Escolar Documentos
Profissional Documentos
Cultura Documentos
January 2005
Operation and
Maintenance
Manual
G3612 and G3616 Engines
1YG1-Up (Engine)
4CG1-Up (Engine)
i01658146
SEBU6496-06
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 6
General Hazard Information ................................. 13
Burn Prevention .................................................... 15
Fire Prevention and Explosion Prevention ............ 16
Crushing Prevention and Cutting Prevention ........ 17
Mounting and Dismounting ................................... 17
Ignition Systems ................................................... 18
Before Starting Engine .......................................... 18
Engine Starting ..................................................... 19
Engine Stopping ................................................... 19
Electrical System .................................................. 19
Operation Section
Lifting and Storage ................................................ 32
Features and Controls .......................................... 34
Engine Starting ..................................................... 46
Engine Operation .................................................. 52
Engine Stopping ................................................... 53
Maintenance Section
Refill Capacities .................................................... 55
Maintenance Interval Schedule (G3612 and G3616
Engines That Use Bio-Gas) ................................ 59
Maintenance Interval Schedule (G3612 and G3616
Engines That Have a 10.5:1 or an 11:1 Compression
Ratio and Use Natural Gas) ................................ 61
3
Table of Contents
Index Section
Index ................................................................... 132
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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Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation and application. We recommend that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engines permanent record.
See the section in the Operation and Maintenance
Manual, Maintenance Records for information
regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized
Caterpillar dealer can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
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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
Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on
your engine. The exact location and a description of
the safety messages 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
illustrations are not visible. Use a cloth, water,
and soap to clean the safety messages. Do not
use solvents, gasoline, or other harsh chemicals.
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 safety message that is damaged or
missing. If a safety message is attached to a part
of the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
Illustration 1
g00299779
g00123168
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7
Safety Section
Safety Messages
Illustration 2
g00294550
Illustration 3
g00123170
g00294548
g00296929
8
Safety Section
Safety Messages
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Illustration 4
g00299781
Illustration 5
g00299840
g00299818
g00299841
Improper lift rigging can allow unit to tumble causing injury and damage.
Improper lift rigging can allow unit to tumble causing injury and damage.
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9
Safety Section
Safety Messages
Barring Device
Base Lifting
Illustration 6
g00296938
Illustration 7
g00295926
g00296943
g00296978
Improper lift rigging can allow unit to tumble causing injury and damage.
10
Safety Section
Safety Messages
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Drain Coolant
Illustration 8
Crankcase Covers
g00123178
Illustration 9
g00123184
g00123185
g00123182
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11
Safety Section
Safety Messages
g00297180
g00296980
Do not connect generator to a utility electrical distribution system unless it is isolated from the system. Electrical feedback into the distribution system can occur and could cause personal injury or
death.
Open and secure main distribution system switch,
or if the connection is permanent, install a double
throw transfer switch to prevent electrical feedback. Some generators are specifically approved
by a utility to run in parallel with the distribution
system and isolation may not be required. Always
check with your utility as to the applicable circumstances.
Illustration 10
g00299842
Illustration 11
g00297181
12
Safety Section
Safety Messages
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Illustration 12
g00297183
g00297177
g00297178
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13
Safety Section
General Hazard Information
Illustration 14
g00702020
Illustration 13
g00104545
Filler caps
Grease fittings
Pressure taps
Breathers
Drain plugs
14
Safety Section
General Hazard Information
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Asbestos Information
Fluid Penetration
Illustration 16
g00702022
Illustration 15
g00687600
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15
Safety Section
Burn Prevention
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. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the
cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool. Ensure
that the filler cap is cool before removing the filler
cap. The filler cap must be cool enough to touch with
a bare hand. Remove the filler cap slowly in order
to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot components
to contact the skin.
If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.
Illustration 17
g00706404
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 appropriate system before any lines, fittings or
related items are disconnected.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
16
Safety Section
Fire Prevention and Explosion Prevention
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i01372262
Illustration 18
g00704000
Illustration 19
g00704135
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Fire Extinguisher
17
Safety Section
Crushing Prevention and Cutting Prevention
i01359666
i01372247
18
Safety Section
Ignition Systems
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i00661252
Ignition Systems
SMCS Code: 1550
Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and
wiring.
Electronic Ignition
Do not inspect the valve mechanism or the
transformers while the engine is operating. Personal
injury or death may result.
The ignition system will be damaged if the ignition
harness is removed during engine operation.
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.
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.
Magneto
The storage capacitor in a breakerless magneto can
be charged by turning the magneto by hand. The
storage capacitor can be charged even when the
wiring harness is disconnected from the magneto.
If the mode control switch is in the AUTOMATIC
or START position and the wiring harness is being
connected, the storage capacitor 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.
Before connecting the wiring harness to a breakerless
magneto, discharge the storage capacitor to the
ground. Use the following procedure to discharge the
storage capacitor:
1. Attach one end of a wire to the magneto housing.
2. Contact the other end of the wire to the connector
pins for the wiring harness that is on the magneto.
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19
Safety Section
Engine Starting
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 operators compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, Engine Starting topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature 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).
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.
20
Safety Section
Electrical System
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21
Product Information Section
General Information
Product Information
Section
General Information
i01472899
22
Product Information Section
Model Views and Specifications
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g00295813
Illustration 20
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Crankcase breather
Transformer
Oil filter
Junction box
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23
Product Information Section
Model Views and Specifications
g00295814
Illustration 21
(13) Air choke actuator
(14) Crankcase explosion relief valve
24
Product Information Section
Model Views and Specifications
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g00297151
Illustration 22
(17) Air inlet
(18) Exhaust
(19) Jacket water pump
i02245854
Product Description
SMCS Code: 1000; 4450
The G3600 Family of Engines are designed to
provide power for the following applications:
High output
Low emissions
High thermal efficiency
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25
Product Information Section
Model Views and Specifications
26
Product Information Section
Model Views and Specifications
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i02243745
Specifications
SMCS Code: 1000
Engine Specifications
Table 1
Engine Specifications
G3612
G3616
Operating RPM
750 to 1000
550
50 degree vee 12
50 degree vee 16
Bore
Stroke
Aspiration
TA
9.2:1
10.5:1
11:1
Compression Ratio
Displacement Per Cylinder
Total Displacement
Counterclockwise
See this Operation and Maintenance Manual, Refill Capacities
and Recommendations (Maintenance Section). Also, see the
Application and Installation Guide.
Air starting motors
(1)
This measurement is for newer engines. For earlier engines, the valve lash is set by turning an adjustment screw and counting the clicks.
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27
Product Information Section
Model Views and Specifications
Illustration 23
g00291490
g00291362
Illustration 25
SAE standard engine crankshaft rotation
(1) Jacket water pump
(2) Aftercooler and oil cooler pump
(3) Oil pump
Illustration 24
g00291492
g00291363
Illustration 26
SAE standard engine crankshaft rotation
(4)
(5)
(6)
(7)
Water outlet
Water inlet
Oil outlet
Oil inlet
Table 2
Front Drives
Component
Speed(1)
2522
2522
Oil Pump
1524
(1)
28
Product Information Section
Model Views and Specifications
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g00268306
Illustration 27
g00268312
Illustration 28
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(1)
(2)
(3)
(4)
(5)
Crankshaft
Idler
Idler
Jacket water pump
Aftercooler and oil cooler pump
Auxiliary pump
Oil pump
Crankshaft
Large cluster idler
Small cluster idler
Camshaft
Idler
Table 4
Table 3
Gear
Number Of
Teeth
(1) Crankshaft
96
(2) Idler
68
(3) Idler
67
38
38
43
63
Number Of Teeth
(1) Crankshaft
81
90
45
(4) Camshaft
81
(5) Idler
81
Reference Weights
Table 5
G3612
G3616
25084 kg
(55300 lb)
29892 kg
(65900 lb)
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29
Product Information Section
Model Views and Specifications
Table 6
G3612
Engine
G3616
Engine
6805 kg
(14971 lb)
9625 kg
(21219 lb)
Bearing Cap
65 kg (144 lb)
2091 kg
(4600 lb)
Crankshaft
3800 kg
(8378 lb)
Flywheel Assembly
Crankshaft Vibration
Damper
Cylinder Head
Assembly
Cylinder Liner
Piston Assembly
48 kg (106 lb)
Piston Pin
19 kg (42 lb)
57 kg (126 lb)
Turbocharger (one)
Aftercooler Core(1)
94 kg (207 lb)
125 kg
(275 lb)
Front Housing
Rear Housing
29 kg (64 lb)
Table 7
G3612 Engine
G3616 Engine
25084 kg
(55300 lb)
29892 kg
(65900 lb)
61074 kg
(134645 lb)
30
Product Information Section
Product Identification Information
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Product Identification
Information
i02172306
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 30
g01023277
Reference Information
SMCS Code: 1000; 4450
Identification of the items in Table 8 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 8. Make a copy of this
list for a record. Retain the information for future
reference.
The top level part numbers in the Parts Manual for
the engine are listed with the engine arrangement
number.
Illustration 29
g01053234
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31
Product Information Section
Product Identification Information
Table 8
Identification
32
Operation Section
Lifting and Storage
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Operation Section
NOTICE
Do not use the engine lifting eyes to remove the engine and generator together.
i01536259
Product Lifting
SMCS Code: 7000; 7002
Illustration 31
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.
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33
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:
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.
34
Operation Section
Features and Controls
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Monitoring
Controlling
i00664828
Control Panel
SMCS Code: 7451
Stopping
The components of the control panel are briefly
described in this section. For more detailed
information on the engine supervisory system, see
the Service Manual, Systems Operation/Testing and
Adjusting module.
Control Panel
Control panel
Junction box
Actuators
Potentiometers
Relays, solenoids, sensors, and switches
Wiring
The engine supervisory system includes three
systems that are integrated:
Start/Stop/Prelube System This system controls
the starting of the engine, the stopping of the engine,
and the prelube pump.
Engine Monitoring And Protection System This
system provides a display of parameters of engine
operation. The system generates warnings when
one or more parameters are outside acceptable
limits. The system can stop the engine if the engine
operation reaches a setpoint that is programmed
for shutdown. The system can prevent the engine
from starting if certain parameters are outside of
acceptable limits.
Engine Control System This system governs the
engine. This system controls the air/fuel ratio, the
ignition timing, and the limiting of power.
Some of the components within the engine
supervisory system perform more than one function.
For example, the engine control module is involved
with these activities:
Starting
Illustration 32
(1) Caterpillar monitoring system
(2) Timing control module
(3) FUEL ENERGY CONTENT potentiometer
(4) Engine control module
(5) SPEED CONTROL potentiometer
(6) Status control module
(7) Mode control switch
(8) Pyrometers
(9) EMERGENCY STOP button
(10) MANUAL PRELUBE switch
g00291852
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35
Operation Section
Features and Controls
Start/Stop/Prelube
g00291853
AUTO
START
STOP
OFF/RESET
AUTO When the mode control switch is in the
AUTO position, the system is configured for remote
operation. When the remote start/stop initiate contact
closes, the prelube system will operate and 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, the prelube system will
operate. When the prelube pressure is sufficient,
the engine will start. The engine will operate until
the engine supervisory system receives a shutdown
signal.
The following methods cause a shutdown signal:
36
Operation Section
Features and Controls
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Illustration 34
g00291943
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37
Operation Section
Features and Controls
Indication
01
02
03
04
05
06
07
08
09
(1)
(2)
(3)
will flash.
38
Operation Section
Features and Controls
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g00291963
Illustration 35
Caterpillar monitoring system
(1) Small gauges
(2) GAGE GROUP SELECT switch
(3) Identification of the small gauges (film)
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39
Operation Section
Features and Controls
40
Operation Section
Features and Controls
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Indication
F1 CHECK GAGES
One or more gauges indicate that a parameter is outside of the normal range.
F3 AUXILIARY EQUIPMENT(1)
One or more problems exist in the interface for the driven equipment.
One or more problems exist in the system that controls the fuel.
One or more problems exist in the system that controls the inlet air.
F6 EXHAUST
F7
SYSTEM(1)
MODULES/WIRING(1)
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41
Operation Section
Features and Controls
One or more problems exist in the controls for the feedback from the
combustion system.
F9 IGNITION SYSTEM(1)
F10 SENSORS/DEVICES(1)
(1)
Note the diagnostic codes that are displayed on the engine control module. Refer to the Service Manual, Troubleshooting module.
Pyrometer
The digital pyrometer is an electronic instrument
that is designed to monitor exhaust temperatures.
The pyrometer uses K type thermocouple probes.
The pyrometer can display the temperatures of nine
points in the exhaust system. The nine points include
the exhaust stack and eight exhaust ports.
G3612 and G3616 Engines use two pyrometers. One
pyrometer is for the left side and one pyrometer is for
the right side of the exhaust system.
Illustration 36
g00292106
Pyrometer
(1)
(2)
(3)
(4)
Display
PUSH TO ADVANCE button
PUSH TO READ button
Adjustment screw (setpoint)
42
Operation Section
Features and Controls
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torque
Monitoring operation
Protecting the engine
Starting the engine
Stopping the engine
Most of the functions of the engine supervisory
system are routed through the engine control module.
The module controls most of the operations of the
engine supervisory system. The control strategy of
the module contains many of the setpoints for the
protective system.
Illustration 37
g00292108
Illustration 38
Engine control module
(1) Display
(2) LED indicators
(3) DISPLAY SELECT switch
g00292112
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43
Operation Section
Features and Controls
Color
Indication
STATUS
Green
COMMUNICATION LINK 1
ACTIVE
Green
COMMUNICATION LINK 2
ACTIVE
Yellow
CAUTION MODE
Red
One or more problems exist. The code that indicates the exact nature
of the condition will be displayed.
SENSOR FAULT
Red
A problem with one of the sensors has been detected. One or more
problems exist. The code that indicates the exact nature of the condition
will be displayed.
ACTUATOR FAULT
Red
A problem with one of the actuators has been detected. The code that
indicates the exact nature of the problem will be displayed.
(continued)
44
Operation Section
Features and Controls
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SYSTEM FAULT
Red
A problem with one of the control systems has been detected. The code
that indicates the exact nature of the problem will be displayed.
Red
A problem with one of the control modules has been detected. The code
that indicates the exact nature of the problem will be displayed.
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Operation Section
Features and Controls
Green
Red
Red
Red
Red
Red
SIGNAL(1)
SIGNAL(1)
NO COMMUNICATION SIGNAL(1)
(1)
Red
Red
Red
g00292329
Illustration 39
Color
(continued)
46
Operation Section
Engine Starting
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Engine Starting
Cooling System
Inspect the cooling system for leaks or loose
i02277554
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.
Electrical System
Inspect the wiring for the following conditions:
Loose connections
clear.
Ensure that the air inlet piping and the air filters
are in place.
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47
Operation Section
Engine Starting
Lubrication System
Starting System
Ensure that the barring device is fully disengaged.
Drain moisture and sediment from the air tank and
Illustration 40
g01140341
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.
Fuel System
Inspect the fuel lines for loose fittings and leaks.
Ensure that the fuel lines are properly clamped.
i00662769
48
Operation Section
Engine Starting
SEBU6496-06
i02169979
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.
Water Separator
Emergency stop
Engine overspeed
SEBU6496-06
49
Operation Section
Engine Starting
Illustration 41
Automatic Starting
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.
g00402399
50
Operation Section
Engine Starting
SEBU6496-06
i01934760
Ensure that the oil pressure and the fuel pressure are
in the normal ranges. After the engine has started
and the warm-up is complete, the engine can be
operated at low rpm and low load. The engine will
reach normal operating temperature faster if the
engine is operated at low rpm and with a low power
demand. This procedure is more effective than idling
the engine with no load. The engine should reach
normal operating temperature in a few minutes.
NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
Starting Failure
Ensure that the main power switch is in the OFF position before attaching the jump start cables to the engine being started.
1. Turn the start switch to the OFF position. Turn off
all accessories.
2. Connect one positive end of the jump start cable
to the positive cable terminal of the discharged
battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the
electrical source.
3. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.
4. Start the engine.
SEBU6496-06
51
Operation Section
Engine Starting
52
Operation Section
Engine Operation
SEBU6496-06
Engine Operation
i01765829
Engine Operation
SMCS Code: 1000
Proper operation and maintenance are key factors in
attaining the maximum service life and economy for
the engine. Follow the instructions in this Operation
and Maintenance Manual in order to minimize
operating costs and maximize the service life of the
engine.
Observe the gauges 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 gauge
readings. Monitor the engine operation and take
action when discrepancies are found.
(1)
Engine Load
Time Limit
0 to 30 percent
1/2 hour
31 to 50 percent
2 hours
51 to 100 percent
Continuous
(1)
SEBU6496-06
53
Operation Section
Engine Stopping
Engine Stopping
i02158236
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.
Illustration 42
(1) Emergency stop button
(2) Mode control switch in the OFF/RESET position
g00290992
54
Operation Section
Engine Stopping
SEBU6496-06
i02150753
g00293074
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.
SEBU6496-06
55
Maintenance Section
Refill Capacities
Maintenance Section
Table 15
Refill Capacities
Sales Model
Liters
US Gallons
G3612
1030
272
G3616
1325
351
i02213831
Lubrication System
Lubricant Recommendations
Due to significant variations in the quality and in
the performance of commercially available oils,
Caterpillar makes the following recommendations:
(1)
Ambient Temperature
Cat NGEO
Grade of
Viscosity
Minimum
Maximum
SAE 40(1)
5 C (41 F)
50 C (122 F)
Lubricant Capacities
The capacity of the engine crankcase includes the
capacity of the oil filters that are installed at the
factory.
Liters
US Gallons
19
56
Maintenance Section
Refill Capacities
SEBU6496-06
Fuel
Cooling System
Fuel Recommendations
Coolant Recommendations
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
content. 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. To minimize
these effects, Caterpillar recommends the following
guidelines:
1. Evaluate the fuel with the Caterpillar Methane
Number Program, LEKQ6378.
Methane values below 30 are not recommended
for use in a Caterpillar 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.
2. If necessary, use an engine that is configured
for a fuel that has a high energy. Consult the
appropriate manual for the engine in order to
determine the recommended engine timing.
3. Reduce the oil change interval according to the
results of the oil analysis.
For further information on fuels, see Special
Publication, SEBU6400, Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations.
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:
SEBU6496-06
Caterpillar dealer
57
Maintenance Section
Refill Capacities
Table 18
Agricultural agent
Coolant/Antifreeze
Cat NGEC
Independent laboratory
Glycol
NOTICE
Do not use Extended Life Coolant (ELC) with
Caterpillar Gas Engines.
ELC was not formulated for use in Caterpillar Gas Engines.
Cat DEAC
Two Years
Commercial Heavy-Duty
Coolant/Antifreeze that
meets ASTM D4985
One Year
Two Years
One Year
(1)
(1)
Three Years
Commercial Heavy-Duty
Coolant/Antifreeze that
meets ASTM D6210
Service Life
Additives
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.
58
Maintenance Section
Refill Capacities
SEBU6496-06
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 total cooling system
capacity is the sum of the capacities of the following
components: jacket water circuit, aftercooler circuit,
accessory module, and external system. 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:
Table 19
Liters
US Gallons
Jacket Water
669 L
177 US gal
Aftercooler
64 L
17 US gal
Accessory Module
345 L
91 US gal
External System
Total Cooling System
Table 20
Liters
US Gallons
Jacket Water
900
238
Aftercooler
72
19
Accessory Module
345
91
External System
Total Cooling System
SEBU6496-06
59
Maintenance Section
Maintenance Interval Schedule
i02213863
When Required
Actuator Control Linkage - Replace ...................... 65
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 ..................................... 115
Valve Stem Projection - Measure/Record ........... 121
Daily
60
Maintenance Section
Maintenance Interval Schedule
Overhaul
Connecting Rod Bearings - Inspect/Replace ........ 73
SEBU6496-06
SEBU6496-06
61
Maintenance Section
Maintenance Interval Schedule
i02213861
When Required
Actuator Control Linkage - Replace ...................... 65
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 ..................................... 115
Valve Stem Projection - Measure/Record ........... 121
Daily
Air Starting Motor Lubricator Oil Level - Check .... 68
Air Tank Moisture and Sediment - Drain ............... 68
Control Panel - Inspect ......................................... 73
Cooling System Coolant Level - Check ................ 75
Driven Equipment - Inspect/Replace/Lubricate ... 83
Electrohydraulic System - Inspect ........................ 85
Engine Air Cleaner Service Indicator - Inspect ..... 90
Engine Oil Level - Check ...................................... 96
Fuel System Fuel Filter Differential Pressure Check ................................................................ 102
Walk-Around Inspection ...................................... 122
70
76
78
97
62
Maintenance Section
Maintenance Interval Schedule
Overhaul
Connecting Rod Bearings - Inspect/Replace ........ 73
SEBU6496-06
SEBU6496-06
63
Maintenance Section
Maintenance Interval Schedule
i02213859
When Required
Actuator Control Linkage - Replace ...................... 65
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 ..................................... 115
Valve Stem Projection - Measure/Record ........... 121
Daily
Air Starting Motor Lubricator Oil Level - Check .... 68
Air Tank Moisture and Sediment - Drain ............... 68
Control Panel - Inspect ......................................... 73
Cooling System Coolant Level - Check ................ 75
Driven Equipment - Inspect/Replace/Lubricate ... 83
Electrohydraulic System - Inspect ........................ 85
Engine Air Cleaner Service Indicator - Inspect ..... 90
Engine Oil Level - Check ...................................... 96
Fuel System Fuel Filter Differential Pressure Check ................................................................ 102
Walk-Around Inspection ...................................... 122
70
76
78
97
64
Maintenance Section
Maintenance Interval Schedule
Overhaul
Connecting Rod Bearings - Inspect/Replace ........ 73
SEBU6496-06
SEBU6496-06
65
Maintenance Section
Actuator Control Linkage - Lubricate
i02277937
Hydraulic Actuators
Heinzmann Actuators
Illustration 45
g01120800
i02277941
g01120791
66
Maintenance Section
Aftercooler Condensation - Drain
SEBU6496-06
Heinzmann Actuators
Illustration 48
g00788934
A drain plug is located on the right side near the rear of the engine.
(1) Plug
Illustration 46
g01120823
Hydraulic Actuators
Illustration 49
g00788946
A drain plug is located on the left side near the front of the engine.
(2) Plug
g00799207
i01762572
SEBU6496-06
67
Maintenance Section
Air Starting Motor Lines Screen - Clean
i01762654
Illustration 50
g00789123
(1) Plug
(2) Screen
Illustration 51
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
3. Place a suitable container under bowl (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.
68
Maintenance Section
Air Starting Motor Lubricator Oil Level - Check
SEBU6496-06
g00745561
Freezing
Personal injury can result from removing hoses or
fittings in a pressure system.
SEBU6496-06
69
Maintenance Section
Alternator - Inspect
Alternator - Inspect
SMCS Code: 1405-040
Inspect the alternator for the following conditions:
Proper connections
Illustration 53
g00334420
Illustration 54
g01098831
70
Maintenance Section
Battery Electrolyte Level - Check
SEBU6496-06
i02213936
Illustration 55
g00991445
g01098833
SEBU6496-06
71
Maintenance Section
Belts - Inspect/Adjust/Replace
i02154849
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.
Slippage of loose belts can reduce the efficiency
of the driven components. Vibration of loose belts
can cause unnecessary wear on the following
components:
Belts
Pulleys
Bearings
If the belts are too tight, unnecessary stress is placed
on the components. This reduces the service life of
the components.
Replacement
Illustration 57
(1) Mounting bolt
(2) Adjusting nuts
(3) Mounting bolt
g01092641
72
Maintenance Section
Combustion Sensor - Clean/Inspect/Replace
SEBU6496-06
Illustration 58
g00789241
Harness connector
Connector
Extension
Sensor
Gasket
Discs
Illustration 59
g00789274
Combustion sensor
(6) Terminal post
(7) Insulator
(8) Shell
(9) Gasket
(10) Electrode
SEBU6496-06
73
Maintenance Section
Connecting Rod Bearings - Inspect/Replace
Excessive oil
i02243193
i01762721
74
Maintenance Section
Cooling System Coolant (NGEC) - Change
SEBU6496-06
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.
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
g00792409
Illustration 61
g00901833
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.
SEBU6496-06
75
Maintenance Section
Cooling System Coolant Level - Check
76
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
Illustration 62
SEBU6496-06
g00750429
Illustration 63
g00103639
Gaskets
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
Check the coolant level when the engine is stopped
and cool. Check the coolant level only after the
engine has been stopped and the cooling system
filler cap is cool enough to touch with your bare hand.
Remove the cooling system filler cap slowly in order
to relieve any pressure. Maintain the coolant within
13 mm (0.5 inch) below the bottom of the filler pipe.
Add Coolant
Note: For the proper coolant mixture to use, see
this Operation and Maintenance Manual, Refill
Capacities and Recommendations (Maintenance
Section).
1. Stop the engine. Allow the engine to cool.
SEBU6496-06
77
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
i01519993
Illustration 64
g00789360
(1) Switch
(2) Lines
78
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
SEBU6496-06
Number of
Drops
Concentration
of SCA
Maintenance
Required
Less than 25
Add SCA.
Retest the
coolant.
25 to 30
The
recommended
concentration of
SCA
None
More than 30
Remove the
coolant.
Replace with
water only
Retest the
coolant.
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.
SEBU6496-06
79
Maintenance Section
Cooling System Water Temperature Regulator - Replace
NOTICE
Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engines
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
Excessive supplemental coolant additive 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.
4. Clean the cooling system filler cap. Install the
cooling system filler cap.
i02168842
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.
piston rings
cylinder liners
80
Maintenance Section
Crankshaft Vibration Damper - Inspect
SEBU6496-06
i01949731
SEBU6496-06
81
Maintenance Section
Cylinder Pressure - Measure/Record
Excessive deposits
Guttering of valves
A broken valve
A piston ring that sticks
A broken piston ring
Worn piston rings
Worn cylinder liners
If the cylinder pressure has risen by one or more
compression ratios, the engine needs a top end
overhaul in order to remove deposits. Failure to
remove the deposits will increase the chance for
detonation. Severe guttering of the valves will occur.
Illustration 65
g00789376
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.
82
Maintenance Section
Driven Equipment - Check
SEBU6496-06
i00693905
Valve wear
Caterpillar
OEM of the coupling
OEM of the driven equipment
SEBU6496-06
83
Maintenance Section
Driven Equipment - Inspect/Replace/Lubricate
i00935098
Illustration 66
Inspection
Lubricating grease and lubricating oil requirements
Specifications for adjustment
Replacement of components
Requirements for ventilation
i01610487
(1)
(2)
(3)
(4)
g00833473
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 67
(5) Rod end
(6) Clevis
(7) Boot
g00833477
84
Maintenance Section
Electrohydraulic Actuator - Recondition
SEBU6496-06
Illustration 68
g00833592
i01610640
Illustration 69
(3)
(4)
(5)
(6)
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.
g00833594
Rod end
Clevis
Boot
Nut
SEBU6496-06
85
Maintenance Section
Electrohydraulic System - Check/Adjust
15. Connect the supply line and the return line for the
hydraulic oil.
16. Connect the wiring harness to receptacle (1).
i01525261
Illustration 70
g00833595
(7) Housing
(8) Piston assembly
(9) O-ring seal
(10) Bolt
(11) Solenoid
(12) O-ring seal
Oil level
g00792283
86
Maintenance Section
Electrohydraulic System Oil - Change
SEBU6496-06
Illustration 72
g00792335
Actuators
Pressure relief valve
3. Pour the proper oil into the oil filler. Clean the oil
filler cap. Install the oil filler cap.
Pump
Make repairs, if necessary.
SEBU6496-06
87
Maintenance Section
Electrohydraulic System Oil Filter - Change
i02246458
Illustration 73
g00792302
(1) Filter
(2) Sight gauge
(3) Filler cap
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.
g00103713
88
Maintenance Section
Engine Air Cleaner Element (Single Element) - Clean/Replace
SEBU6496-06
Pressurized air
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).
Illustration 75
g00281692
SEBU6496-06
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.
g00281694
g00281693
Date of cleaning
Number of cleanings
Store the box in a dry location.
90
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Illustration 78
g00294189
SEBU6496-06
Illustration 79
g00789538
Service indicator
(1 inch of H2O).
SEBU6496-06
91
Maintenance Section
Engine Air Precleaner - Clean
g00351792
Porous filter
Illustration 82
(1)
(2)
(3)
(4)
(5)
g00789623
Breather assembly
Tee
Hose clamp
O-ring seal
Retaining clamp
g00476231
92
Maintenance Section
Engine Mounts - Check
SEBU6496-06
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.
Illustration 83
g00789667
SEBU6496-06
93
Maintenance Section
Engine Oil Filter - Change
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 oils 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 84
g00789729
94
Maintenance Section
Engine Oil Filter - Change
SEBU6496-06
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.
Illustration 86
g00789772
Illustration 85
(1)
(2)
(3)
(4)
g00789754
Pressure gauge
Drain
Cover
Control valve
SEBU6496-06
95
Maintenance Section
Engine Oil Filter - Change
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.
Illustration 88
g00789772
g00789754
Pressure gauge
Drain
Cover
Control valve
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).
SEBU6496-06
Illustration 89
g00789822
Illustration 90
g01140702
SEBU6496-06
97
Maintenance Section
Engine Oil Sample - Obtain
Engine model
Service hours on the engine
The number of hours that have accumulated since
the last oil change
i01935337
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
SEBU6496-06
Connectors
Control panel
Junction box
Sensors
g00449867
Fraying
Damaged insulation
Corrosion
Make repairs, as needed.
SEBU6496-06
99
Maintenance Section
Engine Protective Device Connections - Inspect
Corrosion
Fraying
a. If corrosion is found, scrape large deposits.
Use cotton swabs with isopropyl alcohol to
clean any corrosion that remains.
Illustration 92
g00453241
Connectors
Sensors
Perform a pull test for each wire. This test will
ensure that the wiring is properly attached. Test
each wire individually.
Illustration 93
g00453242
Connectors
Relays
Switches
Terminal strips
Engine sensors
100
Maintenance Section
Engine Protective Devices - Check
SEBU6496-06
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.
i01765700
SEBU6496-06
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.
101
Maintenance Section
Engine Valve Rotators - Inspect
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.
Valve Bridge
NOTICE
Do NOT attempt to adjust the valves if the crankshaft
and camshaft are not synchronized. Disregard for this
can result in engine damage such as bent valves.
Check the valve bridges. Perform the procedure for
both valve bridges for each cylinder.
After the valve bridge is checked for each cylinder,
check the valve lash for the exhaust valves, the inlet
valves, and the gas admission valves.
102
Maintenance Section
Exhaust Bypass - Recondition
SEBU6496-06
i01765718
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.
Illustration 94
g00799396
Typical example
(1) Rod ends
(2) Cover and seal
(3) Shaft
i01763022
SEBU6496-06
103
Maintenance Section
Gas Admission Valve - Recondition
i01765725
Illustration 96
g00833994
Angle and dimensions for the valve seat in the support assembly
Illustration 95
g00833978
Exploded view and section view of the parts for the gas admission
valve
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Retainer locks
Valve rotator
Outer valve spring
Inner valve spring
Valve guide
Support assembly
Valve
104
Maintenance Section
Gas Pressure Regulator - Inspect/Replace
SEBU6496-06
Illustration 97
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
Wear
Cracks
Pin holes
Improper operation
Illustration 98
(1)
(2)
(3)
(4)
(5)
g00834076
Receptacle
Gasket
Cap
Bolt
Cover
SEBU6496-06
105
Maintenance Section
Hoses and Clamps - Inspect/Replace
Cracking
Softness
Type of hose
Type of fitting material
Anticipated expansion and contraction of the hose
Anticipated expansion and contraction of the
fittings
Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
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.
Check for the following conditions:
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.
a. Before servicing a coolant hose, stop the
engine. Allow the engine to cool. Loosen the
cooling system filler cap slowly in order to
relieve any pressure. Remove the cooling
system filler cap. Drain the coolant from the
cooling system to a level that is below the hose
that is being replaced.
106
Maintenance Section
Ignition System Spark Plugs - Check/Adjust
SEBU6496-06
Personal injury or death can result from improperly checking for a leak.
SEBU6496-06
107
Maintenance Section
Ignition System Spark Plugs - Check/Adjust
Illustration 99
g00294914
(1) Connector
(2) Bolt
(3) Transformer
Illustration 100
(3)
(4)
(5)
(6)
(7)
(8)
(9)
g00295199
Transformer
Gasket
Extension
Spark plug
Gasket
Cover
Tube
108
Maintenance Section
Ignition System Spark Plugs - Check/Adjust
SEBU6496-06
Illustration 102
Illustration 101
(1)
(2)
(3)
(4)
(5)
g00295207
Terminal post
Insulator
Shell
Gasket
Electrode
g00353860
(6) Precious metal pads on the electrode and the ground strap
Excessive oil
Use of the wrong oil
A substance that is introduced through the fuel
system or the air system
SEBU6496-06
109
Maintenance Section
Ignition System Spark Plugs - Replace
Illustration 103
g00451015
110
Maintenance Section
Inlet Air System - Inspect
SEBU6496-06
i01113853
Fuel inlet
Control valve
Fuel manifold
Cracks
Leaks
Loose connections
Turbocharger
Aftercooler
aftercooler
i00683392
Cracks
Deterioration
Leaks
Illustration 104
Loose connections
Wear
Inspect the following components:
g00283415
SEBU6496-06
111
Maintenance Section
Magneto Drive Coupling - Inspect
i02252012
Overhaul (In-Frame)
SMCS Code: 1000-020
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
Illustration 105
g00296073
(1) Coupling
112
Maintenance Section
Overhaul (In-Frame)
SEBU6496-06
In-Frame Overhaul
Procedure
Inspect
Replace
(1)
Component
Aftercooler
Cylinder liners
Oil cooler
Pistons
Rebuild
Replace
Camshaft bearings
Camshaft followers
Connecting rod bearings
Crankshaft seals
Electrohydraulic systems
oil pump
Prechamber assemblies
Main bearings
Piston rings
Water pumps
Water temperature
regulators
(1)
SEBU6496-06
113
Maintenance Section
Overhaul (Major)
i02252260
Overhaul (Major)
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
114
Maintenance Section
Overhaul (Top End)
SEBU6496-06
Major Overhaul(1)
Procedure
Inspect
Replace
Component
Camshafts
Crankshaft
Inlet air piping
Replace
Aftercooler
Camshaft lifters
Exhaust manifolds
Gear train bearings
Oil cooler
(1)
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
Connecting rods
Rebuild
Table 26
Torque wrenches
Dial indicators
Accurate measurement tools
SEBU6496-06
Cleaning equipment
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.
115
Maintenance Section
Overhaul Considerations
Procedure
consumption
Inspect/Replace
Rebuild
poorly maintained
Component
Starting motor
Turbochargers
Replace
i02250409
Overhaul Considerations
Overhaul Information
116
Maintenance Section
Overhaul Considerations
Overhaul Intervals
Top end overhauls are determined by the projection
of exhaust valve stems. In-frame overhauls are
determined by cylinder compression, crankcase
blowby, and oil consumption. Major overhauls are
determined by the in-frame tests, and by results of
SOS oil analysis.
Some other factors that are important for determining
the overhaul intervals include the following
considerations:
SEBU6496-06
Bio-Gas
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.
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.
Engine load
Overhaul Programs
Engine speed
Alternators
Connecting rods
SEBU6496-06
117
Maintenance Section
Prechamber Check Valves - Clean
Crankshafts
Cylinder heads
Oil Pumps
Starting motors
i01765755
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.
Illustration 106
(1)
(2)
(3)
(4)
(5)
g00789869
Plug
O-ring seal
Check valve assembly
O-ring seal
Gasket
118
Maintenance Section
Prechamber Check Valves - Replace
SEBU6496-06
i01765759
Wear
Damage
Fraying
Ensure that the wiring is in good condition.
Inspect the electrical connections. Ensure that the
electrical connections are secure.
If repair or replacement is necessary, refer to the
engines Disassembly and Assembly manual. Consult
your Caterpillar dealer for assistance.
Illustration 107
(1)
(2)
(3)
(4)
(5)
g00789869
Plug
O-ring seal
Check valve assembly
O-ring seal
Gasket
i01612991
Cracks
Pin holes
Proper operation
SEBU6496-06
119
Maintenance Section
Turbocharger - Clean
Table 28
Particle Size
1.7 mm
(1/16 inch)
Formed carbon
1 mm (1/32 inch)
1.2 to 2 mm
(3/64 to 5/64 inch)
1.7 mm
(1/16 inch)
Personal injury or death can result from improperly checking for a leak.
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of
injury.
Inspect all of the components in the air circuit for
the starting motor. Inspect all of the air lines and
connections for leaks.
Illustration 108
(1)
(2)
(3)
(4)
i01765784
Turbocharger - Clean
(Cleaning with Dry Particles)
SMCS Code: 1052-070
Note: Use of a platform may be necessary to reach
the turbocharger.
If the engine has more than one turbocharger, each
turbocharger requires cleaning.
Note: The drain openings in the exhaust housing
of the turbocharger are closed during the cleaning
procedure. Some of the particles will be expelled
through the exhaust stack. The particles that are
expelled will be burned.
The materials that are listed in Table 28 are
recommended for use with this cleaning procedure.
g00833073
Air valve
Purge valve
Cap
Gate valve
120
Maintenance Section
Turbocharger - Inspect
SEBU6496-06
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:
SEBU6496-06
121
Maintenance Section
Turbocharger Cleaner Tube - Replace
Illustration 109
(1)
(2)
(3)
(4)
g00790542
Air valve
Purge valve
Gate valve
Tube
122
Maintenance Section
Walk-Around Inspection
SEBU6496-06
i01492446
Walk-Around Inspection
SMCS Code: 1000-040
Check the fuel system for leaks. Look for loose fuel
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.
line clamps.
Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
i00524084
SEBU6496-06
123
Reference Information Section
Customer Service
Reference Information
Section
Customer Service
i02097871
Customer Assistance
SMCS Code: 1000; 4450
124
Reference Information Section
Customer Service
SEBU6496-06
i01028392
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.
SEBU6496-06
125
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:
126
Reference Information Section
Reference Materials
SEBU6496-06
i02209903
Maintenance Log
SMCS Code: 1000; 4450
Table 29
Engine Model
Customer Identifier
Serial Number
Arrangement Number
Service
Hours
Service Item
Date
Authorization
SEBU6496-06
127
Reference Information Section
Reference Materials
i00883868
Engine Model
Cylinder
1
Cylinder
Pressure
Serial Number
Valve Location
Pushrod Side
Exhaust Manifold
Pushrod Side
Exhaust Manifold
Pushrod Side
Exhaust Manifold
Pushrod Side
Exhaust Manifold
Pushrod Side
Exhaust Manifold
Pushrod Side
Exhaust Manifold
Pushrod Side
Exhaust Manifold
Pushrod Side
Exhaust Manifold
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
128
Reference Information Section
Reference Materials
SEBU6496-06
Table 31
Engine Model
Cylinder
1
Cylinder
Pressure
Serial Number
Valve Location
Pushrod Side
Inlet Manifold
Pushrod Side
Inlet Manifold
Pushrod Side
Inlet Manifold
Pushrod Side
Inlet Manifold
Pushrod Side
Inlet Manifold
Pushrod Side
Inlet Manifold
Pushrod Side
Inlet Manifold
Pushrod Side
Inlet Manifold
Pushrod Side
Inlet Manifold
10
Pushrod Side
Inlet Manifold
11
Pushrod Side
Inlet Manifold
12
Pushrod Side
Inlet Manifold
13
Pushrod Side
Inlet Manifold
14
Pushrod Side
Inlet Manifold
15
Pushrod Side
Inlet Manifold
16
Pushrod Side
Inlet Manifold
Service Hours
Current
Measure
Authorization
Stem
Baseline
Rotator
Baseline
Wear
SEBU6496-06
129
Reference Information Section
Reference Materials
i02251018
Reference Material
SMCS Code: 1000; 4450
The following literature can be obtained through any
Caterpillar dealer.
Coolants
Special Publication, PEDP7036, SOS Fluid
Analysis
Lubricants
Purpose Grease)
Analysis
Fuels
Cooling System
Engine
Miscellaneous
Special Instruction, GMG00694, Analyzing
Cylinder Condition By Measuring Air Flow
130
Reference Information Section
Reference Materials
SEBU6496-06
SEBU6496-06
131
Reference Information Section
Reference Materials
i00382622
Warranty Information
SMCS Code: 1000
132
Index Section
SEBU6496-06
Index
A
Actuator Control Linkage - Lubricate (If
applicable) ...........................................................
Heinzmann Actuators.........................................
Hydraulic Actuators............................................
Actuator Control Linkage - Replace.......................
Heinzmann Actuators.........................................
Hydraulic Actuators............................................
Removal and Installation....................................
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 ................................................
65
65
65
65
66
66
65
51
51
54
66
67
67
68
68
68
69
B
Barring Device - Lubricate ..................................... 69
Electric Barring Device....................................... 69
Manual Barring Device....................................... 70
Battery Electrolyte Level - Check .......................... 70
Before Starting Engine .................................... 18, 46
Air Inlet System.................................................. 46
Cooling System.................................................. 46
Driven Equipment .............................................. 46
Electrical System ............................................... 46
Fuel System ....................................................... 47
Hydraulic Actuator System................................. 47
Lubrication System ............................................ 47
Starting System.................................................. 47
Walk-Around Inspection..................................... 46
Belts - Inspect/Adjust/Replace............................... 71
Adjusting the Alternator Belt .............................. 71
Adjusting the Fan Drive Belt .............................. 71
Inspection........................................................... 71
Replacement...................................................... 71
Burn Prevention..................................................... 15
Batteries............................................................. 15
Coolant............................................................... 15
Oils..................................................................... 15
C
Cold Weather Starting ...........................................
Jacket Water Heaters ........................................
Lubricating Oil Heaters ......................................
Requirements for Starting with Air .....................
Combustion Sensor - Clean/Inspect/Replace........
Connecting Rod Bearings - Inspect/Replace.........
47
48
48
48
71
73
Control Panel......................................................... 34
Control Panel ..................................................... 34
Engine Supervisory System............................... 34
Control Panel - Inspect .......................................... 73
Record the Data and Review the Data .............. 73
Cooling System Coolant (NGEC) - Change .......... 73
Clean the Cooling System ................................. 74
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 ................. 75
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 .................................................................. 76
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 ................................ 78
Test the Concentration of the SCA..................... 78
Cooling System Water Temperature Regulator Replace................................................................ 79
Crankcase Blowby - Measure/Record ................... 79
Crankshaft Vibration Damper - Inspect ................. 80
Removal and Installation.................................... 81
Crushing Prevention and Cutting Prevention ........ 17
Customer Assistance........................................... 123
Outside of the USA and of Canada.................. 123
USA and Canada ............................................. 123
Customer Service ................................................ 123
Cylinder Pressure - Measure/Record .................... 81
Cylinders - Inspect (Inspect the Combustion
Chamber)............................................................. 81
D
Driven Equipment - Check.....................................
Check the Alignment..........................................
Every 10,000 Service Hours ..............................
Every 5000 Service Hours .................................
Driven Equipment - Inspect/Replace/Lubricate .....
82
82
82
82
83
E
Electrical System ...................................................
Grounding Practices ..........................................
Electrohydraulic Actuator - Inspect........................
Electrohydraulic Actuator - Recondition ................
Electrohydraulic System - Check/Adjust................
Check the Pressure Relief Valve .......................
19
19
83
84
85
85
SEBU6496-06
133
Index Section
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................................................................. 102
34
16
17
17
G
Gas Admission Valve - Recondition .................... 103
Gas Admission Valve Seals - Inspect/Replace.... 103
Gas Pressure Regulator - Inspect/Replace ......... 104
Gas Shutoff Valve - Inspect ................................. 104
General Hazard Information .................................. 13
Asbestos Information ......................................... 14
Containing Fluid Spillage ................................... 14
Dispose of Waste Properly ................................ 15
Fluid Penetration................................................ 14
Pressure Air and Water...................................... 14
General Information............................................... 21
H
Hoses and Clamps - Inspect/Replace ................. 105
Replace the Hoses and the Clamps ................ 105
I
Ignition System Spark Plugs - Check/Adjust ....... 106
Cleaning the Spark Plug .................................. 108
Inspecting the Spark Plug ................................ 108
Installing the Spark Plug .................................. 109
Removing the Spark Plug ................................ 107
Ignition System Spark Plugs - Replace ............... 109
Ignition Systems .................................................... 18
Electronic Ignition............................................... 18
Magneto ............................................................. 18
Important Safety Information ................................... 2
Inlet Air System - Inspect...................................... 110
Inlet Gas Manifold and Piping - Inspect/Replace .. 110
L
M
Magnetic Pickups - Clean/Inspect ........................ 110
Magneto Drive Coupling - Inspect ........................ 111
Maintenance Interval Schedule (G3612 and G3616
Engines That Have a 10.5:1 or an 11:1 Compression
Ratio and Use Natural Gas)................................. 61
134
Index Section
SEBU6496-06
Table of Contents..................................................... 3
Turbocharger - Clean (Cleaning with Dry
Particles)............................................................. 119
Turbocharger - Inspect ........................................ 120
Turbocharger Cleaner Tube - Replace ................ 121
R
Reference Information ........................................... 30
Reference Information Section ............................ 123
V
Valve Data Sheet................................................. 127
Valve Stem Projection - Measure/Record............ 121
W
Walk-Around Inspection ...................................... 122
Inspect the Engine for Leaks and for Loose
Connections ................................................... 122
Warranty Information ........................................... 131
Engine Protection Plans................................... 131
Water Pump - Inspect .......................................... 122
Welding on Engines with Electronic Controls ........ 21
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
2005 Caterpillar
All Rights Reserved
Printed in U.S.A.