surfaces. To prevent damage to the crankshaft bearings, DO NOT crank the engine before prelube, especially after this maintenance procedure.

If the valve lash is within the tolerance, an adjustment of the valve lash is NOT necessary. The crankshaft and camshaft timing must be checked, and valve bridge adjustment must be performed before making a valve lash adjustment. Perform the valve lash setting when the engine is cold. After the engine has been shut down and the valve covers are removed, the engine is considered cold. Before performing maintenance, prevent the entry of foreign matter into the top of the cylinder head and the valve mechanism. Thoroughly clean the area around the valve mechanism covers.

102 Maintenance Section Engine Valve Rotators - Inspect

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Gas Admission Valve

i01765718

Check the valve lash for the gas admission valve when the valve lash for the inlet valves and exhaust valves are checked. Adjust the valve lash for the gas admission valves, if necessary.

Exhaust Bypass - Recondition SMCS Code: 1057-020

i01765711

Engine Valve Rotators - Inspect SMCS Code: 1109-040 NOTICE A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life. If a damaged rotator is not replaced, valve face guttering could result and cause pieces of the valve to fall into the cylinder. This can cause piston and cylinder head damage.

Illustration 90

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Typical example

Note: Use of a platform may be necessary to reach the engine valve rotators.

(1) Rod ends (2) Cover and seal (3) Shaft

Perform this procedure after the valve lash has been set.

Note: Use of a platform may be necessary in order to reach the components of the exhaust bypass.

1. Mark the tops of the valve rotators with a permanent marker. Note the position of the marks.

Replace the following parts:

2. Install the valve covers. See the Service Manual for the procedure. 3. Start the engine. Operate the engine for 5 minutes. Stop the engine. 4. Remove the valve covers. Observe the position of the marks that are on the valve rotators. If a valve fails to rotate, consult your Caterpillar dealer.

• Rod ends (1) • Cover and seal (2) • Shaft (3) For instructions on assembling the exhaust bypass, refer to the Specifications. i00457458

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.

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103 Maintenance Section Fuel System Fuel Filter Differential Pressure - Check

i01765725

NOTICE The exhaust shields can be damaged if work is performed on the exhaust shields or around the exhaust shields. Remove the exhaust shields or protect the exhaust shields before performing work on the exhaust shields or around the exhaust shields. Handle the exhaust shields carefully. Do not tear the foil that is inside of the exhaust shields. Torn foil will allow the insulation to absorb flammable liquids and a fire can result from engine heat. Ensure that the exhaust manifold is cool. Inspect the exhaust shields. Replace any exhaust shield that is damaged. Refer to the Service Manual for the procedure to remove the exhaust shields and install the exhaust shields.

Gas Admission Valve Recondition SMCS Code: 1105-020-GS Note: Use of a platform may be necessary to reach the gas admission valves. For the procedure to remove the gas admission valve, refer to the engine's Disassembly and Assembly. When you disassemble the gas admission valve, inspect the seals. Replace the seals, if necessary. Refer to this Operation and Maintenance Manual, “Gas Admission Valve Seals - Inspect/Replace”.

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. Service the fuel filter when the fuel filter differential pressure reaches 1.7 kPa (0.25 psi).

Illustration 91

For instructions, refer to Special Instruction, SEHS9298, “Installation and Maintenance of Gaseous Fuel Filters”. Consult your Caterpillar dealer for assistance.

(1) (2) (3) (4) (5) (6) (7)

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Exploded view and section view of the parts for the gas admission valve Retainer locks Valve rotator Outer valve spring Inner valve spring Valve guide Support assembly 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 Maintenance Section Gas Admission Valve Seals - Inspect/Replace

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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.

Illustration 92

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Angle and dimensions for the valve seat in the support assembly

If the valve seat is worn, the valve seat can be slightly ground according to these specifications:

• The angle for the valve seat is 44.75 ± 0.5 degrees. • The gauge diameter of the valve seat within a maximum depth of 2.0 mm (0.079 inch) from the end of the support assembly is 39.75 mm (1.565 inch).

Use some Prussian blue to verify complete contact of the valve in the valve seat. i01765734

Illustration 93

g00833829

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

Note: The portion of the valve stem in lower valve stem seal (2) may be slightly worn. This shallow wear does not affect the performance of the gas admission valve. Inspect valve stem seals (1) and (2). Inspect O-ring seals (3), (4), and (5). Replace the seals, if necessary. i00679524

Gas Admission Valve Seals Inspect/Replace

Gas Pressure Regulator Inspect/Replace

SMCS Code: 1105-040-GS; 1105-510-GS

SMCS Code: 1550-040; 1550-510

The camshaft operates the mechanism for the gas admission valve in order to allow fuel to enter the inlet port of the cylinder.

Inspect the gas pressure regulator for the following conditions:

Note: Use of a platform may be necessary to reach the gas admission valves. For the procedure to remove the gas admission valve, refer to the engine's Disassembly and Assembly.

• Wear • Cracks • Pin holes • Improper operation

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105 Maintenance Section Gas Shutoff Valve - Inspect

If any of those conditions are found, the gas pressure regulator must be repaired or replaced.

8. Remove bolts (4) and cover (5) in order to inspect the internal parts of the GSOV.

For information on replacing the gas pressure regulator, see the Service Manual. Consult your Caterpillar dealer for assistance.

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

i01611465

Gas Shutoff Valve - Inspect SMCS Code: 1329-040 The gas shutoff valve (GSOV) has a solenoid that is operated with 24 VDC. When power is supplied to the solenoid, fuel flows through the GSOV to the engine. When the power is interrupted, the gas is shut off.

10. Inspect the internal passages. Remove any debris. 11. Reassemble the diaphragm, the center pin for the diaphragm, and the shaft for the solenoid. Install cover (5) with bolts (4). 12. Install cap (3). Connect the wiring harness to receptacle (1). 13. Turn on the fuel supply to the GSOV. Use a gas detector to check for gas leaks.

1. Shut off the engine. 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.

Illustration 94 (1) (2) (3) (4) (5)

g00834076

Receptacle Gasket Cap Bolt Cover

3. Disconnect the wiring harness from receptacle (1). Inspect the connectors for damage and corrosion. Make repairs, as needed. 4. Inspect gasket (2) for damage and wear. Replace the gasket, if necessary. 5. Remove cap (3). Remove the washer under the cap in order to inspect the solenoid.

Note: Always use a board or cardboard when the engine components are checked for leaks. Leaking fluid that is under pressure can cause serious injury or possible death. This includes leaks that are the size of a pin hole. Refer to Operation and Maintenance Manual, “General Hazard Information” for more information.

Inspect the Hoses and the Clamps Inspect all hoses for leaks that are caused by the following conditions. Replace any hose which exhibits any of the following conditions. Failure to replace a hose which exhibits any of the following conditions may result in a hazardous situation.

• Hoses which are cracked

6. Inspect the solenoid for damage. If the epoxy coating is cracked or damaged, obtain a new solenoid for assembly.

• Hoses which are soft

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

• Exposed wire that is used for reinforcement

• Outer covering that is chafed or cut

• Outer covering that is ballooning locally

106 Maintenance Section Hoses and Clamps - Inspect/Replace

• Flexible part of the hose that is kinked or crushed • Armoring that is embedded in the outer covering • Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps

Inspect all clamps for the following conditions. Replace any clamp which exhibits signs of any of the following conditions.

• Cracking • Looseness • Damage Inspect all couplings for leaks. Replace any coupling which exhibits signs of leaks. Each installation application can be different. The differences depend on the following factors:

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Replace the Hoses and the Clamps NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Caterpillar Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Cooling System

• Type of hose • Type of fitting material • Anticipated expansion and contraction of the hose • Anticipated expansion and contraction of the fittings

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. Replace hoses that are cracked or soft. Replace hoses that show signs of leakage. Replace hoses that show signs of damage. Replace hose clamps that are cracked or damaged. Tighten or replace hose clamps which are loose.

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

Personal injury can result from removing hoses or fittings in a pressure system. Failure to relieve pressure can cause personal injury. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved. 1. 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.

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7. Disconnect the old hose. 8. Replace the old hose with a new hose. 9. 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. 10. Refill the cooling system. 11. Clean the filler cap for the cooling system. Inspect the gaskets on the filler cap. Replace the filler cap if the gaskets are damaged. Install the filler cap. 12. Start the engine. Inspect the cooling system for leaks.

Fuel System

Personal injury can result from removing hoses or fittings in a pressure system. Failure to relieve pressure can cause personal injury. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.

107 Maintenance Section Hoses and Clamps - Inspect/Replace

Note: High pressure fuel lines may be installed between the high pressure fuel pump and the fuel injectors. High pressure fuel lines are constantly charged with high pressure. Do not check the high pressure fuel lines with the engine or the starting motor in operation. Wait for 10 minutes after the engine stops before you perform any service or repair on high pressure fuel lines in order to allow pressure to be purged. 1. Drain the fuel from the fuel system to a level that is below the hose that is being replaced. 2. Remove the hose clamps. 3. Disconnect the old hose. 4. Replace the old hose with a new hose. 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. 6. Carefully inspect the engine for any spilled fuel. Make sure that no fuel remains on or close to the engine. Note: Fuel must be added to the fuel system ahead of the fuel filter. 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 penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

8. Start the engine. Inspect the fuel system for leaks.

NOTICE Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair 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 recommended torque.

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

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

Lubrication System

1. Drain the oil from the lubrication system to a level that is below the hose that is being replaced. 2. Remove the hose clamps. 3. Disconnect the old hose. 4. Replace the old hose with a new hose. 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 Maintenance Section Ignition System Spark Plugs - Check/Adjust

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6. Refill the lubrication system. Refer to this 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.

Removing the Spark Plug

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.

Illustration 95

g00823378

4. 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.

(1) (2) (3) (4) (5) (6)

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

Ignition System Spark Plugs Check/Adjust SMCS Code: 1555-535 Maintenance of the spark plugs is required in order to obtain the following benefits:

• Normal fuel consumption • Normal levels of emissions • Maximum service life of the spark plugs The service life of the spark plugs is affected by fouling due to deposits from the oil and by peak voltage. Maintenance of the ignition system is also affected by voltage. Higher voltage is required by higher inlet manifold air pressure and a higher compression ratio. Higher voltage reduces the service life of components such as spark plug wires and transformers.

Harness connector Bolt Transformer O-ring seal Extension Spark plug

NOTICE Pulling on the wiring harness may break the wires. Do not pull on the wiring harness. 2. Remove the lockwire. Disconnect harness connector (1). Use pliers to turn the connector counterclockwise. 3. Remove bolts (2). 4. Remove transformer (3). Inspect O-ring seal (4). If the O-ring seal is worn or damaged, discard the O-ring seal and use a new O-ring seal for assembly. 5. Remove extension (5).

Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes. 6. Debris may have collected near the spark plug. Thoroughly remove any debris. Use compressed air. The maximum air pressure for cleaning purposes must be below 207 kPa (30 psi). Ensure that the area around the spark plug is clean and free of dirt and debris.

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109 Maintenance Section Ignition System Spark Plugs - Check/Adjust

7. Use a 4C-4601 Spark Plug Socket and an extension to loosen spark plug (6). After the spark plug has been loosened, remove the spark plug by hand in order to detect problems with the threads. After the spark plug has been removed, discard the used gasket.

Faint marks may extend from shell (3) onto the insulator. The marks may be a result of corona that forms at the top of the shell. The corona develops when a high voltage potential ionizes the air that surrounds a conductor, which is a normal condition. This condition is not an indication of leakage between the shell and the insulator.

NOTICE The use of a thread tap will remove metal unnecessarily. This will also reduce the heat transfer for the spark plug. This can result in a reduction of the spark plug service life and a reduction of the detonation margin.

Inspect shell (3) for damage. Cracks can be caused by overtightening the spark plug. Overtightening can also loosen the shell. Discard any spark plug that has a shell that is cracked or loose.

If the spark plug resists removal by hand, apply penetrating oil to the threads. Use the wrench and apply steady pressure to the spark plug until the spark plug is loose.

Inspect electrode (5) for excessive wear. Flat surfaces with sharp edges provide the best conditions for creating a spark. An electrode will become worn from use. The surfaces erode. A higher voltage is required in order to produce a spark.

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

Illustration 97

g00760569

(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 (1) (2) (3) (4) (5)

g00838300

Terminal post Insulator Shell Gasket Electrode

Inspect the spark plug closely for damage. The condition of the spark plug can indicate the operating condition of the engine. Terminal post (1) must not move. If the terminal post can be moved by hand, discard the spark plug. Inspect insulator (2) for cracks. If a crack is found, discard the spark plug.

Replace the spark plug if the precious metal is worn off. Light brown deposits or beige deposits around the electrode are produced by normal operation. White deposits or gray deposits may be caused by the following substances:

• Excessive oil • Use of the wrong oil • A substance that is introduced through the fuel system or the air system

A spark plug can operate despite a buildup of ash. However, a buildup of ash can cover the electrode gap. 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 Maintenance Section Ignition System Spark Plugs - Check/Adjust

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Cleaning the Spark Plug

• Always use clean glass beads.

NOTICE Do not overtighten the spark plug. The shell can be cracked and the gasket can be deformed. The metal can deform and the gasket can be damaged. The shell can be stretched. This will loosen the seal that is between the shell and the insulator, allowing combustion pressure to blow past the seal. Serious damage to the engine can occur.

• Use care in order to clean only the electrode and

Use the proper torque.

• Do not use glass beads on the outside of the shell

4. Install the spark plug by hand until the spark 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 plug to 45 ± 5 N·m (33 ± 3 lb ft).

Thoroughly clean the spark plug. Do not use a wire brush. Glass beads are the preferred method for cleaning. Follow these guidelines for using glass beads:

the insulator near the electrode.

or on the upper part of the insulator.

Installing the Spark Plug Note: Use the 9U-7516 Spark Plug Gauge to measure the electrode gap. Do not use a flat feeler gauge for measuring the electrode gap of used spark plugs. A feeler gauge will produce a false measurement because the used precious metal surfaces will be curved.

5. Inspect the extension and clean the extension.

1. Before installing the spark plug, set the electrode gap to 0.29 ± 0.03 mm (.011 ± 0.001 inch). Adjust the electrode gap by bending the ground electrode at the existing bend. Then bend the strap near the weld in order to achieve proper alignment and even spacing between the two precious metal surfaces. Measure the electrode gap after the alignment. Correct the electrode gap, if necessary. Note: Do not use anti-seize compound on spark plugs. Most of the heat is transferred through the threads and the seat area of the spark plug. The surfaces must be in contact in order to provide the heat transfer that is required. 2. Ensure that the spark plug is clean and free of dirt and oil. 3. Always use a new gasket when a spark plug is installed. If a used spark plug is installed, place a new 9Y-6792 Gasket on the spark plug. Orient the tabs of the gasket toward the electrode. Otherwise, the gasket may not seat properly. If a gasket for a spark plug is installed incorrectly, do not increase the torque on the spark plug in order to improve the seal. Do not reuse the gasket. Install a new gasket.

Illustration 98

g00823413

(1) O-ring seal (2) Connection of the extension and the transformer (3) Connection of the extension and the spark plug

a. Inspect O-ring seal (1). If the O-ring seal is hard, cracked, or melted, use a new O-ring seal for assembly. b. Use a mild abrasive cleaner to clean deposits and/or corrosion from the extension at connection points (2) and (3). c. Apply one of the following lubricants to O-ring seal (1) and to the extension at connection points (2) and (3):

• 4C-9504 Dielectric Grease • 8T-9020 Dielectric Grease 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.

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111 Maintenance Section Ignition System Spark Plugs - Replace

7. Ensure that the transformer assembly is clean and free of dirt and oil. Assemble the extension into the transformer. Install the transformer. 8. Connect the wiring harness. Tighten the connector clockwise with pliers until the connector cannot be loosened by hand. Replace the lockwire. i01612988

Ignition System Spark Plugs Replace SMCS Code: 1555-510 Remove the used spark plugs. Install new spark plugs. For instructions on removing and installing spark plugs, refer to this Operation and Maintenance Manual, “Ignition System Spark Plugs - Check/Adjust” topic (Maintenance Section). i01935380

Make repairs, if necessary. For information regarding removal and installation of the components, refer to Service Manual, “Disassembly and Assembly”. Consult your Caterpillar dealer for assistance. i00683392

Inlet Gas Manifold and Piping Inspect/Replace SMCS Code: 1550-040; 1550-510 Inspect the components of the fuel inlet system for the following conditions:

• Cracks • Deterioration • Leaks • Loose connections • Wear

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 following components of the air inlet system:

• Fuel lines from the gas regulator to the fuel inlet

• Piping between the air cleaner and the turbocharger • Rubber hoses in the air lines • Turbocharger • Piping between the turbocharger and the aftercooler

• Fuel inlet • Control valve • Fuel manifold • Connections of the fuel manifold and the fuel lines • 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

• Connection of the air plenum to the cylinder head Inspect the components for the following conditions:

• Cracks • Leaks • Loose connections • Debris Ensure that all of the connections are secure. Ensure that the components are in good condition and free of debris.

chamber

• Fuel pressure sensor • Fuel temperature sensor Ensure that all of the connections are secure. Ensure that the components of the fuel system are in good condition. Make repairs, if necessary. For information regarding removal and installation of the components, see the Service Manual. Consult your Caterpillar dealer for assistance.

112 Maintenance Section Overhaul (In-Frame)

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i02252012

Overhaul (In-Frame) SMCS Code: 1000-020

Scheduling an In-Frame Overhaul Table 37 lists the approximate number of service hours before an in-frame overhaul for different G3600 Engine applications. Table 37

Estimated Service Hours Before An In-Frame Overhaul Fuel

Compression Ratio

Service Hours

Wellhead gas or natural gas

9.2:1

50000

Natural gas

10.5:1

45000 to 48000

Bio-gas

9.2:1

27000 to 33000

Scheduling an in-frame overhaul normally depends on the following three conditions:

• An increase of oil consumption • An increase of crankcase blowby • A decrease and a variation of cylinder compression Each individual condition may not indicate a need for an overhaul. However, evaluating the three conditions together is the most accurate method of determining when an overhaul is necessary. The engine may not require an overhaul if the engine is operating within acceptable limits for oil consumption, crankcase blowby, and cylinder compression. Periodically measure each of the three conditions. The first measurement should occur during the first scheduled maintenance. This establishes a baseline for future measurements. Additional measurements are scheduled at regular intervals in order to determine a schedule for the next in-frame overhaul. The following changes in the three conditions normally require a scheduled overhaul:

• A 300 percent increase in oil consumption • A 200 percent increase in crankcase blowby • A 20 percent loss of cylinder compression

Note: These indications do not require an engine to be shut down for service. These indications 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. An in-frame overhaul does not typically require the engine to be removed. Instead, the service is performed with the engine in place. Note: The generator or the driven equipment may also require service when the engine overhaul is performed.

In-Frame Overhaul Information An in-frame overhaul includes all of the work that is done for a top end overhaul. Additionally, some other components that wear are replaced. The condition of components is inspected. Those components are replaced, if necessary. Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”. Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications. If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the following recommendations. The following definitions explain the terminology for the services that are performed during an overhaul: Inspect – Inspect the components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”. The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures. New parts are not required if the existing parts can still be used, reconditioned, or repaired. If the components are not in the reusability guidelines, refer to the Service Manual, “Specifications” module. Rebuild – The component can be reconditioned in order to comply with reusability guidelines.

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113 Maintenance Section Overhaul (Major)

Replace – The service life of the part is exhausted. The part may fail before the next maintenance interval. The part must be replaced with a part that meets functional specifications. The replacement part may be a new part, a CAT remanufactured part, a rebuilt part, or a used part. Various worn components may be exchanged with your Caterpillar dealer. Consult your Caterpillar dealer about repair options for your engine. Table 38

In-Frame Overhaul Procedure Inspect Replace

i02252260

Overhaul (Major) SMCS Code: 7595-020-MJ

Scheduling a Major Overhaul Table 39 lists the approximate number of service hours before a major overhaul for different G3600 Engine applications.

(1)

Component Aftercooler Cylinder liners

Table 39

Estimated Service Hours Before a Major Overhaul Fuel

Compression Ratio

Service Hours

Wellhead gas or natural gas

9.2:1

100000

Natural gas

10.5:1

75000 to 80000

Bio-gas

9.2:1

52000 to 54000

Oil cooler Pistons Rebuild

Gas admission valve Electrohydraulic actuators Vibration damper

Replace

Camshaft bearings Camshaft followers Connecting rod bearings Crankshaft seals Engine oil pump Exhaust shields Gaskets and seals Electrohydraulic system's oil pump Main bearings Oil temperature regulators Piston rings

• An increase of oil consumption • An increase of crankcase blowby • A decrease and variation of cylinder compression The following changes in the three conditions normally require a scheduled overhaul:

• A 300 percent increase in oil consumption

Prechamber assemblies

• A 200 percent increase in crankcase blowby

Water pumps

• A 20 percent loss of cylinder compression

Water temperature regulators (1)

The need for a major overhaul is determined by several factors:

In addition to these procedures, perform the procedures for the top end overhaul.

Note: These indications do not require an engine to be shut down for service. These indications 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 Maintenance Section Overhaul (Top End)

• The service hours of the engine • The wear metal analysis of the lube oil • An increase in the levels of noise and vibration An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced. An increase in the levels of noise and vibration indicates that rotating parts require service. Note: It is possible for oil analysis to indicate a decrease of wear metals in the lube oil. The cylinder liners may be worn so that polishing of the bore occurs. Also, the increased use of lube oil will dilute the wear metals. Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about scheduling a major overhaul. Note: The driven equipment may also require service when the engine is overhauled. Refer to the literature that is provided by the OEM of the driven equipment.

Major Overhaul Information A major overhaul includes all of the work that is done for a top end overhaul. A major overhaul can also include all of the work that is done for an in-frame overhaul. A major overhaul includes additional parts and labor. Additional parts and labor may be required in order to completely rebuild the engine. In some cases, the engine is relocated for disassembly. For the major overhaul, bearings, seals, gaskets, and components that wear are disassembled. The parts are cleaned and inspected. If necessary, the parts are replaced. The crankshaft is measured for wear. The crankshaft may require regrinding. Alternatively, the crankshaft may be replaced with a Caterpillar replacement part.

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Inspect – Inspect the components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”. The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures. New parts are not required if the existing parts can still be used, reconditioned, or repaired. If the components are not in the reusability guidelines, refer to the Service Manual, “Specifications” module. Rebuild – The component can be reconditioned in order to comply with reusability guidelines. Replace – The service life of the part is exhausted. The part may fail before the next maintenance interval. The part must be replaced with a part that meets functional specifications. The replacement part may be a new part, a CAT remanufactured part, a rebuilt part, or a used part. Some worn components may be exchanged with your Caterpillar dealer. Consult your Caterpillar dealer about repair options for your engine. Table 40

Major Overhaul(1) Procedure Inspect Replace

If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the following recommendations. The following definitions explain the terminology for the services that are performed during an overhaul:

Camshafts Connecting rods Crankshaft

Rebuild

Inlet air piping

Replace

Aftercooler Camshaft lifters Exhaust manifolds Gear train bearings Oil cooler

(1)

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

Component

In addition to these procedures, perform the procedures for both the top end overhaul and the in-frame overhaul.

i03247357

Overhaul (Top End) SMCS Code: 7595-020-TE

Scheduling a Top End Overhaul Table 41 lists the approximate number of service hours before a top end overhaul for different G3600 Engine applications.

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115 Maintenance Section Overhaul (Top End)

• Cleaning equipment

Table 41

Estimated Service Hours Before a Top End Overhaul Fuel

Compression Ratio

Service Hours

Wellhead gas or natural gas

9.2:1

25000

Natural gas

10.5:1

15000

Bio-gas

9.2:1

10000 to 14000

Top end overhauls are normally scheduled according 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 predict when a cylinder head requires replacement. Measure the projection of the exhaust valve stems at the first 1000 service hours. This measurement is the baseline. The baseline is a reference for subsequent measurements. Continue to periodically measure the projection. Plan for the top end overhaul as the valve stem projection approaches the maximum limit. Perform the top end overhaul when the valve stem projection has increased by a total of 2.3 mm (.09 inch). Do not allow the projection of the exhaust valve stems to exceed this limit. Note: Generally, cylinder heads wear out at different rates. In some cases, servicing the cylinder heads at different times may be the most economic decision. This depends on the valve stem projection of the individual cylinders. However, this decision must include the costs of additional downtime that is caused by this procedure. Perform an economic analysis in order to determine if cylinder heads should be serviced as a group or divided into smaller groups. Note: The generator or the driven equipment may also require service when the engine overhaul is performed.

Top End Overhaul Information A top end overhaul involves servicing the cylinder heads and turbochargers. Also, some other engine components are inspected. Top end overhauls require more tools than preventive maintenance. The following tools are needed for restoring the engine to factory specifications:

• Torque wrenches • Dial indicators • Accurate measurement tools

• Rebuilding equipment Caterpillar dealers are equipped with these tools. Caterpillar dealers can provide a flat rate price for a top end overhaul. Unexpected problems may be found during a top end overhaul. Plan to correct these problems, if necessary.

• Buildup in the cylinders from excessive oil consumption

• Plugging of the aftercooler from coolant that is poorly maintained

• Degradation of the oil cooler from hydrogen sulfide in the fuel

Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”. Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications. If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the following recommendations. The following definitions explain the terminology for the services that are performed during an overhaul: Inspect – Inspect the components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”. The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures. New parts are not required if the existing parts can still be used, reconditioned, or repaired. If the components are not in the reusability guidelines, refer to the Service Manual, “Specifications” module. Rebuild – The component can be reconditioned in order to comply with reusability guidelines.

116 Maintenance Section Overhaul Considerations

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Replace – The service life of the part is exhausted. The part may fail before the next maintenance interval. The part must be replaced with a part that meets functional specifications. The replacement part may be a new part, a Cat remanufactured part, a rebuilt part, or a used part. Some worn components may be exchanged with your Caterpillar dealer. Consult your Caterpillar dealer about repair options for your engine.

• Costly unplanned downtime can be avoided. • Many original parts can be reused according to the guidelines for reusable parts.

• The service life of the engine can be extended without the risk of a major catastrophe due to engine failure.

• Achieve the best cost/value relationship per hour of extended service life.

Table 42

Top End Overhaul Procedure

Overhaul Intervals

Component

Inspect/Replace

Seals for the gas admission valve Precombustion chambers Drive coupling

Rebuild

Gas pressure regulator Starting motor Turbochargers

Replace

Connecting rod bearings Cylinder heads and gaskets Oil temperature regulators Spark plug extenders Water temperature regulators

Top end overhauls are determined by the projection of exhaust valve stems. In-frame overhauls are determined by cylinder compression, crankcase blowby, and oil consumption. Major overhauls are determined by the in-frame tests, and by results of S·O·S oil analysis. Some other factors that are important for determining the overhaul intervals include the following considerations:

• Performance of preventive maintenance • Use of recommended lubricants • Use of recommended coolants

i02250409

Overhaul Considerations SMCS Code: 7595-043

Overhaul Information An overhaul is replacing the major worn components of the engine. An overhaul is a maintenance interval that is planned. The engine is rebuilt with certain rebuilt parts or new parts that replace the worn parts. An overhaul also includes the following maintenance:

• Inspection of all the parts that are visible during the disassembly

• Replacement of the seals and gaskets that are removed • Cleaning of the internal passages of the engine and the engine block

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:

• Use of recommended fuels • Proper installation • Operating conditions • Operation within acceptable limits • Engine load • Engine speed Note: To avoid oil problems, engines that are turbocharged and aftercooled must be operated at a minimum of 60 percent of rated load. Generally, engines that are operated at a reduced load and/or speed achieve more service life before an overhaul. However, this is for engines that are properly operated and maintained.

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117 Maintenance Section Overhaul Considerations

Bio-Gas

• Crankshafts

The overhaul intervals for engines that use bio-gas depend on the concentration of contaminants in the fuel. Although silicon is the primary contaminant in bio-gas, other contaminants may cause further reductions in the overhaul intervals. For more information, refer to Gas Engines Application and Installation Guide, LEKQ7260, “G3600 - G3300 Low Energy Fuels”.

• Cylinder heads

Overhaul Inspection Refer to the Service Manual for the disassembly and assembly procedures that are necessary in order to perform the required maintenance on the items that are listed. Consult your Caterpillar dealer for assistance. To determine the reusability publications that are needed to inspect the engine, refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”. The Guidelines For Reusable Parts and Salvage Operations is part of an established Caterpillar parts reusability program. These guidelines were developed in order to assist Caterpillar dealers and customers reduce costs by avoiding unnecessary expenditures for new parts. If the engine parts comply with the established inspection specifications, the parts can be reused. New parts are not necessary if the old parts can be reused, repaired, or salvaged. If the parts are not within the inspection specifications, the parts should be salvaged, repaired, replaced, or exchanged. The use of out-of-spec parts could result in unscheduled downtime and/or costly repairs. The use of out-of-spec parts can also contribute to increased fuel consumption and reduction of engine efficiency. Your Caterpillar dealer can provide the parts that are needed to rebuild the engine at the least possible cost.

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

• Alternators • Connecting rods

• Oil Pumps • Starting motors • Turbochargers • Water pumps Consult your Caterpillar dealer for details and for a list of the remanufactured parts that are available. Your Caterpillar dealer may be offering a variety of overhaul options. A Flat Rate Overhaul guarantees the maximum price that you will pay for an overhaul. Flat rate prices on preventive maintenance programs or major repair options are available from many servicing dealers for all Caterpillar Engines. Consult your Caterpillar dealer in order to schedule a before failure overhaul. Overhaul Recommendation Caterpillar recommends a scheduled overhaul in order to minimize downtime. A scheduled overhaul will provide the lowest cost and the greatest value. Schedule an overhaul with your Caterpillar dealer. Overhaul programs vary between dealers. To obtain specific information about the types of overhaul programs and services, consult your Caterpillar dealer.

118 Maintenance Section Prechamber - Clean/Inspect

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i02602727

Prechamber - Clean/Inspect SMCS Code: 1106-571

i02602093

Prechamber Check Valves Clean SMCS Code: 1550-070

Illustration 100

Illustration 99

g01302648

1. Remove the ignition body assembly. Remove prechamber cup (1) from the ignition body. Refer to the engine's Disassembly and Assembly manual for instructions. 2. Clean the deposits from the prechamber cup. 3. Inspect the sealing flange for damage and debris. Replace any prechamber cup that has a damaged flange. Replace any prechamber cup that has eroded holes. Replace any prechamber cup that has cracks that are extending from the holes. 4. Clean the prechamber gasket set in the cylinder head by using the 9U-5156 Cleaning Tool Group. Wipe the surface with a clean cloth and solvent. 5. Install new prechamber gaskets and O-rings. 6. Install the ignition body assembly in cylinder head. Refer to the engine's Specifications manual for the proper torque procedure.

(1) (2) (3) (4) (5)

g00789869

Plug O-ring seal Check valve assembly O-ring seal Gasket

Note: Use of a platform may be necessary to reach the prechamber check valves. Note: Refer to the engine's Disassembly and Assembly manual for instructions on removal and installation of the check valves. 1. Remove check valve assembly (3) and gasket (5). 2. Discard gasket (5) and O-ring (4). Disassemble the check valve by unscrewing the end cap. a. Clean all parts with a non-chlorinated solvent. b. Reassemble the check valve and torque the cap to 2 N·m (1.5 lb ft). 3. Install a new gasket and a new O-ring. Install the clean, dry check valve assembly and torque to 115 N·m (85 lb ft). 4. Do NOT overtighten the plug for the check valve. Tighten to 15 N·m (11 lb ft).

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119 Maintenance Section Prechamber Check Valves - Replace

i02602222

Prechamber Check Valves Replace

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

• Damage

SMCS Code: 1550-510

• 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 Illustration 101 (1) (2) (3) (4) (5)

g00789869

Plug O-ring seal Check valve assembly O-ring seal Gasket

Electric Prelube Pump

Note: Use of a platform may be necessary to reach the prechamber check valves. Note: Refer to the engine's Disassembly and Assembly manual for instructions on removal and installation of the check valves. 1. Remove check valve assembly (3) and gasket (5). 2. Keep plug (1) for reassembly. Discard the other parts. Obtain new parts for reassembly. 3. Install a new gasket and a new O-ring. Install the clean, dry check valve assembly and torque to 115 N·m (85 lb ft). 4. Do NOT overtighten the plug for the check valve. Tighten to 15 N·m (11 lb ft). i01612991

Prelube Pump - Inspect SMCS Code: 1319-040 Inspect the prelube pump for the following conditions:

• Cracks • Pin holes • Proper operation • Wear

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

Inspect the brushes. Replace the brushes, if necessary. i01113939

Starting Motor - Inspect SMCS Code: 1451-040; 1453-040 If the starting motor fails, the engine may not start in an emergency situation. A scheduled inspection of the starting motor is recommended. The starting motor pinion and the flywheel ring gear must be in good condition in order for the engine to start properly. The engine will not start if the starting motor pinion does not engage the flywheel ring gear. The teeth of the starting motor pinion and the flywheel ring gear can be damaged because of irregular engagement. Inspect the starting motor for proper operation. Listen for grinding when the engine is started. Inspect the teeth of the starting motor pinion and the flywheel ring gear. Look for patterns of wear on the teeth. Look for teeth that are broken or chipped. If damaged teeth are found, the starting motor pinion and the flywheel ring gear must be replaced.

120 Maintenance Section Turbocharger - Clean

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

i01765784

Turbocharger - Clean (Cleaning with Dry Particles) SMCS Code: 1052-070

Inspect the electrical system for the following conditions:

Note: Use of a platform may be necessary to reach the turbocharger.

• Loose connections

If the engine has more than one turbocharger, each turbocharger requires cleaning.

• Corrosion • Wires that are worn or frayed • Cleanliness Make repairs, if necessary.

Air Starting Motor

Note: The drain openings in the exhaust housing of the turbocharger are closed during the cleaning procedure. Some of the particles will be expelled through the exhaust stack. The particles that are expelled will be burned. The materials that are listed in Table 43 are recommended for use with this cleaning procedure. Table 43

Materials for Cleaning 3600 Engine Turbochargers

Personal injury or death can result from improperly checking for a leak. Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Material Nut shell

Particle Size 1.7 mm (1/16 inch)

Formed carbon

1 mm (1/32 inch)

Granulated carbon (70% hardness)

1.2 to 2 mm (3/64 to 5/64 inch)

Granulated dry rice

1.7 mm (1/16 inch)

Inspect all of the components in the air circuit for the starting motor. Inspect all of the air lines and connections for leaks. If the teeth of the starting motor pinion and/or the flywheel ring gear are damaged, the air circuit for the starting motor must be examined in order to determine the cause of the problem.

Removal and Installation of the Starting Motor Refer to the Service Manual, “Disassembly and Assembly” module for information on removing the starting motor and installing the starting motor. Consult your Caterpillar dealer for assistance.

Illustration 102 (1) (2) (3) (4)

g00833073

Air valve Purge valve Cap Gate valve

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).

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121 Maintenance Section Turbocharger - Inspect

2. Open air valve (1) in order to remove deposits that may be in the connecting pipe. After three minutes, close air valve (1). Close gate valve (4). 3. Open purge valve (2) in order to relieve any pressure from the container. Close purge valve (2). 4. Remove cap (3). Pour 0.5 L (0.5 qt) of the particles into the container. Tighten cap (3). 5. Ensure that purge valve (2) is closed. Reduce the output of the engine so that the exhaust temperature before the turbine is less than 577 °C (1070 °F). 6. Open gate valve (4). Open air valve (1). 7. After 60 to 90 seconds, close air valve (1). Close gate valve (4). 8. Open purge valve (2) in order to relieve any pressure from the container. Close purge valve (2). i00908991

Turbocharger - Inspect SMCS Code: 1052-040 Periodic inspection and cleaning is recommended for the turbocharger. Fouling of the turbine wheels can contribute to loss of engine power and overall loss of engine efficiency. If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to the turbocharger compressor wheel could allow parts from the compressor wheel to enter an engine cylinder. This can cause additional damage to the pistons, the valves, and the cylinder head.

NOTICE Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems. Loss of engine lubricant can result in serious engine damage. Minor leakage of a turbocharger housing under extended low idle operation should not cause problems as long as a turbocharger bearing failure has not occurred. When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine rpm up at no load), do not continue engine operation until the turbocharger is repaired or replaced. An inspection of the turbocharger can minimize unscheduled downtime. An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts. Note: Turbocharger components require clearances that are precise. The turbocharger cartridge must be balanced due to high rpm. The following conditions can cause the turbocharger to be out-of-balance:

• The buildup of deposits • Chipping and/or flaking of deposits If the turbocharger must be removed for inspection, use caution. Do not break deposits from the turbine wheel. Do not attempt to clean the turbine wheel. For options regarding removal, installation, repair and replacement, see the Service Manual or consult your Caterpillar dealer. 1. Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger. Visually inspect the piping for the presence of oil. 2. Turn the compressor wheel and the turbine wheel by hand. The assembly should turn freely. Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing. There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing. If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing, the turbocharger must be reconditioned.

122 Maintenance Section Turbocharger Cleaner Tube - Replace

3. Check the compressor wheel for cleanliness. If only the blade side of the wheel is dirty, dirt and/or moisture is passing through the air filtering system. If oil is found only on the back side of the wheel, there is a possibility of a failed turbocharger oil seal.

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i01765785

Turbocharger Cleaner Tube Replace 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 deposits of ash and silicon. If deposits of 1 mm (1/32 inch) thickness are found, the turbocharger must be disassembled and cleaned at an ABBrepair facility.

Illustration 103

5. Inspect the bore of the turbine housing for corrosion.

Note: Use of a platform may be necessary in order to reach the cleaner tube.

6. Clean the turbocharger housing with standard shop solvents and a soft bristle brush.

1. Stop the engine.

7. Check the clearances of the turbocharger bearing. Compare the clearances to the Service Manual, “Specifications”. If the clearances are not within the specifications, the turbocharger must be repaired. 8. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing.

(1) (2) (3) (4)

Air valve Purge valve Gate valve Tube

2. Ensure that air valve (1) and gate valve (3) are closed. 3. Open purge valve (2) in order to relieve any pressure from the container. 4. Remove tube (4). Discard the used tube. 5. Install a new tube. 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.

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The actual measurement of the valve recession inside of the cylinder head is difficult to obtain. Two simpler methods are used to determine valve recession:

• Measure the projection of the valve stem above

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

• Measure the projection of the valve rotator above

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

Make several copies of this Operation and Maintenance Manual, “Valve Data Sheet” (Reference Materials Section). Record the measurements on the sheets.

• Measure the projection of the inlet and exhaust

valve stems and the exhaust valve rotators at the first 1000 service hours. This measurement is the baseline. The baseline is a reference for subsequent measurements.

• Measure the projection of the inlet and exhaust

valve rotators when the engine valve lash is checked. Continue this periodic measurement until the projection of the valve rotator has increased by a total of 1.6 mm (.063 inch). This is 70 percent of the maximum limit. Measure the projection of the valve stems when this occurs. This measurement will determine the actual wear of both the valves and the valve seats.

• After 70 percent of the maximum limit has been reached, measure the projection of the exhaust valve stems at every 500 hours of operation.

• Plan for the top end overhaul as the valve

stem projection approaches the maximum limit. Perform the top end overhaul when the valve stem projection has increased by a total of 2.3 mm (.09 inch). Do not allow the valve recession to exceed this limit. The valve head can break. This will cause severe damage in the combustion chamber and the turbocharger.

Consult your Caterpillar dealer for assistance.

123 Maintenance Section Walk-Around Inspection

i01492446

Walk-Around Inspection SMCS Code: 1000-040

Inspect the Engine for Leaks and for Loose Connections A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided. For maximum engine service life, thoroughly inspect the engine room before starting the engine. Look for items such as leaks, loose bolts, loose connections and trash buildup. Make repairs, as needed.

• The guards must be in the proper place. Repair damaged guards or replace missing guards.

• Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system contamination.

NOTICE For any type of leak, clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted. NOTICE Accumulated grease and/or oil on an engine or deck is a fire hazard. Remove this debris with steam cleaning or high pressure water.

• Ensure that cooling lines are properly clamped.

Check for leaks. Check the condition of all pipes.

• Inspect the water pumps for coolant leaks. Note: The water pump seal is lubricated by coolant in the cooling system. It is normal for a small amount of leakage to occur when the engine cools and the parts contract. Excessive coolant leakage may indicate the need to replace the water pump seal. For instructions on removal and installation of water pumps and/or seals, refer to the Service Manual, “Disassembly and Assembly” module for the engine or consult your Caterpillar dealer.

• Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters and the valve covers.

124 Maintenance Section Water Pump - Inspect

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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.

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125 Reference Information Section Customer Service

Reference Information Section

Latin America, Mexico, Carribean Caterpillar Americas Co. 701 Waterford Way, Suite 200 Miami, FL 33126-4670 USA Phone: 305-476-6800 Fax: 305-476-6801

Customer Service i03910306

Customer Assistance SMCS Code: 1000; 4450

USA and Canada When a problem arises concerning the operation or the service of an engine, the problem will normally be managed by the dealer in your area. Your satisfaction is a primary concern to Caterpillar and to Caterpillar dealers. If you have a problem that has not been handled to your complete satisfaction, follow these steps: 1. Discuss your problem with a manager from the dealership. 2. If your problem cannot be resolved at the dealer level, use the phone number that is listed below to talk with a Field Service Coordinator: 1-800-447-4986 The normal hours are from 8:00 to 4:30 Monday through Friday Central Standard Time. 3. If your needs have not been met still, submit the matter in writing to the following address: Caterpillar Inc. Manager, Customer Service, Engine Division Mossville Bldg AC P.O. Box 610 Mossville, Illinois 61552-0610 Please keep in mind: probably, your problem will ultimately be solved at the dealership, using the dealership facilities, equipment, and personnel. Therefore, follow the steps in sequence when a problem is experienced.

Outside of the USA and of Canada If a problem arises outside the USA and outside Canada, and if the problem cannot be resolved at the dealer level, consult the appropriate Caterpillar office.

Europe, Africa, and Middle East Caterpillar Overseas S.A. 76 Route de Frontenex P.O. Box 6000 CH-1211 Geneva 6 Switzerland Phone: 22-849-4444 Fax: 22-849-4544 Far East Caterpillar Asia Pte. Ltd. 7 Tractor Road Jurong, Singapore 627968 Republic of Singapore Phone: 65-662-8333 Fax: 65-662-8302 China Caterpillar China Ltd. 37/F., The Lee Gardens 33 Hysan Avenue Causeway Bay G.P.O. Box 3069 Hong Kong Phone: 852-2848-0333 Fax: 852-2848-0440 Japan Shin Caterpillar Mitsubishi Ltd. SBS Tower 10-1, Yoga 4-Chome Setagaya-Ku, Tokyo 158-8530 Japan Phone: 81-3-5717-1150 Fax: 81-3-5717-1177 Japan Caterpillar Power Systems, Inc. SBS Tower (14th floor) 4-10-1, Yoga Setagaya-Ku, Tokyo 158-0097 Phone: 81-3-5797-4300 Fax: 81-3-5797-4359 Australia and New Zealand Caterpillar of Australia Ltd. 1 Caterpillar Drive Private Mail Bag 4 Tullamarine, Victoria 3043 Australia Phone: 03-9953-9333 Fax: 03-9335-3366

126 Reference Information Section Customer Service

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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 specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature 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.

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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 Reference Information Section Reference Materials

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i03905196

Maintenance Log SMCS Code: 1000; 4450 Table 44

Engine Model

Customer Identifier

Serial Number

Arrangement Number

Service Hours

Service Item

Date

Authorization

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129 Reference Information Section Reference Materials

i00769479

Valve Data Sheet SMCS Code: 1000 Table 45

Engine Model Cylinder 1

Cylinder Pressure

Serial Number Valve Location 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

Authorization

Service Hours Current Measure

Stem Baseline

Rotator Baseline

Wear

130 Reference Information Section Reference Materials

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i02602385

Reference Material SMCS Code: 1000; 4450

• Application and Installation Guide, LEBW4977, “Gaseous Fuels”

• Application and Installation Guide, LEBW5336, “Gaseous Fuel Systems”

The following literature can be obtained through any Caterpillar dealer.

• Application and Installation Guide, LEKQ7260,

Lubricants

• Special Publication, LEKQ9360, “Internal

Oils • Special Publication, PEDP7036, “S·O·S Fluid Analysis”

• Special Publication, PEHP6001, “How To Take A Good Oil Sample”

• Data Sheet, PEHP0004, “Cat NGEO” • Data Sheet, PEHJ0006, “Cat NGEO EL350” • Special Publication, SEBD0640, “Oil and Your Engine”

• Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations”

Grease • Data Sheet, NEHP6010, “Cat Ultra 5Moly Grease” (NLGI grades 1 and 2)

• Data Sheet, NEHP6015, “Cat High Speed Ball Bearing Grease” (NLGI grade 2)

• Special Publication, PEGJ0035, “Grease Selection Guide” • Data Sheet, PEHJ0088, “Cat Multipurpose Grease” (NLGI grade 2)

• Data Sheet, PEHP0002, “Cat Advanced 3Moly Grease” (NLGI grade 2)

• Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations”

Fuels • Special Publication, LEKQ5404, “Fuels

Specifications Changes” (Only available through www.cat.com)

• Software Program, LEKQ6378, “Methane Number Program”

“Low Energy Fuels”

Combustion Engine Fuel Gases” (Only available through www.cat.com)

• Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations”

• Special Instruction, SEHS9298, “Installation and Maintenance of Gaseous Fuel Filters”

Coolants • Special Publication, PEDP7036, “S·O·S Fluid Analysis”

• Data Sheet, PEHJ0040, “Cat NGEC (Premix)” • Special Instruction, PEHP7057, “Coolant Analysis” • Data Sheet, PEHP9554, “Cat DEAC (Concentrate)” • Special Publication, SEBD0518, “Know Your Cooling System”

• Special Publication, SEBD0970, “Coolant and Your Engine”

• Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations”

Miscellaneous • Special Instruction, GMG00694, “Analyzing Cylinder Condition By Measuring Air Flow”

• Data Sheet, LEKQ2364, “US Stationary Engine Regulations/Spark Ignited Emissions”

• Application and Installation Guide, LEBW4969, “Air Intake System”

• Application and Installation Guide, LEBW4970, “Exhaust Systems”

• Application and Installation Guide, LEBW4971, “Engine Room Ventilation”

• Application and Installation Guide, LEBW4958, “Crankcase Ventilation”

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• Application and Installation Guide, LEBW4974, “Mounting”

• Application and Installation Guide, LEBW4975, “Alignment”

• Application and Installation Guide, LEBW4978, “Cooling Systems”

• Application and Installation Guide, LEBW4957, “Lubrication Systems”

• Special Publication, NEHS0526, “Service Technician Application Guide”

• Special Publication, NENG2500, “Caterpillar Dealer Service Tools Catalog”

• Special Publication, PECP9067, “One Safe Source”

• Service Manual, RENR5905, “G3600 Engines” • Special Publication, SEBF8029, “Index to

Guidelines for Reusable Parts and Salvage Operations”

• Special Publication, SEBF8062, “Procedure to Inspect and Clean Air Filters”

• Special Instruction, SEHS7332, “Do Not Operate Tag”

• Special Instruction, SEHS7633, “Battery Test Procedure”

• Special Instruction, SEHS8622, “Using the FT1984 Air-To-Air Aftercooler Leak Test Group”

• Special Instruction, SEHS8712, “Using the 8T-2700 Blowby/Airflow Indicator Group”

• Special Instruction, SEHS8984, “Using the

1U-8860 Large Engine Blowby Pickup Group”

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

• Special Instruction, SEHS9162, “Spring Isolator Group Installation and Adjustment Procedure”

• Specifications, SENR3130, “Torque Specifications”

Additional Reference Material The “Engine Fluids Data Book” can be obtained from the following locations: local technological society, local library, and local college. If necessary, consult EMA at the following address:

131 Reference Information Section Reference Materials

Engine Manufacturers Associaton Two North LaSalle Street, Suite 2200 Chicago, IL, USA 60602 E-mail: [email protected] Telephone: (312) 827-8700 Facsimile: (312) 827-8737 The “Society of Automotive Engineers (SAE) Specifications” can be found in your SAE handbook. This publication can also be obtained from the following locations: local technological society, local library, and local college. If necessary, consult SAE at the following address: SAE International 400 Commonwealth Drive Warrendale, PA, USA 15096-0001 Telephone: (724) 776-4841 The “American Petroleum Institute Publication No. 1509” can be obtained from the following locations: local technological society, local library, and local college. If necessary, consult API at the following address: American Petroleum Institute 1220 L St. N.W. Washington, DC, USA 20005 Telephone: (202) 682-8000 The International Organization for Standardization (ISO) offers information and customer service regarding international standards and standardizing activities. ISO can also supply information on the following subjects that are not controlled by ISO: national standards, local standards, regulations, certification, and related activities. Consult the member of ISO in your country. International Organization for Standardization (ISO) 1, rue de Varembé Case postale 56 CH-1211 Genève 20 Switzerland Telephone: +41 22 749 01 11 Facsimile: +41 22 733 34 30 E-mail: [email protected] Web site: http://www.iso.ch European classifications are established by the Counseil International Des Machines a Combustion (CIMAC) (International Council on Combustion Engines). CIMAC Central Secretariat Lyoner Strasse 18 60528 Frankfurt Germany Telephone: +49 69 6603 1567 Facsimile: +49 69 6603 1566

132 Reference Information Section Reference Materials

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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 Actuator Control Linkage - Lubricate (If applicable) ........................................................... Hydraulic Actuators............................................ Actuator Control Linkage - Replace....................... Removal and Installation.................................... Additional Messages ............................................. After Starting Engine ............................................. Engaging the Driven Equipment ........................ After Stopping Engine............................................ Aftercooler Condensation - Drain .......................... Air Starting Motor Lines Screen - Clean ................ Air Starting Motor Lubricator Bowl - Clean ............ Air Starting Motor Lubricator Oil Level - Check ..... Adjust the Lubricator .......................................... Air Tank Moisture and Sediment - Drain................ Alternator - Inspect ................................................

66 66 66 66 10 49 49 53 67 67 67 68 69 69 69

B Barring Device - Lubricate ..................................... 69 Electric Barring Device....................................... 70 Manual Barring Device....................................... 70 Battery Electrolyte Level - Check .......................... 71 Before Starting Engine .................................... 17, 45 Air Inlet System.................................................. 45 Cooling System.................................................. 45 Driven Equipment .............................................. 45 Electrical System ............................................... 45 Fuel System ....................................................... 46 Hydraulic Actuator System................................. 46 Lubrication System ............................................ 46 Starting System.................................................. 46 Walk-Around Inspection..................................... 45 Belts - Inspect/Adjust/Replace............................... 71 Adjusting the Alternator Belt .............................. 71 Adjusting the Fan Drive Belt .............................. 72 Inspection........................................................... 71 Replacement...................................................... 72 Burn Prevention..................................................... 14 Batteries............................................................. 14 Coolant............................................................... 14 Oils..................................................................... 14

D

C Cold Weather Starting ........................................... Jacket Water Heaters ........................................ Lubricating Oil Heaters ...................................... Requirements for Starting with Air ..................... Combustion Sensor - Clean/Inspect/Replace........ Configuration Parameters......................................

Control Panel......................................................... 38 Advisor II ........................................................... 38 “DESIRED SPEED” Potentiometer .................... 43 “EMERGENCY STOP” Button ........................... 41 Indicators ........................................................... 41 “MANUAL PRELUBE” Switch and “PRELUBE ACTIVE” Indicator ............................................ 42 Mode Control Switch.......................................... 42 Control Panel - Inspect .......................................... 74 Record the Data and Review the Data .............. 74 Cooling System Coolant (NGEC) - Change .......... 74 Clean the Cooling System ................................. 75 Cleaning a Cooling System that has Heavy Deposits or Plugging ........................................ 75 Drain the Cooling System .................................. 74 Fill the Cooling System ...................................... 75 Cooling System Coolant Level - Check ................. 76 Add Coolant ....................................................... 76 Engines That Are Equipped With a Sight Gauge .............................................................. 76 Engines That Are Not Equipped With a Sight Gauge .............................................................. 76 Cooling System Coolant Sample (Level 1) Obtain .................................................................. 77 Cooling System Coolant Sample (Level 2) Obtain .................................................................. 77 Cooling System Level Switch - Inspect ................. 77 Cooling System Supplemental Coolant Additive (SCA) - Test/Add.................................................. 78 Add the SCA, If Necessary ................................ 79 Test the Concentration of the SCA..................... 78 Cooling System Water Temperature Regulator Replace................................................................ 79 Crankcase Blowby - Measure/Record ................... 80 Crankshaft Vibration Damper - Inspect ................. 80 Removal and Installation.................................... 81 Crushing Prevention and Cutting Prevention ........ 16 Customer Assistance........................................... 125 Outside of the USA and of Canada.................. 125 USA and Canada ............................................. 125 Customer Service ................................................ 125 Cylinder Pressure - Measure/Record .................... 81 Cylinders - Inspect (Inspect the Combustion Chamber)............................................................. 82

46 47 47 47 72 44

Driven Equipment - Check..................................... Check the Alignment.......................................... Every 10,000 Service Hours .............................. Every 5000 Service Hours ................................. Driven Equipment - Inspect/Replace/Lubricate .....

82 83 83 82 83

134 Index Section

SEBU7563-09

E

F

Electrical System ................................................... 18 Grounding Practices .......................................... 18 Electrohydraulic Actuator - Inspect........................ 83 Electrohydraulic Actuator - Recondition ................ 84 Electrohydraulic System - Check/Adjust................ 85 Check the Pressure Relief Valve ....................... 85 Electrohydraulic System - Inspect ......................... 86 Check the Oil Level............................................ 86 Inspect the Lines, Connections, and Components..................................................... 86 Electrohydraulic System Oil - Change................... 86 Electrohydraulic System Oil Filter - Change.......... 87 Emergency Stopping ............................................. 52 Emergency Stop Button ..................................... 52 Engine Air Cleaner Element (Single Element) Clean/Replace ..................................................... 87 Cleaning the Air Cleaner Elements.................... 88 Crankcase Air Cleaner....................................... 89 Servicing the Air Cleaner Elements ................... 87 Engine Air Cleaner Service Indicator - Inspect...... 90 Test the Service Indicator................................... 90 Engine Air Precleaner - Clean ............................... 91 Engine Crankcase Breather - Clean...................... 91 Engine Diagnostics................................................ 44 Engine Mounts - Check ......................................... 92 Engine Oil - Change .............................................. 92 Change the Engine Oil....................................... 92 Oil Change Interval ............................................ 92 Engine Oil Filter - Change ..................................... 93 Inspect the Used Oil Filter Elements.................. 96 Replacing the Engine Oil Filters During Engine Operation ......................................................... 95 Replacing the Engine Oil Filters With the Engine Stopped............................................................ 94 Engine Oil Level - Check ....................................... 96 Engine Oil Sample - Obtain ................................... 97 Obtain the Sample and the Analysis.................. 97 Engine Oil Temperature Regulator - Replace........ 98 Engine Operation................................................... 50 Oil Consumption ................................................ 50 Operating the Engine and the Driven Equipment ........................................................ 50 Partial Load Operation ....................................... 50 Engine Protective Device Connections - Inspect... 98 Engine Protective Devices - Check ..................... 100 Visual Inspection.............................................. 100 Engine Speed/Timing Sensor - Clean/Inspect..... 100 Engine Starting ................................................ 17, 45 Engine Stopping .............................................. 17, 52 Engine Valve Lash - Inspect/Adjust ..................... 101 Check the Timing of the Crankshaft and Camshaft........................................................ 101 Engine Valve Lash ........................................... 101 Gas Admission Valve ....................................... 102 Valve Bridge..................................................... 101 Engine Valve Rotators - Inspect .......................... 102 Exhaust Bypass - Recondition............................. 102 Exhaust Shields - Inspect .................................... 102

Features and Controls ........................................... 32 Fire Prevention and Explosion Prevention ............ 14 Fire Extinguisher ................................................ 15 Lines, Tubes and Hoses .................................... 16 Foreword ................................................................. 5 California Proposition 65 Warning ....................... 4 Literature Information........................................... 4 Maintenance ........................................................ 4 Maintenance Intervals.......................................... 4 Operation ............................................................. 4 Overhaul .............................................................. 5 Safety................................................................... 4 Fuel System Fuel Filter Differential Pressure Check................................................................. 103 G Gas Admission Valve - Recondition .................... 103 Gas Admission Valve Seals - Inspect/Replace.... 104 Gas Pressure Regulator - Inspect/Replace ......... 104 Gas Shutoff Valve - Inspect ................................. 105 General Hazard Information .................................. 12 Asbestos Information ......................................... 13 Containing Fluid Spillage ................................... 13 Dispose of Waste Properly ................................ 14 Fluid Penetration................................................ 13 Pressurized Air and Water ................................. 13 H Hoses and Clamps - Inspect/Replace ................. 105 Inspect the Hoses and the Clamps .................. 105 Replace the Hoses and the Clamps ................ 106 I Ignition System Spark Plugs - Check/Adjust ....... 108 Cleaning the Spark Plug ................................... 110 Inspecting the Spark Plug ................................ 109 Installing the Spark Plug ................................... 110 Removing the Spark Plug ................................ 108 Ignition System Spark Plugs - Replace ................ 111 Ignition Systems .................................................... 16 Important Safety Information ................................... 2 Inlet Air System - Inspect...................................... 111 Inlet Gas Manifold and Piping - Inspect/Replace .. 111 L Lifting and Storage ................................................ 30

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135 Index Section

M

R

Maintenance Interval Schedule (G3600 Engines That use Bio-Gas)........................................................ 64 Maintenance Interval Schedule (G3600 Engines That Use Natural Gas and Have a Compression Ratio of 10.5:1 or 11:1)...................................................... 62 Maintenance Interval Schedule (G3600 Engines That Use Wellhead or Natural Gas and Have a Compression Ratio of 9.2:1) ................................ 60 Maintenance Log ................................................. 128 Maintenance Recommendations ........................... 58 Maintenance Records.......................................... 127 Maintenance Section ............................................. 54 Manual Stop Procedure......................................... 52 Model View Illustrations......................................... 19 Model Views and Specifications ............................ 19 Monitoring System................................................. 32 Integrated Combustion Sensing Module (ICSM).............................................................. 36 Mounting and Dismounting.................................... 16

Reference Information ........................................... 28 Reference Information Section ............................ 125 Reference Material .............................................. 130 Additional Reference Material.......................... 131 Coolants........................................................... 130 Fuels ................................................................ 130 Lubricants ........................................................ 130 Miscellaneous .................................................. 130 Reference Materials ............................................ 127 Refill Capacities..................................................... 54 Refill Capacities and Recommendations............... 54 Cooling System.................................................. 56 Fuel .................................................................... 55 Hydraulic Actuator System................................. 54 Lubrication System ............................................ 54

O Operation Section.................................................. 30 Ordering Replacement Parts ............................... 126 Overhaul (In-Frame) ............................................. 112 In-Frame Overhaul Information......................... 112 Scheduling an In-Frame Overhaul .................... 112 Overhaul (Major)................................................... 113 Major Overhaul Information .............................. 114 Scheduling a Major Overhaul............................ 113 Overhaul (Top End) .............................................. 114 Scheduling a Top End Overhaul ....................... 114 Top End Overhaul Information .......................... 115 Overhaul Considerations ...................................... 116 Overhaul Information ........................................ 116 P Plate Locations and Film Locations....................... 28 Engine Identification........................................... 28 Information Plate................................................ 28 Serial Number Plate........................................... 28 Prechamber - Clean/Inspect................................. 118 Prechamber Check Valves - Clean....................... 118 Prechamber Check Valves - Replace................... 119 Prelube Pump - Inspect ........................................ 119 Air Prelube Pump.............................................. 119 Electric Prelube Pump ...................................... 119 Product Description ............................................... 21 Engine Service Life ............................................ 22 Product Identification Information .......................... 28 Product Information Section .................................. 19 Product Lifting........................................................ 30 Engine Lifting with a Generator.......................... 30 Product Storage..................................................... 31 Generator Storage ............................................. 31

S Safety Messages ..................................................... 6 Safety Section ......................................................... 6 Specifications ........................................................ 23 Drives and Gear Trains ...................................... 24 Engine Specifications......................................... 23 Reference Weights ............................................ 27 Starting Motor - Inspect ........................................ 119 Air Starting Motor ............................................. 120 Electric Starting Motor...................................... 120 Removal and Installation of the Starting Motor .............................................................. 120 Starting the Engine ................................................ 47 Automatic Starting.............................................. 48 Manual Starting.................................................. 48 Purging Unburned Gas ...................................... 47 System Pressure Release ..................................... 58 Coolant System.................................................. 58 Engine Oil .......................................................... 58 Fuel System ....................................................... 58 T Table of Contents..................................................... 3 Turbocharger - Clean (Cleaning with Dry Particles)............................................................ 120 Turbocharger - Inspect ........................................ 121 Turbocharger Cleaner Tube - Replace ................ 122 V Valve Data Sheet................................................. 129 Valve Stem Projection - Measure/Record............ 122

136 Index Section

W 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

SEBU7563-09

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 Sales: Parts: Service:

Phone Number

Hours

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