SEBU7563-07

August 2006

Operation and
Maintenance
Manual
G3600 Engines
BLB1-Up (Engine)
BKE1-Up (Engine)
BEN1-Up (Engine)
4ZS1-Up (Engine)
 i01658146

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.
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. 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 be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

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

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SEBU7563-07 3
Table of Contents

Table of Contents Maintenance Interval Schedule (G3600 Engines That

Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 6
Have a 10.5:1 or an 11:1 Compression Ratio and
Use Natural Gas) ................................................ 60
Maintenance Interval Schedule (G3600 Engines That
Use Bio-Gas) ...................................................... 62
Reference Information Section

Additional Messages ............................................. 10 Customer Service ............................................... 122

General Hazard Information ................................. 12 Reference Materials ............................................ 124

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

Fire Prevention and Explosion Prevention ............ 14 Index ................................................................... 130

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

General Information .............................................. 19

Model Views and Specifications ........................... 20

Product Identification Information ........................ 29

Operation Section
Lifting and Storage ................................................ 31

Features and Controls .......................................... 33

Engine Starting ..................................................... 46

Engine Operation .................................................. 51

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

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

Maintenance Interval Schedule (G3600 Engines

That Have a 9.2:1 Compression Ratio and That
UseWellhead or Natural Gas) ............................. 58
4 SEBU7563-07
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.
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.
SEBU7563-07 5
Foreword

Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
programs. If you experience a major engine failure,
there are also numerous after failure overhaul options
available from your Caterpillar dealer. Consult with
your dealer for information regarding these options.
6 SEBU7563-07
Safety Section
Safety Messages

Safety Section
i02602825

Safety Messages
SMCS Code: 1000; 7405

g01048357
Illustration 1
Right side view
SEBU7563-07 7
Safety Section
Safety Messages

g01048362
Illustration 2
Left side view

There may be several specific safety messages

on the engine. The exact location of the hazards
and the description of the hazards are reviewed in
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.
Do not operate or work on this engine unless you
have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. 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.

Replace any damaged safety messages or missing

safety messages. If a safety message is attached
to a part of the package that is replaced, install a
new safety message on the replacement part. Any
Caterpillar dealer can provide new safety messages.
8 SEBU7563-07
Safety Section
Safety Messages

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

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 .
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.

g00123168

During operation, the linkage of the electrohy-

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

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

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

(2) Attach two properly rated cables to the spreader

bar from the engine lift shackles.

g00123185

Flash fire may result in personal injury, if

crankcase covers are removed within fifteen
minutes after emergency shut down. Do not
restart engine until cause for shutdown has been
corrected.
SEBU7563-07 9
Safety Section
Safety Messages

(4) Engine Lifting (Label On the

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

g00299818

Improper lift rigging can allow unit to tumble caus-

ing injury and damage.

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

(2) Attach two properly rated cables to the spreader

bar from the engine lift shackles.
10 SEBU7563-07
Safety Section
Additional Messages

i02040045

Additional Messages
SMCS Code: 1000; 7405

g01049170
Illustration 3
Right side view
SEBU7563-07 11
Safety Section
Additional Messages

g01049171
Illustration 4
Left side view

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

Replace any damaged messages or missing
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.
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
i02602865
General Hazard Information
SMCS Code: 1000; 4450; 7405
g00104545
Illustration 5
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.
SEBU7563-07
g00702020
Illustration 6
• Wear a hard hat, protective glasses, and other
protective equipment, as required.
• 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.
SEBU7563-07
Pressurized Air and Water
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).
Fluid Penetration
Illustration 7
g00687600
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.
Containing Fluid Spillage
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.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tools Catalog” for the following items:
• Tools that are suitable for collecting fluids and
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.
13
Safety Section
General Hazard Information
Asbestos Information
g00702022
Illustration 8
Caterpillar equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
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.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
14
Safety Section
Burn Prevention
• 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.
Dispose of Waste Properly
g00706404
Illustration 9
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.
i01480768
Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.
Coolant
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.
SEBU7563-07
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 to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
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
Illustration 10
g00704000
All fuels, most lubricants, and some coolant mixtures
are flammable.
SEBU7563-07 15
Safety Section
Fire Prevention and Explosion Prevention

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

If the application involves the presence of combustible

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

Remove all flammable materials such as fuel, oil, and

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

Store fuels and lubricants in properly marked

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

Do not expose the engine to any flame.

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

Arcing or sparking could cause a fire. Secure Fire Extinguisher

connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
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
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.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
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.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• 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.
SEBU7563-07
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
Mounting and Dismounting
SMCS Code: 1000; 4450; 7405
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.
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.
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.
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.
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.
SEBU7563-07
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.
17
Safety Section
Before Starting Engine
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 SEBU7563-07
Safety Section
Electrical System

i01032810

Electrical System
SMCS Code: 1000; 1400

Never disconnect any charging unit circuit or battery

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

Check the electrical wires daily for wires that are

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

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

Uncontrolled electrical circuit paths can result in

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

Ensure that all grounds are secure and free of

corrosion.

The engine alternator must be grounded to the

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

For the starting motor, do not attach the battery

negative terminal to the engine block.

Ground the engine block with a ground strap that is

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

Use a separate ground strap to ground the battery

negative terminal for the control system to the ground
plane.

If rubber couplings connect the steel piping of the

cooling system and the radiator, the piping and the
radiator can be electrically isolated. Ensure that the
piping and the radiator are continuously grounded
to the engine. Use ground straps that bypass the
rubber couplings.
SEBU7563-07
Product Information
Section
General Information
i02596003
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 equip-
ment 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 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 com-
ponents.
Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.
1. Stop the engine. Turn the switched power to the
OFF position.
2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
open the switch.
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.
19
Product Information Section
General Information
Illustration 12
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) Engine
(2) Welding rod
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Maximize distance between the component that is being
welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
4. Connect the welding ground cable directly to the
part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to bearings,
hydraulic components, electrical components, and
ground straps.
Note: If electrical/electronic components are used
as a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.
5. Protect the wiring harness from welding debris
and spatter.
6. Use standard welding practices to weld the
materials.
20 SEBU7563-07
Product Information Section
Model Views and Specifications

Model Views and

Specifications
i01744053

Model View Illustrations

SMCS Code: 1000; 4450

The illustrations show various typical features of

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

g00892828
Illustration 13
Right hand view (in-line engine)
(1) Gas shutoff valve (5) Engine oil filter
(2) Fuel actuator (6) Junction box
(3) Ignition transformer (7) Crankcase pressure sensor
(4) Integrated Combustion Sensing Module (8) Engine oil level gauge
(ICSM) (9) Engine oil filler
SEBU7563-07 21
Product Information Section
Model Views and Specifications

Illustration 14
Left hand view (in-line engine)
(1) Exhaust bypass actuator
(2) Air choke actuator
g00892830
(3) Hydraulic oil tank (5) Hydraulic oil filter
(4) Hydraulic oil pump

g00893222
Illustration 15
Right hand view (vee engine)
(1) Gas shutoff valve (5) Engine oil filter (10) Engine oil filler
(2) Exhaust bypass actuator (6) Junction box
(3) Fuel actuator (7) Ignition rail
(4) Integrated Combustion Sensing Module (8) Crankcase pressure sensor
(ICSM) (9) Engine oil level gauge
22
Product Information Section
Model Views and Specifications
Illustration 16
Left hand view (vee engine)
(1) Ignition transformer (4)
(2) Integrated Combustion Sensing Module (5)
(ICSM) (6)
(3) Air choke actuator (7)
Product Description
SMCS Code: 1000; 4450
The G3600 Family of Engines is designed to provide
power for the following applications:
• 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.
SEBU7563-07
g00893223
Ignition rail
Hydraulic oil tank
Hydraulic oil pump
Hydraulic oil filter
i02062100 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 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.
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.
SEBU7563-07
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.
23
Product Information Section
Model Views and Specifications
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).
24 SEBU7563-07
Product Information Section
Model Views and Specifications

i02600144

Specifications
SMCS Code: 1000

Engine Specifications
Table 1
G3600 Engine Specifications
G3606 G3608 G3612 G3616
Operating rpm 750 to 1000 750 to 1000 750 to 1000 750 to 1000
Low idle rpm 550 550 550 550
Arrangement and In-line In-line 50 degree V-12 50 degree V-16
cylinders 6 8
Bore 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch)
Stroke 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch) 300 mm (11.8 inch)
Aspiration TA TA TA TA
Compression ratio 9:1 9:1 9:1 9:1
10.5:1 10.5:1
Displacement per 21.2 L (1294 in3) 21.2 L (1294 in3) 21.2 L (1294 in3) 21.2 L (1294 in3)
cylinder
Total displacement 127.2 L (7762 in3) 169.6 L (10 350 in3) 254.4 L (15 528 in3) 339.2 L (20 704 in3)
Mean velocity of the 9 m/s (1772 ft/min) 9 m/s (1772 ft/min) 9 m/s (1772 ft/min) 9 m/s (1772 ft/min)
pistons at 900 rpm
Mean velocity of the 10 m/s (1969 ft/min) 10 m/s (1969 ft/min) 10 m/s (1969 ft/min) 10 m/s (1969 ft/min)
pistons at 1000 rpm
Flywheel rotation Counterclockwise Counterclockwise Counterclockwise Counterclockwise
(standard)
Fuel, Lubricant, and See this Operation and Maintenance Manual, “Refill Capacities and Recommendations”
Coolant (Maintenance Section). Also, see the Application and Installation Guide.
Method of starting Air starting motors Air starting motors Air starting motors Air starting motors
Performance of the See the Application See the Application See the Application See the Application
cooling system and Installation Guide. and Installation and Installation Guide. and Installation Guide.
Guide.
Maximum allowable 3 kPa 3 kPa 3 kPa 3 kPa
exhaust back pressure (12 inches of H2O) (12 inches of H2O) (12 inches of H2O) (12 inches of H2O)
Maximum allowable 3.7 kPa 3.7 kPa 3.7 kPa 3.7 kPa
inlet air restriction (15 inches of H2O) (15 inches of H2O) (15 inches of H2O) (15 inches of H2O)
Air cleaners Remote Remote Remote Remote
SEBU7563-07 25
Product Information Section
Model Views and Specifications

g00891513 g00790805
Illustration 17 Illustration 20
G3606 Engine design G3616 Engine design
(A) Gas admission valves (A) Gas admission valves
(B) Inlet valves (B) Inlet valves
(C) Exhaust valves (C) Exhaust valves

Drives and Gear Trains

Front Drives

g00891514
Illustration 18
G3608 Engine design
(A) Gas admission valves
(B) Inlet valves
(C) Exhaust valves g00790861
Illustration 21
SAE standard engine crankshaft rotation
In-line engines and vee engines
(1) Jacket water pump
(2) Aftercooler and oil cooler pump
(3) Oil pump

g00790801
Illustration 19
G3612 Engine design
(A) Gas admission valves
(B) Inlet valves
(C) Exhaust valves
26 SEBU7563-07
Product Information Section
Model Views and Specifications

Engine Front Gear Train

g00790864
Illustration 22
SAE standard engine crankshaft rotation g00891685
Illustration 23
In-line engines and vee engines SAE standard engine crankshaft rotation
(4) Water outlet In-line engines and vee engines
(5) Water inlet
(1) Crankshaft
(6) Oil outlet
(2) Idler
(7) Oil inlet
(3) Idler
(4) Jacket water pump
Table 2 (5) Aftercooler and oil cooler pump
Front Drives (6) Auxiliary pump
(7) Oil pump
Component Speed(1)
Table 3
Jacket water pump 2522
Front Gear Train
Aftercooler and oil cooler pump 2522
Gear Number Of
Oil pump 1524 Teeth
(1) The speed of the component is listed for an engine that is (1) Crankshaft 96
operating at 1000 rpm. For an engine that is operating at
900 rpm, multiply the speed of the component by .9. For an (2) Idler 68
engine that is operating at 800 rpm, multiply the speed of the
component by .8. (3) Idler 67
(4) Jacket water pump 38
(5) Aftercooler and oil cooler Pump 38
(6) Auxiliary pump 43
(7) Oil pump 63
SEBU7563-07 27
Product Information Section
Model Views and Specifications

Engine Rear Gear Train

g01056736
Illustration 24
SAE standard engine crankshaft rotation
In-line engines
(1) Crankshaft
(2) Large cluster idler
(3) Small cluster idler
(4) Camshaft

g00891688
Illustration 25
SAE standard engine crankshaft rotation
Vee engines
(1) Crankshaft
(2) Large cluster idler
(3) Small cluster idler
(4) Camshaft
(5) Idler

Table 4

Rear Gear Train

Gear Number Of Teeth
(1) Crankshaft 81
(2) Large cluster idler 90
(3) Small cluster idler 45
(4) Camshaft 81
(5) Idler 81
28 SEBU7563-07
Product Information Section
Model Views and Specifications

Reference Weights
Table 5

Approximate Weights Of Package Generator Sets

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

8270 kg (18 232 lb)

(3)

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

Table 6

Approximate Weights Of Serviceable Parts

Component G3606 Engine G3608 Engine G3612 Engine G3616 Engine
Cylinder block 4638 kg (10 225 lb) 6476 kg (14 260 lb) 6805 kg (14 971 lb) 9625 kg (21 219 lb)
Bearing cap 65 kg (144 lb) 65 kg (144 lb) 65 kg (144 lb) 65 kg (144 lb)
Crankshaft 1782 kg (3929 lb) 2288 kg (5034 lb) 2091 kg (4600 lb) 3800 kg (8378 lb)
Flywheel assembly 491 kg (1082 lb) 491 kg (1082 lb) 491 kg (1082 lb) 491 kg (1082 lb)
Crankshaft vibration damper 183 kg (403 lb) 267 kg (588 lb) 183 kg (403 lb) 183 kg (403 lb)
Cylinder head assembly 196 kg (432 lb) 196 kg (432 lb) 196 kg (432 lb) 196 kg (432 lb)
Cylinder liner 110 kg (243 lb) 110 kg (243 lb) 110 kg (243 lb) 110 kg (243 lb)
Piston assembly 48 kg (106 lb) 48 kg (106 lb) 48 kg (106 lb) 48 kg (106 lb)
Piston pin 19 kg (42 lb) 19 kg (42 lb) 19 kg (42 lb) 19 kg (42 lb)
Piston rod assembly 57 kg (126 lb) 57 kg (126 lb) 57 kg (126 lb) 57 kg (126 lb)
Turbocharger (one) 401 kg (884 lb) 401 kg (884 lb) 401 kg (884 lb) 401 kg (884 lb)
Aftercooler core(1) 52 kg (115 lb) 52 kg (115 lb) 94 kg (207 lb) 125 kg (275 lb)
Front housing 258 kg (569 lb) 258 kg (569 lb) 258 kg (569 lb) 258 kg (569 lb)
Rear housing 222 kg (489 lb) 222 kg (489 lb) 350 kg (772 lb) 350 kg (772 lb)
Used air cleaner element 29 kg (64 lb) 29 kg (64 lb) 29 kg (64 lb) 29 kg (64 lb)
(1) The weight for a single-stage type of aftercooler is listed. The two-stage aftercooler and the aftercooler with a deep core are also available.
SEBU7563-07
Product Identification
Information
i01519197
Plate Locations and Film
Locations
SMCS Code: 1000; 4450
Engine Identification
Caterpillar engines are identified with serial numbers,
with performance specification numbers, and with
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.
Serial Number Plate
g00123229
Illustration 26
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.
29
Product Information Section
Product Identification Information
Information Plate
Illustration 27
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
Reference Information
SMCS Code: 1000; 4450
Identification of the items in Table 7 may be needed
in order to obtain parts and service. Some of the
numbers are on the engine Serial Number Plate
and/or Information Plate. Locate the information
for your engine. Record the information on the
appropriate space in Table 7. Make a copy of this
list for a record. Retain the information for future
reference.
The top level part numbers in the Parts Manual for
the engine are listed with the engine arrangement
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.
30 SEBU7563-07
Product Information Section
Product Identification Information

Table 7
Record Of Reference Numbers
Item Identification
Engine Model
Serial Number
Arrangement Number
Modification Number
Performance Specification
Power Rating
Personality Module (Revision)
Low Idle rpm
High Idle rpm
Full Load rpm
Overspeed Setpoint
Air Choke Actuator
Exhaust Bypass Actuator
Fuel Actuator
Lubrication Oil Filter Element
Lube Oil Capacity (total)
Air Cleaner Element
Alternator Belt
Supplemental Coolant Additive
Cooling System Capacity (total)
Turbocharger
SEBU7563-07 31
Operation Section
Lifting and Storage

Operation Section Engine Lifting with a Generator

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

i01536259 A lifting plate is provided with the package generator

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

Lifting packaged generator sets will not be level if you

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

The single point lifting eye is secured from the

Illustration 28
g00103219
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
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.

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.
32 SEBU7563-07
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.
SEBU7563-07 33
Operation Section
Features and Controls

Features and Controls (Table 8, contd)

Configuration Parameters for G3600 Engines

i02596147 Engine Acceleration Rate

Programmable System Desired Speed Input Configuration

Parameters Governor Type Setting

Engine Speed Droop
SMCS Code: 1900
Governor (Proportional) Gain Percentage
Certain parameters are unique for each engine Governor (Integral) Stability Percentage
application. Table 8 is a list of the parameters that can
be configured in the Electronic Control Module (ECM) Governor (Derivative) Compensation Percentage
for G3600 Engines. The values of the parameters Governor Auxiliary 1 (Proportional) Gain Percentage
can be viewed on the “Configuration” screen of
Caterpillar Electronic Technician (ET). Governor Auxiliary 1 (Integral) Stability Percentage
Governor Auxiliary 1 (Derivative) Compensation
Note: The latest flash file installed in the ECM and Percentage
the latest version of Cat ET are required to access all
parameters in the table.
Start/Stop Control
Table 8
Driven Equipment Delay Time
Configuration Parameters for G3600 Engines
Crank Terminate RPM
Air/Fuel Ratio Control
Engine Purge Cycle Time
Fuel Quality Input Type Configuration
Cooldown Duration
Fuel Quality
Cycle Crank Time
Fuel Quality Sensor LHV Lower Setpoint
Engine Overcrank Time
Fuel Quality Sensor LHV Upper Setpoint
Engine Speed Drop Time
Gas Specific Gravity
Engine Pre-Lube Time Out Period
Desired Engine Exhaust Port Temperature
Maximum Choke Position
Monitoring and Protection
Engine Start Choke Position
Engine Post-Lube Duration
Engine Start Turbo Wastegate Position
High Inlet Air Temp Engine Load Set Point
Wastegate (Proportional) Gain Percentage
Wastegate (Integral) Stability Percentage
Module Information
Wastegate (Derivative) Compensation Percentage
Engine Serial Number
Choke (Proportional) Gain Percentage
Equipment ID
Choke (Integral) Stability Percentage
Choke (Derivative) Compensation Percentage Passwords
Ignition Multi Strike Feature Enable Customer Password #1
Ignition Multi Strike Mode Configuration Customer Password #2
Ignition Multi Strike Engine Startup Activation Duration Total Tattletale

Speed Control For detailed information on the parameters, refer

to Systems Operation/Testing and Adjusting,
Low Idle Speed
RENR5908, “Electronic Control System Parameters”.
Minimum Engine High Idle Speed
Maximum Engine High Idle Speed
(continued)
34 SEBU7563-07
Operation Section
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 9. 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 9

Engine ECM Monitoring

Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)
Warning 20
E043 20
(1) volts
Low System Always
Engine This item is not programmable.
Voltage On (1) 18
E042 Shutdown 10
volts
(3)
(continued)
SEBU7563-07 35
Operation Section
Features and Controls

(Table 9, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)

High Engine Warning

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

High Engine Warning

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

High Engine Warning

E017 On 115°C
Coolant (1)
Temperature Engine
(110° C Jacket Always
E016 Shutdown 120°C
Water Rating) On(1)
(3)
Low Engine
Warning
Coolant E038 On 25°C 5° to 80°C
(1)
Temperature
Engine
High Pump Outlet Always 462
E224 Shutdown
Pressure(2) On(1) kPa
(3)
Warning Always 124
10 This item is not programmable.
Low Jacket (1) On(1) kPa
Water Outlet E228 Engine
Pressure(2) Always 103
Shutdown
On(1) kPa
(3)
1017
Engine rpm
Engine Always 800 to 1300
E004 Shutdown or 0 Factory 0
Overspeed On(1) rpm
(3) 1130
rpm
Warning Always
Engine Overload E242 110% 0 This item is not programmable.
(1) On(1)
Warning
E020 On 88°C 5 Customer 85° to 102°C
(1)
High Engine Oil
Engine 1 to 60
Temperature Always
E019 Shutdown 90°C 1 Factory 85° to 104°C
On(1)
(3)
(continued)
36 SEBU7563-07
Operation Section
Features and Controls

(Table 9, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)
Warning Always 175
E100 5
Low Engine Oil (1) On(1) kPa
Pressure(2) Engine
(Under 600 RPM) Always 100
E040 Shutdown 0
On(1) kPa
(3)
This item is not programmable.
Warning Always 400
E100 5
Low Engine Oil (1) On(1) kPa
Pressure(2) Engine
(Over 600 RPM) Always 350
E040 Shutdown 0
On(1) kPa
(3)
Warning 650
E125 On
(1) kPa
High Engine Oil 600 to 1200
Engine 25 Customer
Pressure Always 1000 kPa
E126 Shutdown
On(1) kPa
(3)
Warning 100
E129 Off 15 Customer
High Oil Filter (1) kPa
Differential Engine 0 to 350 kPa
Pressure Always 300
E130 Shutdown 25 Factory
On(1) kPa
(3)
Warning
E127 Off 5 kPa Customer
Low Oil Filter (1) 1 to 60
Differential Engine 10 0 to 150 kPa
Pressure E128 Shutdown Off 3 kPa Factory
(3)
High Fuel Warning
E223 60°C 20 0° to 60°C
Temperature (1)
Low Fuel On
Warning
Differential E864 5 kPa 60 0 to 100 kPa
(1) Customer
Pressure
High Fuel
Warning Always 160
Differential E865 30 0 to 195 kPa
(1) On(1) kPa
Pressure
High System Warning 34
E050 On 20 This item is not programmable.
Voltage (1) volts
(continued)
SEBU7563-07 37
Operation Section
Features and Controls

(Table 9, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)

High Inlet Air Warning

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

High Inlet Air Warning

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

High Inlet Air Warning

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

High Inlet Air Warning

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

High Inlet Air Warning

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

High Engine Warning Always

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

High Engine Warning

E123 On 10°C Customer
Oil to Engine (1)
Coolant Engine 60 0° to 80°C 1 to 60
Differential Always
E124 Shutdown 15°C Factory
Temperature On(1)
(3)
(continued)
38 SEBU7563-07
Operation Section
Features and Controls

(Table 9, contd)
Engine ECM Monitoring
Delay
Delay
Event System Trip Security Trip Point Time
Parameter State Time
Code Response Point Level Range Range
(Seconds)
(Seconds)
Warning Always
20 This item is not programmable.
High Inlet Air (1) On(1)
Restriction E385 Engine
(Right) This item is not
Shutdown Off 0 Customer 0 to 65
programmable.
(3) 5.23
Warning Always kPa
20 This item is not programmable.
(1) On(1)
High Inlet Air
E384 Engine This item is not
Restriction (Left)
Shutdown Off 0 Customer programmable. 0 to 65
(3)
(1) This parameter is permanently active. This parameter cannot be turned off.
(2) This event will not appear on the monitor.

Integrated Combustion Sensing

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

Table 10 lists default examples of the values for the

parameters.
SEBU7563-07 39
Operation Section
Features and Controls

Table 10
ICSM Monitoring
Delay Security Delay
System Trip Trip Point
Description Event Code State Time Level Range
Response Point Range
(Seconds) Password (Seconds)
High Exhaust Warning (1) 600°C
Temperature (Port) E801 through 100° to
Engine Off 10
E816 Shutdown 650°C 1000°C
(3)
Exhaust Port Warning (1) On 50°C 240
Temperature High E821 through
Deviation Engine
E836 Shutdown Off 100°C 600
(3) 10° to
Exhaust Port Warning (1) On 120°C 500°C
Temperature Low E841 through
Deviation Engine 300 Customer 1 to 1200
E856 Shutdown Off 400°C
(3)
High Turbo Turbine E245 (Right Warning (1) 600°C
Inlet Temperature Bank) 400 to 700
Engine
E246 (Left Shutdown 650°C °C
Bank) (3)
On 10
High Turbo Turbine E243 (Left Warning (1) 570°C
Outlet Temperature Bank) 400 to
Engine
E244 (Right Shutdown 600°C 650°C
Bank) (3)
40 SEBU7563-07
Operation Section
Features and Controls

i02600163

Control Panel
SMCS Code: 7451

g00799615
Illustration 30
Keypad

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

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

The keypad is protected in a sealed membrane.

When you press a key, press firmly. When a key is
pressed sufficiently, a small red indicator in the upper
left corner of the keypad will flash once.
g00824832
Illustration 29
Control panel
When the control panel is powered up, the screen
becomes active. To view the options for the display,
(1) Advisor II display
(2) Keypad for the Advisor II press the “?” key. Table 11 lists the menu.
(3) “EMERGENCY STOP” button
(4) “ENGINE ON” indicator Table 11
(5) “ACTIVE ALARM” indicator
(6) “ENGINE FAILURE” indicator
Menu
(7) “MANUAL PRELUBE” switch and “PRELUBE ACTIVE” 1 Status Screen Mode
indicator
(8) Mode control switch 2 Detonation Levels
(9) “DESIRED SPEED” potentiometer
3 Ignition Times
The features of the control panel are described below. 4 Burn Times
5 Temperatures
Advisor II
6 Secondary Voltages
Advisor II is a device which enables the operator to 7 Not Used
monitor engine operation. The Advisor II receives
information from the Electronic Control Module 8 Events and Diagnostics
(ECM). The device cannot be used for programming. 9 Display Setup
A screen display and a keypad provide the interface
for the operator. ? Menu

To select an option, press the number on the keypad

that corresponds to the selection. To exit the option,
press the “?” key or any of the numbered keys. It
is not necessary to return to the menu in order to
select a different option. When you press a different
numbered key, the corresponding option is displayed.
SEBU7563-07 41
Operation Section
Features and Controls

Status Screen Mode Speed Status

Table 12 The “Speed Status” screen displays parameters that

Status Screen Mode pertain to the engine speed and some additional
parameters. Table 15 lists the information that is
1 Status Screen Menu displayed.
2 Engine Status
Table 15
3 Air/Fuel Ratio Status
Speed Status
4 Speed Status
Engine Speed Desired Engine Percent Load
5 Pressure Status Speed

6 Temperature Status Speed Control Droop Setting Governor Type

7 Misc Status Wastegate Choke command Fuel Command

Command
8 Relay Status
9 Not Used Pressure Status
? Menu
The “Pressure Status” screen displays parameters
that pertain to the engine pressures. Table 16 lists
Status Screen Menu the information that is displayed.
Pressing “1” returns the user to the “Menu” screen. Table 16

Pressure Status
Engine Status
Fuel Pressure Air Pressure Desired Air
The “Engine Status” screen displays basic Pressure
information about the condition of the engine. Table Oil Pressure Differential Oil Crankcase
13 lists the information that is displayed. Pressure pressure
Table 13 Not Used Jacket Water Not Used
Engine Status
Temperature Status
Engine Speed Desired Engine Percent Load
RPM Speed
The “Temperature Status” screen displays
Oil Pressure Air Pressure Air Temperature parameters that pertain to the engine temperatures.
Oil Temperature Jacket Water Fuel Correction
Table 17 lists the information that is displayed.
Temperature
Table 17

Temperature Status
Air/Fuel Ratio Status
Air Temperature Jacket Water Oil Temperature
The “Air/Fuel Ratio Status” screen displays the status Fuel Even Bank
Odd Bank
of parameters that pertain to the air and fuel. The Temperature
actual data is continuously updated. Table 14 lists
the information that is displayed. Not Used Not Used Not Used

Table 14
Miscellaneous Status
Air/Fuel Ratio Status
A/F Ratio Desired A/F Fuel Quality
The “Miscellaneous Status” screen displays the
Ratio parameters that are listed in Table 18.

Air Pressure Desired Air Specific Gravity

Pressure
Air Flow Fuel Flow Feedback Status
42 SEBU7563-07
Operation Section
Features and Controls

Table 18 Ignition Timing

Miscellaneous Status
The “Ignition Timing” screen displays the current
Detonation Level Service Hours Battery Voltage degrees before top center for the timing of each
Engine Multi Strike Engine Cylinders
cylinder. The values for the programmable desired
Configuration Feature timing are listed. The current active selected timing
is indicated.
Multi Strike Mode Multi Strike Multi Strike
Switch Status Table 21
Ignition Timing
Relay Status
Even Bank Odd Bank
The “Relay Status” screen displays the status of Actual Timing
switches and relays that are identified in Table 19. Base Timing

Table 19
Burn Times
Relay Status
Speed Status The “Burn Times” screen can display either the
“Filtered Burn Times” or the “Unfiltered Burn Times”.
Mode Status “Filtered Burn Times” displays an average of the
E-Stop Status combustion burn time for each bank of cylinders. The
desired combustion burn time and the time for each
Driven Equipment individual cylinder are also displayed. “Unfiltered
Prelube Solenoid Burn Times” displays the actual instantaneous
combustion burn time for each individual cylinder.
Prelube Oil Pressure Switch The desired combustion burn time and the average
Initiate Contact combustion burn time for each bank of cylinders are
also displayed.
Start Solenoid
Table 22
Fuel Control Solenoid
Burn Times
Hydrax Oil Pressure Switch
Filtered Unfiltered
Normal Stop
Even Bank Odd Bank
Not Used Even Bank Odd Bank
Desired Burn Fuel Correction
Option 9 of this screen is not used at this time.

Menu Temperatures
Pressing “?” returns the user to the “Menu” screen. The “Temperatures” screen can display either
“Exhaust Temperatures” or “Turbo Temperatures”.
Detonation Levels “Exhaust Temperatures” displays the actual exhaust
port temperature for each cylinder. The average
The “Detonation Levels” screen displays the level of temperature for all of the exhaust ports in each bank
detonation for each cylinder as bars on the screen. is also displayed. If the engine is operating at a load
The average detonation level for all of the cylinders is that is less than 40 percent, the desired exhaust
also displayed. temperature is displayed. If the engine load is greater
than 40 percent, the desired exhaust temperature
Table 20 is not a factor. “Turbo Temperatures” displays the
Detonation Levels temperatures of the exhaust at the inlet and outlet
of each turbocharger. The average temperature for
Even Bank Odd Bank each bank is also displayed.
Engine Average
Detonation Level
SEBU7563-07 43
Operation Section
Features and Controls

Table 23 Table 26
Temperatures Display Setup
Exhaust Turbo
Even Bank Odd Bank LCD Contrast Backlighting
Offset Lights On
Even Bank Odd Bank
Desired Temp Fuel Correction
Metric
English
Secondary Voltages Imperial
Units
The “Secondary Voltages” screen display the voltage
drop across the spark plugs as a percent.

Table 24
Menu
Secondary Voltage
Even Bank Odd Bank
Pressing “?” returns you to the “Menu” screen.

Actual Timing
Base Timing “EMERGENCY STOP” Button
NOTICE
Not Used Only use the “Emergency Stop” button in order to stop
the engine in an emergency situation. Do not use the
Option 7 of this screen is not used at this time. “Emergency Stop” button for normal engine stopping.

Events and Diagnostics To prevent damage to the engine, use the mode con-
trol switch or use the remote start/stop initiate contact
The “Events and Diagnostics” screen displays event for normal engine stopping.
codes and diagnostic codes.

Table 25
Codes
Events and Diagnostics

MID Code OCC First Last Act

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.
g00824884
Illustration 31
The fuel and the ignition are immediately shut off
when the “EMERGENCY STOP” button is pressed.
No postlube cycle occurs.
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.

Note: The engine mounted junction box also has an

“EMERGENCY STOP” button.
44 SEBU7563-07
Operation Section
Features and Controls

Indicators
The remote panel has three indicators for the status
of the engine operation.

g00825028
Illustration 33
“MANUAL PRELUBE” switch and “PRELUBE ACTIVE” indicator

The “MANUAL PRELUBE” switch enables the

g00824980
Illustration 32
(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.
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

“MANUAL PRELUBE” Switch and

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

Lubrication of the engine is required prior to rotation

of the crankshaft. This includes crankshaft rotation in
order to service the engine. Rotating the crankshaft
before prelube may cause damage to the crankshaft
bearings if the surfaces of the bearings are dry. Illustration 34
g00825037

Mode control switch in the “AUTO” position

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

“START”, “STOP”, and “OFF/RESET”
SEBU7563-07 45
Operation Section
Features and Controls

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

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

“START” – When the mode control switch is turned

to the “START” position (3 o’clock), the prelube
system will operate. When the prelube pressure
is sufficient, the engine will start. The engine will
operate until the ECM receives a shutdown signal.
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.
g00825039
Illustration 35
“DESIRED SPEED” potentiometer
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.

• 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.
46
Operation Section
Engine Starting
Engine Starting
i02601065
Before Starting Engine
SMCS Code: 1000; 1400; 1450
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).
Walk-Around Inspection
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.
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.
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
• Ensure that the areas around the rotating parts are
clear.
Air Inlet System
Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal
injury and/or property damage may result.
Before starting an engine that may contain un-
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.
• Ensure that the air inlet piping and the air filters
are in place.
• Ensure that all clamps and connections are secure.
SEBU7563-07
Cooling System
• Inspect the cooling system for leaks or loose
connections. Inspect the condition of all the pipes
for the cooling system. Ensure that the connections
are properly clamped.
• Inspect the water pumps for evidence of leaks.
• Check the coolant level. Add coolant, if necessary.
For information on the proper coolant to use, refer
to this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” (Maintenance
Section).
Driven Equipment
• If necessary, check the oil levels of the driven
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.
• For generator set engines, ensure that the main
circuit breaker is open.
Electrical System
Inspect the wiring for the following conditions:
• Loose connections
• Wiring that is worn or frayed
Inspect the gauge panel and the control panel
for good condition. Reset any shutoff or alarm
components.
SEBU7563-07
Lubrication System
g01140341
Illustration 36
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.
• 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).
47
Operation Section
Engine Starting
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
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.
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.
48
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 ex-
ceed 150 °C (300 °F). The maximum heat density
of the heating surface must not exceed 1.24 w/cm2
(8W/in2).
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.
Requirements for Starting with Air
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.
Water Separator
Condensation of vapor in the air supply can freeze in
cold weather. This can enable the following problems
to occur:
• Ice that forms in the supply lines will restrict the
air supply.
• If particles of ice enter the inlet of the starting
motor, the starting motor can be damaged.
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.
SEBU7563-07
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.
Before starting an engine that may contain un-
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.
Note: The “EMERGENCY STOP” button will shut off
both the fuel and the ignition.
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.
Ensure that no one will be endangered before the
engine is started and when the engine is started.
Perform the procedures that are described in this
Operation and Maintenance Manual, “Before Starting
Engine” (Operation Section).
Purging Unburned Gas
The following events cause unburned gas to remain
in the air inlet and in the exhaust manifold:
• Emergency stop
• Engine overspeed
SEBU7563-07
• The engine control is set to the STOP mode and
the gas shutoff valve does not close.
• Unsuccessful successive attempts to start the
engine
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.
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.
4. Continue with your previous procedure.
Automatic Starting
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.
49
Operation Section
Engine Starting
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.
g00791099
Illustration 37
(1) Engine control switch in the “START” position
(2) “DESIRED SPEED” potentiometer
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. 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.
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.
50 SEBU7563-07
Operation Section
Engine Starting

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

Ensure that the oil pressure and the fuel pressure are
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
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.

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

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

Check the Advisor II panel during the warm-up.

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

Engaging the Driven Equipment

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

DO NOT apply a load to the engine or increase the

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

1. Increase the engine rpm.

The minimum rpm for operating an engine with a

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

a. For engines with a “SPEED CONTROL”

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

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

toggle the switch to the “RATED” position.

Ensure that the gauges are in the normal

ranges for the engine rpm.

Note: It may be necessary to apply some load in

order to attain normal operating temperatures.

2. After verifying that the engine systems are normal,

engage the driven equipment.
SEBU7563-07
Engine Operation
i02601285
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 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
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.
Partial Load 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:
• Accelerated wear of components
• Loss of control of the exhaust emissions
• Narrow margin for detonation
• Poor performance
• Power loss
51
Operation Section
Engine Operation
Caterpillar Engines can be operated at very light
loads for limited times with no harmful effects. Table
27 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 27.
Table 27
Time Limits for Low Load Operation
Engine Load Time Limit
0 to 30 percent 1/2 hour
31 to 50 percent 2 hours
51 to 100 percent Continuous (1)
(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 28 lists the normal mid-life BSOC for G3600
engines under the following conditions:
• Load factor of 100 percent
• Maintenance is performed according to this
Operation and Maintenance Manual, “Maintenance
Interval Schedule”.
Table 28
BSOC for G3600 Engines
0.304 g/bkw h (.00052 lb/bhp h)
52
Operation Section
Engine Stopping
Engine Stopping
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 un-
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.
SEBU7563-07
Emergency Stop Button
Illustration 38
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 ac-
celerated wear of engine components.
Excessive temperatures in the turbocharger center-
housing will cause oil coking problems.
Allow the engine to gradually cool before stopping the
engine
Note: Remove the load at a rate that will avoid
detonation.
SEBU7563-07
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.
Note: Extended idling can cause excessive oil
consumption and related problems. See this
Operation and Maintenance Manual, “Engine
Operation” topic (Operation Section).
2. Reduce the engine rpm to low idle.
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:
g00825057
Illustration 39
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.
53
Operation Section
Engine Stopping
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
After Stopping Engine
SMCS Code: 1000
• Check the engine crankcase oil level. Maintain
the 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 dam-
age.
• Allow the engine to cool. Check the coolant level.
• If freezing temperatures are expected, check the
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 SEBU7563-07
Maintenance Section
Refill Capacities

Maintenance Section Hydraulic Actuator System

Hydraulic Oil
Refill Capacities Cat HYDO (Hydraulic Oil) is recommended in most
hydraulic systems. If Caterpillar oils cannot be used,
the following commercial classifications can be used
i02601419
in hydraulic systems:
Refill Capacities and
• CH-4 engine oils that have a minimum zinc additive
Recommendations of 0.09 percent (900 ppm)

SMCS Code: 1348; 1395; 7560
Lubrication System
Lubricant Recommendations
Due to significant variations in the quality and in
the performance of commercially available oils,
Caterpillar makes the following recommendations:
• Cat NGEO (Natural Gas Engine Oil)
• Cat NGEO EL350 (Natural Gas Engine Oil)
Note: SAE 40 is the ONLY type of oil that is
recommended for 3600 Gas engines. Multigrade oils
are NOT recommended for use in Caterpillar Gas
Engines.
For further information about oils, see Special
Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”.
Lubricant Capacities
The capacity of the engine crankcase includes the
capacity of the oil filters that are installed at the
factory.
Table 29
Approximate Refill Capacity of Crankcase
• CG-4 engine oils that have a minimum zinc additive
of 0.09 percent (900 ppm)
• CF-4 engine oils that have a minimum zinc additive
of 0.09 percent (900 ppm)
• CF engine oils that have a minimum zinc additive
of 0.09 percent (900 ppm)
Note: Industrial hydraulic oils are not recommended
for use in Caterpillar hydraulic systems.
Caterpillar also has a biodegradable hydraulic oil
that is available for use in hydraulic systems. This
fluid is recommended for the hydraulic systems when
environmental compliance is required or desired.
For further information on choosing a hydraulic oil,
see Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel and Coolant
Recommendations”.
Capacity of the Electrohydraulic
Actuator’s System
Table 30
G3600 Electrohydraulic Actuator System
Approximate Refill Capacity
Compartment or System Liters US Gallons
Hydraulic Oil Tank 19 5

Sales Model Liters US Gallons

G3606 708 187
Fuel
G3608 912 241 Fuel Recommendations
G3612 1030 272
Caterpillar gas engines will operate successfully on
G3616 1325 351 a broad range of gaseous fuels. Pipeline natural
gas has been used for many years. Commercial
fuel gases are mixtures of gases. These fuels
consist primarily of hydrocarbons (combinations of
hydrogen and carbon) and some inert gases. The
compositions of these gas mixtures have extreme
variations. Fuels such as wellhead gas, bio-gas,
and manufactured gas need to be reviewed for
acceptability. Analyze the fuel in order to determine
the following characteristics:
SEBU7563-07 55
Maintenance Section
Refill Capacities

• Composition Cooling System

• Heat value Coolant Recommendations
• Methane number During shipping and storage, the engine must be
protected from damage that can be caused by
• Specific gravity freezing of the cooling system. If the engine is
shipped to a site with freezing temperatures and/or
Also check for contaminants such as the following: if the engine is stored in a location with freezing
temperatures, the cooling system must contain
• Halides antifreeze that will withstand the lowest ambient
temperature. Frequently check the concentration
• Sulfur Compounds of glycol in the coolant/antifreeze. Make sure that
the concentration is adequate in order to prevent
• Siloxanes freezing. Otherwise, the cooling system must be
completely drained and all of the drain plugs must
Field gas can have varying characteristics of be removed.
combustion. Field gas can contain numerous
harmful impurities. The impurities can alter the BTU Coolant/antifreeze is normally composed of three
content. The impurities can also alter the methane elements: water, glycol, and additives. Each element
number. The impurities include everything from must meet specific guidelines.
water up to complex hydrocarbons that can lead to
detonation and severe engine damage. To minimize Water
these effects, Caterpillar recommends the following
guidelines: Deionized water or distilled water is
recommended for use in engine cooling systems.
1. Evaluate the fuel with the Caterpillar Methane If distilled water or deionized water is not available,
Number Program, LEKQ6378. use water with the properties that are listed in Table
31.
Methane values below 30 are not recommended
for use in a Caterpillar engine. Fuels with a Table 31
methane number that is below 30 must first be
Caterpillar Minimum Acceptable Water Requirements
processed in order to remove harmful impurities
in the fuel and raising the methane number into Property Maximum Limit ASTM Test
the acceptable range.
40 mg/L “D512”,
Chloride (Cl)
(2.4 grains per US gal) “D4327”
2. If necessary, use an engine that is configured
for a fuel that has a high energy. Consult the Sulfate (SO4)
100 mg/L
“D516”
appropriate manual for the engine in order to (5.9 grains per US gal)
determine the recommended engine timing. 170 mg/L
Total Hardness “D1126”
(10 grains per US gal)
3. Reduce the oil change interval according to the
results of the oil analysis. 340 mg/L
Total Solids “D1888”
(20 grains per US gal)
For further information on fuels, see Special Acidity pH of 5.5 to 9.0 “D1293”
Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”.
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:
56 SEBU7563-07
Maintenance Section
Refill Capacities

• Caterpillar dealer Table 32

Recommended Coolant/Antifreeze and Service
• Local water utility company Life of the Coolant/Antifreeze

• Agricultural agent Coolant/Antifreeze Service Life (1)

• Independent laboratory
Glycol
NOTICE
Do not use Extended Life Coolant (ELC) with
Caterpillar Gas Engines.
ELC was not formulated for use in Caterpillar Gas En-
gines.
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 31 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 32 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.
Cat NGEC
Three Years
Cat DEAC
Commercial Heavy-Duty
Antifreeze/Coolant that Two Years
meets “ASTM D6210”
Commercial Heavy-Duty
Antifreeze/Coolant that One Year
meets “ASTM D4985”
Cat SCA and Water Two Years
Commercial SCA and
One Year
Water
(1) 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
1200 mg/L (70 grains per US gal) or 1200 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”.
For further information on coolant, see Special
Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”.
SEBU7563-07 57
Maintenance Section
Refill Capacities

Coolant Capacities Table 36

G3616 Engine Cooling System
To properly maintain the cooling system, the total Approximate Refill Capacity
cooling system capacity must be determined. The
total cooling system capacity will vary between Compartment or System Liters US Gallons
individual installations. The external system capacity Jacket Water 900 238
includes the following components: expansion tank,
heat exchanger, radiator, and piping. Refer to the Aftercooler 72 19
specifications that are provided by Caterpillar or by Accessory Module 345 91
the OEM of the equipment. Record the total cooling
system capacity in the appropriate Tables: External System
Total Cooling System
Table 33
G3606 Engine Cooling System
Approximate Refill Capacities
Compartment or System Liters US Gallons
Jacket Water 340 90
Aftercooler 61 16
Accessory Module 345 91
External System
Total Cooling System

Table 34

G3608 Engine Cooling System

Approximate Refill Capacities
Compartment or System Liters US Gallons
Jacket Water 469 124
Aftercooler 61 16
Accessory Module 345 91
External System
Total Cooling System

Table 35

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
58
Maintenance Section
Maintenance Interval Schedule
i02599617
Maintenance Interval Schedule
(G3600 Engines That Have a
9.2:1 Compression Ratio and
That UseWellhead or Natural
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
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICHEVER OCCURS FIRST,
in order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
When Required
Actuator Control Linkage - Replace ...................... 64
Barring Device - Lubricate .................................... 67
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 75
Engine Air Cleaner Element (Single Element) -
Clean/Replace .................................................... 86
Engine Air Precleaner - Clean .............................. 89
Overhaul Considerations ..................................... 113
Valve Stem Projection - Measure/Record ........... 120
Daily
Air Starting Motor Lubricator Oil Level - Check .... 66
Air Tank Moisture and Sediment - Drain ............... 67
Control Panel - Inspect ......................................... 72
Cooling System Coolant Level - Check ................ 74
Driven Equipment - Inspect/Replace/Lubricate ... 81
Electrohydraulic System - Inspect ........................ 84
Engine Oil Level - Check ...................................... 95
Fuel System Fuel Filter Differential Pressure -
Check ................................................................ 101
Walk-Around Inspection ...................................... 121
SEBU7563-07
Every 250 Service Hours
Battery Electrolyte Level - Check .......................... 69
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 75
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 76
Engine Oil Sample - Obtain .................................. 95
Initial 1000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 65
Air Starting Motor Lubricator Bowl - Clean ........... 65
Crankcase Blowby - Measure/Record .................. 78
Cylinder Pressure - Measure/Record ................... 79
Electrohydraulic System Oil Filter - Change ......... 85
Engine Crankcase Breather - Clean ..................... 90
Engine Protective Device Connections - Inspect .. 96
Engine Speed/Timing Sensor - Clean/Inspect ...... 99
Engine Valve Lash - Inspect/Adjust ...................... 99
Engine Valve Rotators - Inspect ......................... 100
Valve Stem Projection - Measure/Record ........... 120
Every 1000 Service Hours
Actuator Control Linkage - Lubricate .................... 64
Belts - Inspect/Adjust/Replace .............................. 69
Hoses and Clamps - Inspect/Replace ................ 104
Ignition System Spark Plugs - Check/Adjust ...... 105
Every 2000 Service Hours
Aftercooler Condensation - Drain ......................... 65
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 75
Crankshaft Vibration Damper - Inspect ................. 78
Engine Crankcase Breather - Clean ..................... 90
Engine Mounts - Check ........................................ 90
Engine Valve Lash - Inspect/Adjust ...................... 99
Engine Valve Rotators - Inspect ......................... 100
Valve Stem Projection - Measure/Record ........... 120
Every 5000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 65
Air Starting Motor Lubricator Bowl - Clean ........... 65
Combustion Sensor - Clean/Inspect/Replace ....... 70
Cooling System Level Switch - Inspect ................. 76
Crankcase Blowby - Measure/Record .................. 78
Cylinder Pressure - Measure/Record ................... 79
Driven Equipment - Check .................................... 81
Electrohydraulic System - Check/Adjust ............... 84
Electrohydraulic System Oil - Change .................. 84
Electrohydraulic System Oil Filter - Change ......... 85
Engine Oil - Change ............................................. 90
Engine Oil Filter - Change .................................... 92
Engine Protective Device Connections - Inspect .. 96
Engine Protective Devices - Check ...................... 98
Exhaust Bypass - Recondition ............................ 101
Gas Shutoff Valve - Inspect ................................ 103
Ignition System Spark Plugs - Replace .............. 108
Inlet Air System - Inspect .................................... 108
SEBU7563-07 59
Maintenance Section
Maintenance Interval Schedule

Inlet Gas Manifold and Piping - Inspect/Replace .. 109

Prechamber Check Valves - Clean ...................... 116
Starting Motor - Inspect ....................................... 117
Turbocharger - Inspect ......................................... 118

Every 10 000 Service Hours

Alternator - Inspect ............................................... 67
Cooling System Water Temperature Regulator -
Replace ............................................................... 77
Electrohydraulic Actuator - Inspect ....................... 81
Engine Oil Temperature Regulator - Replace ....... 96
Engine Speed/Timing Sensor - Clean/Inspect ...... 99
Exhaust Shields - Inspect ................................... 101
Gas Pressure Regulator - Inspect/Replace ........ 103
Prechamber Check Valves - Replace .................. 116
Prelube Pump - Inspect ....................................... 116
Water Pump - Inspect ......................................... 121

Every 20 000 Service Hours or 3 Years

Cooling System Coolant (NGEC) - Change .......... 72

Every 25 000 Service Hours

Gas Admission Valve Seals - Inspect/Replace ... 102
Overhaul (Top End) .............................................. 112
Prechamber - Clean/Inspect ................................ 115

Every 50 000 Service Hours

Electrohydraulic Actuator - Recondition ................ 82
Gas Admission Valve - Recondition .................... 102
Overhaul (In-Frame) ........................................... 109

Every 100 000 Service Hours

Overhaul (Major) .................................................. 111

Overhaul
Connecting Rod Bearings - Inspect/Replace ........ 72
60
Maintenance Section
Maintenance Interval Schedule
i02599631
Maintenance Interval Schedule
(G3600 Engines That Have a
10.5:1 or an 11:1 Compression
Ratio and Use Natural 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
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICHEVER OCCURS FIRST,
in order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
When Required
Actuator Control Linkage - Replace ...................... 64
Barring Device - Lubricate .................................... 67
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 75
Engine Air Cleaner Element (Single Element) -
Clean/Replace .................................................... 86
Engine Air Precleaner - Clean .............................. 89
Overhaul Considerations ..................................... 113
Valve Stem Projection - Measure/Record ........... 120
Daily
Air Starting Motor Lubricator Oil Level - Check .... 66
Air Tank Moisture and Sediment - Drain ............... 67
Control Panel - Inspect ......................................... 72
Cooling System Coolant Level - Check ................ 74
Driven Equipment - Inspect/Replace/Lubricate ... 81
Electrohydraulic System - Inspect ........................ 84
Engine Oil Level - Check ...................................... 95
Fuel System Fuel Filter Differential Pressure -
Check ................................................................ 101
Walk-Around Inspection ...................................... 121
Every 250 Service Hours
Battery Electrolyte Level - Check .......................... 69
SEBU7563-07
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 75
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 76
Engine Oil Sample - Obtain .................................. 95
Initial 1000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 65
Air Starting Motor Lubricator Bowl - Clean ........... 65
Crankcase Blowby - Measure/Record .................. 78
Cylinder Pressure - Measure/Record ................... 79
Electrohydraulic System Oil Filter - Change ......... 85
Engine Crankcase Breather - Clean ..................... 90
Engine Protective Device Connections - Inspect .. 96
Engine Speed/Timing Sensor - Clean/Inspect ...... 99
Engine Valve Lash - Inspect/Adjust ...................... 99
Engine Valve Rotators - Inspect ......................... 100
Valve Stem Projection - Measure/Record ........... 120
Every 1000 Service Hours
Actuator Control Linkage - Lubricate .................... 64
Belts - Inspect/Adjust/Replace .............................. 69
Hoses and Clamps - Inspect/Replace ................ 104
Ignition System Spark Plugs - Replace .............. 108
Every 2000 Service Hours
Aftercooler Condensation - Drain ......................... 65
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 75
Crankshaft Vibration Damper - Inspect ................. 78
Engine Crankcase Breather - Clean ..................... 90
Engine Mounts - Check ........................................ 90
Engine Valve Lash - Inspect/Adjust ...................... 99
Engine Valve Rotators - Inspect ......................... 100
Valve Stem Projection - Measure/Record ........... 120
Every 5000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 65
Air Starting Motor Lubricator Bowl - Clean ........... 65
Combustion Sensor - Clean/Inspect/Replace ....... 70
Cooling System Level Switch - Inspect ................. 76
Crankcase Blowby - Measure/Record .................. 78
Cylinder Pressure - Measure/Record ................... 79
Driven Equipment - Check .................................... 81
Electrohydraulic System - Check/Adjust ............... 84
Electrohydraulic System Oil - Change .................. 84
Electrohydraulic System Oil Filter - Change ......... 85
Engine Oil - Change ............................................. 90
Engine Oil Filter - Change .................................... 92
Engine Protective Device Connections - Inspect .. 96
Engine Protective Devices - Check ...................... 98
Exhaust Bypass - Recondition ............................ 101
Gas Shutoff Valve - Inspect ................................ 103
Inlet Air System - Inspect .................................... 108
Inlet Gas Manifold and Piping - Inspect/Replace .. 109
Prechamber Check Valves - Clean ...................... 116
Starting Motor - Inspect ....................................... 117
Turbocharger - Inspect ......................................... 118
SEBU7563-07 61
Maintenance Section
Maintenance Interval Schedule

Every 10 000 Service Hours

Alternator - Inspect ............................................... 67
Cooling System Water Temperature Regulator -
Replace ............................................................... 77
Electrohydraulic Actuator - Inspect ....................... 81
Engine Oil Temperature Regulator - Replace ....... 96
Engine Speed/Timing Sensor - Clean/Inspect ...... 99
Exhaust Shields - Inspect ................................... 101
Gas Pressure Regulator - Inspect/Replace ........ 103
Prechamber Check Valves - Replace .................. 116
Prelube Pump - Inspect ....................................... 116
Water Pump - Inspect ......................................... 121

Every 15 000 Service Hours

Gas Admission Valve Seals - Inspect/Replace ... 102
Overhaul (Top End) .............................................. 112
Prechamber - Clean/Inspect ................................ 115

Every 20 000 Service Hours or 3 Years

Cooling System Coolant (NGEC) - Change .......... 72

Between 45 000 and 48 000 Service Hours

Electrohydraulic Actuator - Recondition ................ 82
Gas Admission Valve - Recondition .................... 102
Overhaul (In-Frame) ........................................... 109

Between 75 000 and 80 000 Service Hours

Overhaul (Major) .................................................. 111

Overhaul
Connecting Rod Bearings - Inspect/Replace ........ 72
62
Maintenance Section
Maintenance Interval Schedule
i02599595
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
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICHEVER OCCURS FIRST,
in order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
When Required
Actuator Control Linkage - Replace ...................... 64
Barring Device - Lubricate .................................... 67
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 75
Engine Air Cleaner Element (Single Element) -
Clean/Replace .................................................... 86
Engine Air Precleaner - Clean .............................. 89
Engine Oil - Change ............................................. 90
Engine Oil Filter - Change .................................... 92
Overhaul Considerations ..................................... 113
Valve Stem Projection - Measure/Record ........... 120
Daily
Air Starting Motor Lubricator Oil Level - Check .... 66
Air Tank Moisture and Sediment - Drain ............... 67
Control Panel - Inspect ......................................... 72
Cooling System Coolant Level - Check ................ 74
Driven Equipment - Inspect/Replace/Lubricate ... 81
Electrohydraulic System - Inspect ........................ 84
Engine Air Cleaner Service Indicator - Inspect ..... 88
Engine Oil Level - Check ...................................... 95
Fuel System Fuel Filter Differential Pressure -
Check ................................................................ 101
Turbocharger - Clean ........................................... 118
Walk-Around Inspection ...................................... 121
SEBU7563-07
Every 125 Service Hours
Engine Oil Sample - Obtain .................................. 95
Every 250 Service Hours
Battery Electrolyte Level - Check .......................... 69
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 75
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 76
Initial 1000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 65
Air Starting Motor Lubricator Bowl - Clean ........... 65
Crankcase Blowby - Measure/Record .................. 78
Cylinder Pressure - Measure/Record ................... 79
Electrohydraulic System Oil Filter - Change ......... 85
Engine Crankcase Breather - Clean ..................... 90
Engine Protective Device Connections - Inspect .. 96
Engine Speed/Timing Sensor - Clean/Inspect ...... 99
Engine Valve Lash - Inspect/Adjust ...................... 99
Engine Valve Rotators - Inspect ......................... 100
Valve Stem Projection - Measure/Record ........... 120
Every 1000 Service Hours
Actuator Control Linkage - Lubricate .................... 64
Belts - Inspect/Adjust/Replace .............................. 69
Combustion Sensor - Clean/Inspect/Replace ....... 70
Hoses and Clamps - Inspect/Replace ................ 104
Ignition System Spark Plugs - Replace .............. 108
Prechamber Check Valves - Clean ...................... 116
Every 2000 Service Hours
Aftercooler Condensation - Drain ......................... 65
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 75
Crankshaft Vibration Damper - Inspect ................. 78
Cylinders - Inspect ................................................ 80
Engine Crankcase Breather - Clean ..................... 90
Engine Mounts - Check ........................................ 90
Engine Valve Lash - Inspect/Adjust ...................... 99
Engine Valve Rotators - Inspect ......................... 100
Valve Stem Projection - Measure/Record ........... 120
Every 5000 Service Hours
Air Starting Motor Lines Screen - Clean ............... 65
Air Starting Motor Lubricator Bowl - Clean ........... 65
Cooling System Level Switch - Inspect ................. 76
Crankcase Blowby - Measure/Record .................. 78
Cylinder Pressure - Measure/Record ................... 79
Driven Equipment - Check .................................... 81
Electrohydraulic System - Check/Adjust ............... 84
Electrohydraulic System Oil - Change .................. 84
Electrohydraulic System Oil Filter - Change ......... 85
Engine Protective Device Connections - Inspect .. 96
Engine Protective Devices - Check ...................... 98
Exhaust Bypass - Recondition ............................ 101
Gas Shutoff Valve - Inspect ................................ 103
SEBU7563-07 63
Maintenance Section
Maintenance Interval Schedule

Inlet Air System - Inspect .................................... 108

Inlet Gas Manifold and Piping - Inspect/Replace .. 109
Prechamber Check Valves - Replace .................. 116
Starting Motor - Inspect ....................................... 117
Turbocharger - Inspect ......................................... 118
Turbocharger Cleaner Tube - Replace ............... 120

Between 10 000 and 14 000 Service Hours

Gas Admission Valve Seals - Inspect/Replace ... 102
Overhaul (Top End) .............................................. 112
Prechamber - Clean/Inspect ................................ 115

Every 10 000 Service Hours

Alternator - Inspect ............................................... 67
Cooling System Water Temperature Regulator -
Replace ............................................................... 77
Electrohydraulic Actuator - Inspect ....................... 81
Engine Oil Temperature Regulator - Replace ....... 96
Engine Speed/Timing Sensor - Clean/Inspect ...... 99
Exhaust Shields - Inspect ................................... 101
Gas Pressure Regulator - Inspect/Replace ........ 103
Prelube Pump - Inspect ....................................... 116
Water Pump - Inspect ......................................... 121

Every 20 000 Service Hours or 3 Years

Cooling System Coolant (NGEC) - Change .......... 72

Between 27 000 and 33 000 Service Hours

Electrohydraulic Actuator - Recondition ................ 82
Gas Admission Valve - Recondition .................... 102
Overhaul (In-Frame) ........................................... 109

Between 36 000 and 44 000 Service Hours

Gas Admission Valve Seals - Inspect/Replace ... 102
Overhaul (Top End) .............................................. 112

Between 52 000 and 54 000 Service Hours

Overhaul (Major) .................................................. 111

Overhaul
Connecting Rod Bearings - Inspect/Replace ........ 72
64 SEBU7563-07
Maintenance Section
Actuator Control Linkage - Lubricate

i02601608 i02236400

Actuator Control Linkage - Actuator Control Linkage -

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

Note: Use of a platform may be necessary to reach

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

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

Note: The exhaust heat shields must be in place and

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

Hydraulic Actuators

g00799207
Illustration 41
Typical example of rod ends on an actuator and on the linkage
for an actuator

For instructions on removal and installation of the

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

g01120800
Illustration 40
Typical locations of grease fittings
SEBU7563-07 65
Maintenance Section
Aftercooler Condensation - Drain

i01762572 i01762654

Aftercooler Condensation - Air Starting Motor Lines

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

The aftercooler is similar to a radiator. Coolant

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

Condensation can form in the passages of the

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

g00789123
Illustration 44
(1) Plug
(2) Screen

If the engine is equipped with an air starting motor,

use the following procedure:

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

2. Remove plug (1).

g00788934
Illustration 42
A drain plug is located on the right side near the rear of the engine.
3. Carefully remove screen (2). Clean the screen
with nonflammable solvent. Inspect the screen for
(1) Plug
damage. If the screen is damaged, replace the
damaged screen with a new screen.

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

the plug.

i02581222

Air Starting Motor Lubricator

Bowl - Clean
SMCS Code: 1451-070

If the engine is equipped with an air starting motor,

g00788946 use the following procedure:
Illustration 43
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.

66 SEBU7563-07
Maintenance Section
Air Starting Motor Lubricator Oil Level - Check

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

bowl is cracked, replace the damaged bowl with
a new bowl. Inspect the gasket. If the gasket is
Personal injury can result from removing hoses or
damaged, replace the gasket.
fittings in a pressure system.
6. Install the bowl.
Failure to relieve pressure can cause personal in-
jury.
7. Make sure that drain valve (3) is closed.
Do not disconnect or remove hoses or fittings un-
8. For instructions on filling the lubricator, see this
til all pressure in the system has been relieved.
Operation and Maintenance Manual, “Air Starting
Motor Lubricator Oil Level - Check” topic.
1. Ensure that the air supply to the lubricator is OFF.
i02213914

Air Starting Motor Lubricator

Oil Level - Check
SMCS Code: 1451-535

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

g00745554
Illustration 45
(1) Filler plug
(2) Bowl
(3) Drain valve

2. Slowly loosen filler plug (1) in order to release the

pressure from the lubricator.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- g00745561
Illustration 46
ing any compartment or disassembling any compo-
nent containing fluids. 1. Observe the oil level in sight gauge (3). If the oil
level is less than 1/2, add oil to the lubricator bowl.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Personal injury can result from removing hoses or
Dispose of all fluids according to local regulations and fittings in a pressure system.
mandates.
Failure to relieve pressure can cause personal in-
jury.
3. Place a suitable container under bowl (2) and
open drain valve (3) in order to drain the oil from Do not disconnect or remove hoses or fittings un-
the bowl. til all pressure in the system has been relieved.
4. Remove bowl (2). Clean the bowl with warm water.
2. Ensure that the air supply to the lubricator is OFF.
Slowly loosen filler plug (4) in order to release
pressure from the lubricator bowl.
SEBU7563-07
3. Remove filler plug (4). Pour oil into the lubricator
bowl. Use nondetergent SAE 10W oil for
temperatures that are greater than 0 °C (32 °F).
Use air tool oil for temperatures that are below
0 °C (32 °F).
4. Install filler plug (4).
Adjust the Lubricator
Note: Adjust the lubricator with a constant rate of air
flow. After the adjustment, the lubricator will release
oil in proportion to variations of the air flow.
1. Ensure that the fuel supply to the engine is OFF.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
2. Operate the air starting motor. Observe the drops
of oil that are released in dome (1).
Note: Some lubricators have an adjustment screw
rather than a knob.
3. If necessary, adjust the lubricator in order
to release from one to three drops of oil per
second. To increase the rate, turn knob (2)
counterclockwise. To decrease the rate, turn the
knob clockwise.
i00351324
Air Tank Moisture and
Sediment - Drain
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 cloth-
ing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal
injury.
67
Maintenance Section
Air Tank Moisture and Sediment - Drain
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
Alternator - Inspect
SMCS Code: 1405-040
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.
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.
68 SEBU7563-07
Maintenance Section
Barring Device - Lubricate

Lubricating the Reducer

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

Electric Barring Device

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

g00991445
Illustration 49

1. Ensure that the barring device is locked in the

disengaged position.

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

level.

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

4C-6767 Synthetic Oil until the oil is visible at the
level plugs.
g00334420
Illustration 47
Rear view of an electrically driven barring device 4. Reinstall the level plugs and reinstall the cap.

Lubricating the Pinion Manual Barring Device

g01098831 g01098833
Illustration 48 Illustration 50
Section view of a barring device without the electric motor (1) Grease fitting
(1) Grease fitting (2) Gear end
(2) Vent
1. Ensure that the barring device is locked in the
1. Ensure that the barring device is locked in the disengaged position.
disengaged position.
2. Lubricate grease fitting (1) with Cat Advanced
2. Lubricate grease fitting (1) with Cat Advanced 3Moly Grease until the grease is visible at gear
3Moly Grease until the grease is visible at vent (2). end (2).
SEBU7563-07 69
Maintenance Section
Battery Electrolyte Level - Check

i02601752 i02601764

Battery Electrolyte Level - Belts - Inspect/Adjust/Replace

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.
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

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.
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:

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

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

Clean the battery case with one of the following

cleaning solutions:

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

1 L (1 qt) of clean water

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

(1 qt) of clean water

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean the

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

g01092641
Illustration 51
Typical alternator
(1) Mounting bolt
(2) Adjusting nuts
(3) Mounting bolt

1. Remove the drive belt guard.

70 SEBU7563-07
Maintenance Section
Combustion Sensor - Clean/Inspect/Replace

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

mounting bolt (3).

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

decrease the drive belt tension.

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

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

5. Reinstall the drive belt guard.

If new drive belts are installed, check the drive belt

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

Adjusting the Fan Drive Belt

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

Replacement
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
g00789241
drive belt to carry more load because the older drive Illustration 52
belts are stretched. The additional load on the new Section view of a cylinder head with a combustion sensor
drive belt could cause the new drive belt to fail. (1) Harness connector
(2) Connector
(3) Extension
i02601781 (4) Sensor
(5) Gasket
Combustion Sensor - (6) Discs

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

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

1. Disconnect harness connector (1) from connector

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

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

connector’s adapters.

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

extension.
SEBU7563-07
Pressurized air can cause personal injury. When
pressurized air is used for cleaning, wear a pro-
tective face shield, protective clothing, and pro-
tective 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.
Illustration 53
g00789274
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.
71
Maintenance Section
Combustion Sensor - Clean/Inspect/Replace
Light brown deposits or beige deposits around the
electrode is produced by normal operation. White
deposits or gray deposits may be caused by the
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.
• 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).
72 SEBU7563-07
Maintenance Section
Connecting Rod Bearings - Inspect/Replace

i02243193
NOTICE
Connecting Rod Bearings - Use of commercially available cooling system clean-
Inspect/Replace ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
SMCS Code: 1219-040; 1219-510 proved for Caterpillar engines.

The condition of the connecting rod bearings will

vary depending on the engine application and Drain the Cooling System
the operating conditions. During every overhaul,
bearings should be inspected in order to determine if 1. Stop the engine and allow the engine to cool.
the bearings can be reused. Refer to Guidelines for Ensure that the engine will not start when the
Reusable Parts, SEBF8009, “Main and Connection cooling system is drained.
Rod Bearings” for determining bearing reusability.
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
i01762721
system filler cap.
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 Illustration 54
g00792409

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

i02601979

Cooling System Coolant

(NGEC) - Change
SMCS Code: 1350-044

Clean the cooling system before the recommended

maintenance interval if the following conditions exist:
• The engine overheats frequently.
• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
g00901833
Illustration 55
Location of drain plug for the jacket water system
3. Open the cooling system drain valves (if
equipped). Remove the cooling system drain
plugs. Allow the coolant to drain.
SEBU7563-07
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
Clean the Cooling System
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the cooling system drain valves (if
equipped). Clean the cooling system drain plugs
and install the cooling system drain plugs.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute in order to avoid air locks. Proper venting
of the cooling system is essential to fill at this rate.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
4. Start the engine. Operate the engine for a
minimum of 30 minutes with a coolant temperature
of at least 82 °C (180 °F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valves (if equipped). Remove the cooling system
drain plugs. Allow the water to drain.
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
73
Maintenance Section
Cooling System Coolant (NGEC) - Change
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.
2. Close the cooling system drain valves (if
equipped). Clean the cooling system drain plugs
and install the cooling system drain plugs.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
(1 to 2 US gal) of the cooling system capacity.
Install the cooling system filler cap.
4. Start the engine. Operate the engine for a
minimum of 90 minutes with a coolant temperature
of at least 82 °C (180 °F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valves (if equipped). Remove the cooling system
drain plugs. Allow the water to drain.
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. 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.
74 SEBU7563-07
Maintenance Section
Cooling System Coolant Level - Check

Fill the Cooling System Engines That Are Equipped With a

Sight Gauge
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 Illustration 56

purge the air from the cavities of the engine block.
Allow the coolant to warm and allow the coolant
level to stabilize. Stop the engine.
3. Check the coolant level. Maintain the coolant to
the proper level on the sight gauge (if equipped).
If a sight gauge is not equipped, maintain the
coolant to the level that is specified by the OEM
of the cooling system.
g00750429
(1) Filler cap
(2) Sight gauge
If the engine is equipped with a sight gauge, observe
the position of the coolant in the sight gauge. At
normal operating temperature, the proper coolant
level is in the upper half of the sight gauge. If the
coolant level is low, add the proper coolant mixture.

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
Pressurized System: Hot coolant can cause seri-
ous 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 pres-
sure.

5. Start the engine. Inspect the cooling system for

Check the coolant level when the engine is stopped
leaks and for proper operating temperature.
and cool. Check the coolant level only after the
engine has been stopped and the cooling system
i02062976 filler cap is cool enough to touch with your bare hand.

Cooling System Coolant Level
- Check
SMCS Code: 1350-535-FLV
Climbing equipment may be required to access
this service point. Refer to the Operation and
Maintenance Manual, “Mounting and Dismount-
ing” topic for safety information.
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.
SEBU7563-07
2. Remove the cooling system filler cap slowly in
order to relieve any pressure. Pour the proper
coolant mixture into the filler pipe.
g00103639
Illustration 57
Gaskets
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 incor-
rect 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.
75
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
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 incor-
rect 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.
76
Maintenance Section
Cooling System Level Switch - Inspect
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.
If the coolant level is low, coolant must be added to
the expansion tank or the heat exchanger.
g00789360
Illustration 58
(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).
SEBU7563-07
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.
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 supple-
mental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Follow the instructions
that are provided in the kit.
Water and SCA
NOTICE
Do not exceed the recommended eight percent sup-
plemental 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.
SEBU7563-07 77
Maintenance Section
Cooling System Water Temperature Regulator - Replace

4. Add 2 to 3 drops of the “NITRITE INDICATOR

SOLUTION B” to the mixing bottle. Move the bottle NOTICE
in a circular motion in order to mix the solution. Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
5. Add 1 drop of “NITRITE TEST SOLUTION A” to faces of the cooling system, reducing the engine’s
the mixing bottle. Move the bottle in a circular heat transfer characteristics. Reduced heat transfer
motion in order to mix the solution. could cause cracking of the cylinder head and other
high temperature components.
6. Repeat 5 until the solution changes color from red
to light gray, green, or blue. Record the number of Excessive supplemental coolant additive concentra-
drops of “NITRITE TEST SOLUTION A” that were tion could also result in blockage of the heat exchang-
required to cause the color change. er, overheating, and/or accelerated wear of the water
pump seal.
7. Use Table 37 to interpret the results.
Do not exceed the recommended amount of supple-
Table 37
mental coolant additive concentration.
Number of Concentration Maintenance
Drops of SCA Required
3. Add the proper amount of SCA. The concentration
Less than 25 Less than the Add SCA. of the SCA depends on the type of coolant that
recommended Retest the is used. To determine the proper amount, see
concentration of coolant. this Operation and Maintenance Manual, “Refill
SCA Capacities and Recommendations” topic.
25 to 30 The None
recommended 4. Clean the cooling system filler cap. Install the
concentration of cooling system filler cap.
SCA
More than 30 More than the Remove the i02168842
recommended coolant.
concentration of Replace with Cooling System Water
SCA water only
Retest the Temperature Regulator -
coolant. Replace
SMCS Code: 1355-510
Add the SCA, If Necessary
Replace the water temperature regulators for these
systems:

Pressurized System: Hot coolant can cause seri- • Jacket water

ous 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 pres-
sure.
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.
• 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.
78
Maintenance Section
Crankcase Blowby - Measure/Record
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 en-
gine damage.
Never operate an engine without the water tempera-
ture regulator installed.
If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
i02602965
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
SEBU7563-07
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.
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.
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.
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.
SEBU7563-07
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.
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.
• The damper is dented, cracked, or leaking.
• The paint on the damper is discolored from heat.
• The engine has had a failure because of a broken
crankshaft.
• 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.
79
Maintenance Section
Cylinder Pressure - Measure/Record
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.
• 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
• 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.
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.
80
Maintenance Section
Cylinders - Inspect
Illustration 59 is a graph of typical cylinder pressures
for engines with different compression ratios.
g00789376
Illustration 59
(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.
SEBU7563-07
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.
When possible, insert the borescope through the
opening in the cylinder head for the prechamber
assembly and the ignition body. This location
will provide the best possible view of the entire
combustion chamber. This requires draining the
coolant to a level below the cylinder head. If this
is not possible, insert the borescope through the
opening for the combustion sensor. Look for the
following conditions:
• Valve wear
• Deposits on the valve seat
• Deposits on the valve face
• Polishing of the cylinder walls
• Scratching of the cylinder walls
• Deposits on the cylinder walls that are above the
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.
SEBU7563-07 81
Maintenance Section
Driven Equipment - Check

i02602013 • Caterpillar
Driven Equipment - Check • OEM of the coupling
SMCS Code: 3279-535 • OEM of the driven equipment
Every 5000 Service Hours i00935098

Engines That Are Not Attached To the Driven Equipment -

Base with a Dowel Inspect/Replace/Lubricate
If some engines are too rigidly mounted, excessive SMCS Code: 3279-040
stress may affect the internal support of the cylinder
block. This could cause the following problems: Observe the driven equipment during operation. Look
for the following items:
• 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 Perform any maintenance that is recommended
dowel, check the following: by the OEM of the driven equipment. Refer to the
literature of the OEM of the driven equipment for the
• Check the alignment after every 5000 service following service instructions.
hours.
• Inspection
• Inspect the drive coupling according to the
specifications of the OEM. • Lubricating grease and lubricating oil requirements

Every 10,000 Service Hours • Specifications for adjustment

Engines That Are Attached To the Base • Replacement of components

with a Dowel • Requirements for ventilation
Some engines must be more rigidly mounted. Due to
thermal expansion, a cold engine will expand after i01610487
the engine achieves operating temperature.
Electrohydraulic Actuator -
Some engines are attached to the base with a dowel Inspect
in the rear mounting support. This installation forces
the thermal growth forward. The driven equipment SMCS Code: 1716-040
is also attached with a dowel in order to maintain
alignment with the engine. 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 During operation, the linkage of the electrohy-

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.
draulic 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:
82 SEBU7563-07
Maintenance Section
Electrohydraulic Actuator - Recondition

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”.
g00833473
Illustration 60 8. Install boot (7). Make sure that the outer end of
(1) Receptacle for the wiring harness the boot folds inward when the actuator’s shaft
(2) Solenoid moves from the fully open position to the fully
(3) Bolt
(4) Guards closed position.

1. Disconnect the wiring harness from receptacle (1). 9. Install clevis (6). Connect rod end (5) to the clevis.
Inspect the connectors for damage and corrosion.
Make repairs, if necessary. 10. Install guards (4).

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).
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 electrohy-

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

g00833477
Illustration 61
(5) Rod end
(6) Clevis
(7) Boot

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

6. Remove clevis (6).

SEBU7563-07 83
Maintenance Section
Electrohydraulic Actuator - Recondition

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.

g00833592
Illustration 62
(1) Receptacle for the wiring harness
(2) Guards
g00833595
Illustration 64
1. Disconnect the wiring harness from receptacle (1). (7) Housing
Inspect the connectors for damage and corrosion. (8) Piston assembly
Make repairs, if necessary. (9) O-ring seal
(10) Bolt
2. Remove guards (2). (11) Solenoid
(12) O-ring seal

3. Disconnect the supply line (not shown) and the

Note: The spring in the housing will be loose after
return line (not shown) for the hydraulic oil.
the piston assembly is removed.

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

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

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

assembly.

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

(8). Make sure that the spring in the housing is
properly aligned in the bore of the piston. Tighten
the piston assembly according to the engine’s
Specifications.
g00833594
Illustration 63
9. Remove bolts (10) in order to remove solenoid
(3) Rod end
(4) Clevis
(11). Remove O-ring seal (12) from the joint
(5) Boot between the solenoid and the housing.
(6) Nut
10. Install a new O-ring seal (12) and solenoid (11).
4. Disconnect rod end (3) from clevis (4). Install bolts (10). Tighten the bolts according to
the engine’s Specifications.
5. Remove clevis (4) and rubber boot (5). Inspect the
boot for damage. If the boot is damaged, obtain a 11. Install the actuator in the bracket with nut (6).
new boot for assembly.
12. Install boot (5). Make sure that the outer end of
Note: Handle the actuator carefully. Use care not to the boot folds inward when the actuator’s shaft
damage the actuator’s shaft. Damage to the shaft moves from the fully open position to the fully
can result in premature failure of the O-ring seal. This closed position.
will cause hydraulic fluid to leak.
13. Install clevis (4). Connect rod end (3) to the clevis.
6. Remove nut (6) in order to remove the actuator
from the bracket. 14. Install guards (2).
84 SEBU7563-07
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
Note: For the proper oil to use, refer to this Operation
and Maintenance Manual, “Refill Capacities and
Recommendatons” topic (Maintenance Section).
2. If necessary, remove the oil filler cap. Pour the
correct oil into the oil filler.

Electrohydraulic System - 3. Clean the oil filler cap. Install the oil filler cap.

Check/Adjust Inspect the Lines, Connections,

SMCS Code: 1716-025; 1716-535 and Components
Check the Pressure Relief Valve
Check the pressure relief valve for the hydraulic The linkage can move and form a pinch point
system according to the procedure that is in Systems which can cause personal injury. Keep hands
Operation/Testing and Adjusting. Adjust the pressure away from the linkage.
according to the instructions.
Inspect the hoses and lines for wear and leaks.
i02214104 Ensure that the hoses and lines are properly
clamped. Inspect the connections for leaks. Ensure
Electrohydraulic System - that the connections are secure.
Inspect
Inspect the following items for leaks and good
SMCS Code: 1716-040 condition:

Inspect the conditions of these items for the • Actuators

electrohydraulic system:
• Pressure relief valve
• Oil level
• Pump
• Hoses, lines, connections, and components
Make repairs, if necessary.

i02603161

Electrohydraulic System Oil -

Change
SMCS Code: 1716-510-OC

Ensure that the engine cannot start during this

procedure.

g00792283
Illustration 65
(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.
SEBU7563-07 85
Maintenance Section
Electrohydraulic System Oil Filter - Change

i02246458

Electrohydraulic System Oil

Filter - Change
SMCS Code: 1716-510-FI

g00792335
Illustration 66
(1) Oil filler cap
(2) Valve

1. Remove oil filler cap (1).

Note: Drain the oil into a suitable container. Dispose Illustration 67

g00792302
of fluids according to local regulations.
(1) Filter
(2) Sight gauge
2. Place a suitable container under valve (2). Open (3) Filler cap
the valve. Allow the oil to drain. After the oil has
drained, close the valve. 1. Remove filter (1) with a 1U-8760 Chain Wrench.

Note: For the proper oil to use, refer to the Special 2. Clean the sealing surface of the filter mounting
Publication, SEBU6400, “Caterpillar Gas Engine base. Ensure that all of the old filter gasket is
Lubricant, Fuel and Coolant Recommendations” . removed.

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.

g00103713
Illustration 68
Typical filter mounting base and gasket

Note: For the proper oil to use, refer to this Operation

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

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.
86
Maintenance Section
Engine Air Cleaner Element (Single Element) - Clean/Replace
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.
i02169249
Engine Air Cleaner
Element (Single Element) -
Clean/Replace
SMCS Code: 1051; 1054-037
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne 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
accumulation of dirt and debris. Remove any dirt
and debris, as needed.
• Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner
element.
• The air cleaner element may be cleaned up to
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.
SEBU7563-07
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”.
2. Cover the air inlet with tape in order to keep dirt
out.
3. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
4. Remove the tape for the air inlet. Install an air
cleaner element that is new or cleaned.
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 ser-
vices that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to re-
move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
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.
SEBU7563-07 87
Maintenance Section
Engine Air Cleaner Element (Single Element) - Clean/Replace

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 el-
ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
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”.

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

There are two common methods that are used to

clean air cleaner elements:

• 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).
g00281693
Illustration 70
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.

g00281692
Storing Air Cleaner Elements
Illustration 69
If an air cleaner element that passes inspection will
Note: When the air cleaner elements are cleaned, not be used, the air cleaner element can be stored
always begin with the clean side (inside) in order to for future use.
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”.

88 SEBU7563-07
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

g00281694 g00294189
Illustration 71 Illustration 72
(1) Service indicator
Do not use paint, a waterproof cover, or plastic as a (2) Cover
protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, 1. Remove cover (2).
wrap the air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper. 2. Remove the used element and dispose of the
element.
Place the air cleaner element into a box for storage.
For identification, mark the outside of the box and 3. Clean the inside of cover (2) and clean the inside
mark the air cleaner element. Include the following of the body.
information:
4. Install a new element. Install cover (2).
• Date of cleaning
5. Reset service indicator (1), if necessary.
• Number of cleanings
i01520297
Store the box in a dry location.
Engine Air Cleaner Service
Crankcase Air Cleaner Indicator - Inspect
Engines that are equipped with positive crankcase
SMCS Code: 7452-040
ventilation have an air cleaner for crankcase
ventilation. Clean the air cleaner element or replace
Some engines are equipped with an air cleaner for
the air cleaner element when the following conditions
crankcase ventilation.
occur:
This air cleaner filters air that is drawn into the
• The yellow diaphragm enters the red zone. crankcase. The air dilutes the harmful fumes that
may accumulate in the crankcase. The air and the
• The red piston locks in a visible position. fumes are drawn away from the crankcase.
• The air restriction reaches 0.25 kPa (1 inch of H2O).
SEBU7563-07 89
Maintenance Section
Engine Air Precleaner - Clean

g00789538 g00351792
Illustration 73 Illustration 74
Service indicator Porous filter

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
(1 inch of H2O).
Inspect the service indicator daily for cracks, holes, or
loose fittings. If any of these conditions are present,
repair the service indicator or replace the service
indicator.
Test the Service Indicator
Service indicators are important instruments.
• Check for ease of resetting. The service indicator
should reset in less than three pushes.
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.
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

• Check the movement of the yellow core when the Note: More frequent cleaning may be required in
engine is accelerated to the engine rated rpm. dusty environments.
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.

g00476231
Illustration 75
(1) Clip
(2) Cup
90 SEBU7563-07
Maintenance Section
Engine Crankcase Breather - Clean

1. Loosen clips (1). Remove cup (2).
2. Clean the inside of the cup.
3. Install the cup. Fasten the clips.
i01765695
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.

Engine Crankcase Breather - i01612978

Clean Engine Mounts - Check

SMCS Code: 1317-070 SMCS Code: 1152-535
If the crankcase breather is not maintained on a
Check the torque of the bolts for the mounting
regular basis, the crankcase breather will become plates. For the proper torque, refer to Gas Engines
plugged. A plugged crankcase breather will cause
Application and Installation Guide, LEKQ7252,
excessive crankcase pressure that can shut down
“G3600 Mounting, Alignment”.
the engine. Leakage of the crankshaft seal can occur.
Engine vibration can be caused by the following
Note: Use of a platform may be necessary to reach
conditions:
the engine crankcase breather.

Perform this maintenance when the engine is • Improper mounting of the engine
stopped.
• 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,

g00789623 LEKQ7252, “G3600 Mounting, Alignment”
Illustration 76
(1) Breather assembly
(2) Tee
• Special Instruction, SEHS9162, “Spring Isolator
(3) Hose clamp Group Installation and Adjustment Procedure”
(4) O-ring seal
(5) Retaining clamp Consult your Caterpillar dealer for assistance.

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

(3). Remove breather assemblies (1) and O-ring i02602019

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).
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.
SEBU7563-07
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
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact
skin.
NOTICE
Ensure that the engine is stopped before performing
this procedure. Attach a DO NOT OPERATE tag to the
starting controls.
Do not drain the oil when the engine is cold. As the
oil cools, suspended waste particles settle on the
bottom of the oil pan. The waste particles are not
removed when the cold oil is drained. Drain the
crankcase with the oil warm. This draining method
allows the waste particles that are suspended in the
oil to be drained properly.
Failure to follow this recommended procedure will
allow the waste particles to be recirculated through
the engine lubrication system with the new oil.
1. After the engine has been operated at normal
operating temperature, STOP the engine.
Note: Drain the oil into a suitable container. Dispose
of fluids according to local regulations.
g00789667
Illustration 77
(1) Drain valve
2. Open drain valve (1) in order to drain used oil.
After the oil has drained, close drain valve (1).
91
Maintenance Section
Engine Oil - 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.
Illustration 78
g00789729
(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).
92 SEBU7563-07
Maintenance Section
Engine Oil Filter - Change

Service tools are available to aid in the service of oil

NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip-
stick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction 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. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
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 in-
jury.
Do not allow hot oil or components to contact
skin.

If the oil level is above the “FULL” mark on the oil level Perform the following procedure after the oil has
gauge, drain some of the oil immediately. been drained.

Note: Use this procedure if the engine oil filters do

Note: For the amount of oil to use, refer to not have a control valve.
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” (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 g00789754
Illustration 79
the sump for a minimum of ten minutes. (1) Pressure gauge
(2) Drain
8. Remove the oil level gauge and check the oil level. (3) Cover
Maintain the oil level above the “ADD” mark. (4) Control valve

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

i01520518 suitable container in order to catch the oil.
Engine Oil Filter - Change 2. Open both drain valves (2). Allow the oil to drain.
SMCS Code: 1308-510; 1308 Note: Some oil will remain in the housing after the oil
has been drained. This oil will pour out of the housing
Replace the engine oil filters when the following when cover (3) is removed. Prepare to catch the oil
conditions are met: in a suitable container. Clean up any spilled oil with
rags. DO NOT use absorbent particles to clean up
• Every oil change the oil.
• The engine oil filter differential pressure reaches
100 kPa (15 psi).
SEBU7563-07
Personal injury can result from parts and/or cov-
ers under spring pressure.
Spring force will be released when covers are re-
moved.
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.
g00789772
Illustration 80
(5) Wire rack
(6) O-ring seal
(7) Element
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 speci-
fications. 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.
93
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 per-
sonal injury.
If rapid air movement exists to blow fluid, Stop the
engine to avoid fire.
If it is necessary to replace the oil filters during engine
operation, perform the following procedure.
g00789754
Illustration 81
(1) Pressure gauge
(2) Drain
(3) Cover
(4) 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.
94
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 cov-
ers under spring pressure.
Spring force will be released when covers are re-
moved.
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.
g00789772
Illustration 82
(5) Wire rack
(6) O-ring seal
(7) Element
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.
SEBU7563-07
NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. 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).
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.
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.
SEBU7563-07
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.
Illustration 83
g00789822
(1) Oil level gauge
(2) Oil filler
g01140702
Illustration 84
(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.
95
Maintenance Section
Engine Oil Level - Check
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 (dip-
stick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction 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. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately.
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.
i01935337
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.
96 SEBU7563-07
Maintenance Section
Engine Oil Temperature Regulator - Replace

Obtain the Sample and the Analysis
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
For instructions, see Special Publication, PEHP6001,
“How To Take A Good Oil Sample”. Consult your
Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
i00839584

Engine Oil Temperature

Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order Regulator - Replace
to help obtain the most accurate analysis, provide
the following information: SMCS Code: 1330-510

• Engine model The oil temperature regulators divert the engine

oil to the oil cooler in order to maintain engine oil
• Service hours on the engine temperature.

• 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
For instructions on replacing the oil temperature
regulators, see the Service Manual, “Disassembly
and Assembly” module.
i02601497

To ensure that the sample is representative of the Engine Protective Device

oil in the crankcase, obtain a warm, well mixed oil
sample. Connections - Inspect
To avoid contamination of the oil samples, the tools SMCS Code: 7400-040
and the supplies that are used for obtaining oil
samples must be clean. Inspect the wiring and the electrical connections for
these components:
Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the • Connectors
consistency of the samples are better when the
sampling valve is used. The location of the sampling • Control panel
valve allows oil that is flowing under pressure to be
obtained during normal engine operation. • Junction box

The 169-8373 Fluid Sampling Bottle is • Sensors

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 incor-
rect 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.
SEBU7563-07 97
Maintenance Section
Engine Protective Device Connections - Inspect

g00449867 g01302112
Illustration 85 Illustration 86
Typical examples of electrical connectors Inside of control panel (front)
(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 g01201607
Illustration 87
• Damaged insulation Inside of control panel (rear)
(1) Terminal strips
• Corrosion
3. Check the wiring for secure connections at these
Make repairs, as needed. points of the junction box and the control panel:

• Connectors
• Relays
• Switches
• Terminal strips
98
Maintenance Section
Engine Protective Devices - Check
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.
Investigate the source of the corrosion. Correct
the condition.
If damage is found, replace the part.
b. Remove frayed strands of wire or tin the wire.
c. Perform Steps 6 and 7 for the connectors of
the control panel and the junction box.
5. Check the wiring for secure connections at these
points:
• Connectors
• Sensors
Perform a pull test for each wire. This test will
ensure that the wiring is properly attached. Test
each wire individually.
a. For wiring that is attached to a connector, hold
the body of the connector with one hand. Pull
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
SEBU7563-07
• 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:
• The connection is threaded properly.
• 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.
• 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.
SEBU7563-07
NOTICE
During testing, abnormal operating conditions must be
simulated.
The tests must be performed correctly in order to pre-
vent 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.
i01762818
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.
g00901865
Illustration 88
(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.
99
Maintenance Section
Engine Speed/Timing Sensor - Clean/Inspect
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.
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.
Note: Use of a platform may be necessary for these
procedures.
Check the Timing of the Crankshaft
and Camshaft
The timing of the crankshaft and camshaft must be
checked, and the valve bridge must be adjusted
before the valve lash is adjusted.
NOTICE
If the camshaft is rotated with the timing pin installed,
the timing pin will break. This can result in further dam-
age. Make sure to remove the timing pin before the
camshaft is rotated.
NOTICE
DO NOT use the starting motor to rotate the crank-
shaft. 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.
100 SEBU7563-07
Maintenance Section
Engine Valve Rotators - Inspect

Gas Admission Valve

NOTICE
The prelube pump should not be operated continu-
ously 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.
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.
i01765711

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

Perform this procedure after the valve lash has been

Valve Bridge set.

NOTICE 1. Mark the tops of the valve rotators with a

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

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.
SEBU7563-07 101
Maintenance Section
Exhaust Bypass - Recondition

i01765718
NOTICE
Exhaust Bypass - Recondition The exhaust shields can be damaged if work is per-
formed on the exhaust shields or around the exhaust
SMCS Code: 1057-020
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
g00799396
procedure to remove the exhaust shields and install
Illustration 89 the exhaust shields.
Typical example
(1) Rod ends
(2) Cover and seal i02602064
(3) Shaft
Fuel System Fuel Filter
Note: Use of a platform may be necessary in order to Differential Pressure - Check
reach the components of the exhaust bypass.
SMCS Code: 1261-535
Replace the following parts:
If the engine is equipped with a fuel filter, a fuel filter
• Rod ends (1) differential pressure gauge must be installed. The fuel
filter differential pressure gauge is installed in order to
• Cover and seal (2) determine when the fuel filter requires service. This
gauge and the fuel filter are supplied by the customer.
• Shaft (3)
A fuel filter differential pressure gauge indicates the
For instructions on assembling the exhaust bypass, difference in fuel pressure between the inlet side
refer to the Specifications. and the outlet side of the fuel filter. The differential
pressure increases as the fuel filter becomes
i00457458
plugged.

Exhaust Shields - Inspect Operate the engine with a full load at the rated rpm
and at the normal operating temperature. Check the
SMCS Code: 1067-040 fuel filter differential pressure at full load.

Service the fuel filter when the fuel filter differential

Hot engine components can cause injury from
burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
pressure reaches 1.7 kPa (0.25 psi).
For instructions, refer to Special Instruction,
SEHS9298, “Installation and Maintenance of
Gaseous Fuel Filters”. Consult your Caterpillar dealer
for assistance.
102 SEBU7563-07
Maintenance Section
Gas Admission Valve - Recondition

i01765725 Valve guide (5) will probably have very little wear.
However, measure the inner diameter of the valve
Gas Admission Valve - guide at both ends and the middle. The maximum
Recondition allowable inner diameter of the valve guide at both
ends and the middle is 9.538 mm (0.3755 inch). If
SMCS Code: 1105-020-GS any measurement exceeds this specification, replace
the valve guide. If this is not possible, replace support
Note: Use of a platform may be necessary to reach assembly (6) and the valve guide.
the gas admission valves.
It is unlikely for support assembly (6) to require
For the procedure to remove the gas admission valve, replacement. However, inspect the valve seat in the
refer to the engine’s Disassembly and Assembly. support 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”.

g00833994
Illustration 91
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 90
g00833978
Gas Admission Valve Seals -
Exploded view and section view of the parts for the gas admission
valve Inspect/Replace
(1) Retainer locks
(2) Valve rotator SMCS Code: 1105-040-GS; 1105-510-GS
(3) Outer valve spring
(4) Inner valve spring The camshaft operates the mechanism for the gas
(5) Valve guide admission valve in order to allow fuel to enter the
(6) Support assembly
(7) Valve
inlet port of the cylinder.

To recondition the gas admission valve, replace
retainer locks (1), valve rotator (2), outer valve spring
(3), inner valve spring (4), and valve (7).
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.
SEBU7563-07 103
Maintenance Section
Gas Pressure Regulator - Inspect/Replace

If any of those conditions are found, the gas pressure

regulator must be repaired or replaced.

For information on replacing the gas pressure

regulator, see the Service Manual. Consult your
Caterpillar dealer for assistance.

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.

1. Shut off the engine.

2. Shut off the fuel supply to the GSOV.

g00833829
Illustration 92
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 g00834076
Illustration 93
does not affect the performance of the gas admission
valve. (1) Receptacle
(2) Gasket
(3) Cap
Inspect valve stem seals (1) and (2). Inspect O-ring (4) Bolt
seals (3), (4), and (5). Replace the seals, if necessary. (5) Cover

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

i00679524
Inspect the connectors for damage and corrosion.
Gas Pressure Regulator - Make repairs, as needed.

Inspect/Replace 4. Inspect gasket (2) for damage and wear. Replace

the gasket, if necessary.
SMCS Code: 1550-040; 1550-510
5. Remove cap (3). Remove the washer under the
Inspect the gas pressure regulator for the following cap in order to inspect the solenoid.
conditions:
6. Inspect the solenoid for damage. If the epoxy
• Wear coating is cracked or damaged, obtain a new
solenoid for assembly.
• Cracks
7. Inspect the cavity for the solenoid. Look for
• Pin holes moisture, debris, and abrasion of the wiring. Make
repairs, if necessary. Thoroughly clean the cavity.
• Improper operation
104
Maintenance Section
Hoses and Clamps - Inspect/Replace
8. Remove bolts (4) and cover (5) in order to inspect
the internal parts of the GSOV.
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.
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.
i02394981
Hoses and Clamps -
Inspect/Replace
SMCS Code: 7554-040; 7554-510
Inspect all hoses. Leaks can be caused by the
following conditions:
• Cracking
• Softness
• Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
NOTICE
Do not bend or strike high pressure lines. Do not in-
stall 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 rec-
ommended torque.
Check for the following conditions:
• Fittings that are damaged or leaking
• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
SEBU7563-07
• Armoring that is embedded in the outer covering
Each installation application can be different. The
differences depend on the following factors:
• Type of hose
• Type of fitting material
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the
fittings
Replace the Hoses and the Clamps
1. Service the hoses and clamps according to the
system:
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent 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.
Pressurized System: Hot coolant can cause seri-
ous 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 pres-
sure.
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.
SEBU7563-07
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact
skin.
b. Before servicing an oil hose, stop the engine.
Allow the engine to cool. Drain the oil from the
system to a level that is below the hose that
is being replaced.
Personal injury can result from removing hoses or
fittings in a pressure system.
Failure to relieve pressure can cause personal in-
jury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
c. Before servicing a pressurized air hose, stop
the engine. Ensure that the air supply to the
hose is OFF. Slowly release pressure from the
system.
2. Remove the hose clamps.
3. Disconnect the old hose. Discard the hose.
4. Install a new hose.
5. Install the hose clamps with a torque wrench.
For torques on hose clamps, see Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps”.
6. After servicing the hose, restore the system to an
operational state according to the requirements
of the system:
a. If a coolant hose was serviced, refill the cooling
system. Install the cooling system filler cap.
Start the engine. Inspect the cooling system
for leaks.
b. If an oil hose was serviced, refill the system to
the proper level. Start the engine. Inspect the
system for leaks.
105
Maintenance Section
Ignition System Spark Plugs - Check/Adjust
Personal injury or death can result from improp-
erly 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 tis-
sue 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.
c. If a pressurized air hose was serviced, restore
air pressure to the system. Check for air leaks.
i02602070
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.
106 SEBU7563-07
Maintenance Section
Ignition System Spark Plugs - Check/Adjust

Removing the Spark Plug 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.

NOTICE
The use of a thread tap will remove metal unnecessar-
ily. 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.

If the spark plug resists removal by hand, apply

penetrating oil to the threads. Use the wrench and
g00823378
Illustration 94 apply steady pressure to the spark plug until the
(1) Harness connector spark plug is loose.
(2) Bolt
(3) Transformer If the spark plug cannot be removed by hand, clean
(4) O-ring seal
(5) Extension
the threads with 9U-7511 Spark Plug Seat Cleaner.
(6) Spark plug This tool scrapes debris from the seat and from the
threads.
1. Ensure that the mode control switch is in the
“STOP” or “OFF/RESET” position. Inspecting the 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. Illustration 95
g00838300

(1) Terminal post

5. Remove extension (5). (2) Insulator
(3) Shell
(4) Gasket
(5) Electrode

Pressurized air can cause personal injury. When Inspect the spark plug closely for damage. The
pressurized air is used for cleaning, wear a pro- condition of the spark plug can indicate the operating
tective face shield, protective clothing, and pro- condition of the engine.
tective shoes.
Terminal post (1) must not move. If the terminal post
can be moved by hand, discard the spark plug.
6. Debris may have collected near the spark plug.
Thoroughly remove any debris. Use compressed
Inspect insulator (2) for cracks. If a crack is found,
air. The maximum air pressure for cleaning
discard the spark plug.
purposes must be below 207 kPa (30 psi). Ensure
that the area around the spark plug is clean and
free of dirt and debris.
SEBU7563-07
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 very high voltage potential ionizes the air that
surrounds a conductor. This is a normal condition.
This is not an indication of leakage between the shell
and the insulator.
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.
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.
Illustration 96
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.
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. This will cause misfire. Large deposits may
retain heat which can cause premature fuel ignition.
This can lead to uncontrollable detonation.
107
Maintenance Section
Ignition System Spark Plugs - Check/Adjust
Cleaning the Spark Plug
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:
• Always use clean glass beads.
• 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.
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.
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.
108
Maintenance Section
Ignition System Spark Plugs - Replace
NOTICE
Do not overtighten the spark plug. The shell can be
cracked and the gasket can be deformed. The met-
al 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 combus-
tion pressure to blow past the seal. Serious damage
to the engine can occur.
Use the proper torque.
4. Install the spark plug by hand until the spark
plug bottoms out. For the 194-8518 Spark Plug,
tighten the spark plug to 68 ± 4 N·m (50 ± 3 lb ft).
For the 243-4291 Spark Plug, tighten the spark
plug to 45 ± 5 N·m (33 ± 3 lb ft).
5. Inspect the extension and clean the extension.
g00823413
Illustration 97
(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 will help to protect the connection points
of the extension from corrosion.
6. Ensure that the internal spring exerts force on the
connection points. Install the extension onto the
spark plug.
SEBU7563-07
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
Inlet Air System - Inspect
SMCS Code: 1058-040; 1071-040; 1087-040
Use of a platform may be necessary to inspect the
following components of the air inlet system:
• Piping between the air cleaner and the turbocharger
• Rubber hoses in the air lines
• Turbocharger
• Piping between the turbocharger and the
aftercooler
• Aftercooler
• Connection of the aftercooler to the air plenum
• 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.
SEBU7563-07 109
Maintenance Section
Inlet Gas Manifold and Piping - Inspect/Replace

Make repairs, if necessary. For information regarding i02252012

removal and installation of the components, refer
to Service Manual, “Disassembly and Assembly”. Overhaul (In-Frame)
Consult your Caterpillar dealer for assistance.
SMCS Code: 1000-020

i00683392
Scheduling an In-Frame Overhaul
Inlet Gas Manifold and Piping -
Table 38 lists the approximate number of service
Inspect/Replace hours before an in-frame overhaul for different G3600
Engine applications.
SMCS Code: 1550-040; 1550-510
Table 38
Inspect the components of the fuel inlet system for
Estimated Service Hours Before An
the following conditions: In-Frame Overhaul

• Cracks Fuel Compression Ratio

Service
Hours
• Deterioration Wellhead gas or
9.2:1 50000
natural gas
• Leaks
45000 to
Natural gas 10.5:1
48000
• Loose connections
27000 to
Bio-gas 9.2:1
• Wear 33000

Inspect the following components:

Scheduling an in-frame overhaul normally depends
on the following three conditions:
• Fuel lines from the source to the gas regulator
• Fuel lines from the gas regulator to the fuel inlet • An increase of oil consumption

• Fuel inlet • An increase of crankcase blowby

• Control valve • A decrease and a variation of cylinder compression

• Fuel manifold
• Connections of the fuel manifold and the fuel lines
• Connections of the fuel lines to the orifice
• Connections of the fuel lines to the cylinder head
• Connections of the fuel lines to the precombustion
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.
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
110 SEBU7563-07
Maintenance Section
Overhaul (In-Frame)

Note: These indications do not require an engine Replace – The service life of the part is exhausted.
to be shut down for service. These indications The part may fail before the next maintenance
only mean that an engine should be scheduled for interval. The part must be replaced with a part that
service in the near future. If the engine operation meets functional specifications. The replacement part
is satisfactory, an immediate overhaul is not a may be a new part, a CAT remanufactured part, a
requirement. rebuilt part, or a used part. Various worn components
may be exchanged with your Caterpillar dealer.
An in-frame overhaul does not typically require Consult your Caterpillar dealer about repair options
the engine to be removed. Instead, the service is for your engine.
performed with the engine in place.
Table 39
Note: The generator or the driven equipment may In-Frame Overhaul (1)
also require service when the engine overhaul is
performed. Procedure Component
Inspect Aftercooler
In-Frame Overhaul Information Replace
Cylinder liners

An in-frame overhaul includes all of the work that is Oil cooler

done for a top end overhaul. Additionally, some other Pistons
components that wear are replaced. The condition
of components is inspected. Those components are Rebuild Gas admission valve
replaced, if necessary. Electrohydraulic actuators
Inspect the following components according to Vibration damper
the instructions that are in Caterpillar reusability Replace Camshaft bearings
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index Camshaft followers
of Publications on Reusability or Salvage of Used Connecting rod bearings
Parts”.
Crankshaft seals
Your Caterpillar dealer can provide these services Engine oil pump
and components. Your Caterpillar dealer can ensure
that the components are operating within the Exhaust shields
appropriate specifications.
Gaskets and seals
If you elect to perform an overhaul without the Electrohydraulic system’s
services of a Caterpillar dealer, be aware of the oil pump
following recommendations. Main bearings
The following definitions explain the terminology for Oil temperature regulators
the services that are performed during an overhaul: Piston rings
Inspect – Inspect the components according to Prechamber assemblies
the instructions that are in Caterpillar reusability Water pumps
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index Water temperature
of Publications on Reusability or Salvage of Used regulators
Parts”. The guidelines were developed in order to (1) In addition to these procedures, perform the procedures for
help Caterpillar dealers and customers to avoid the top end overhaul.
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.
SEBU7563-07 111
Maintenance Section
Overhaul (Major)

i02252260 • The service hours of the engine

Overhaul (Major) • The wear metal analysis of the lube oil
SMCS Code: 7595-020-MJ • An increase in the levels of noise and vibration
Scheduling a Major Overhaul An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
Table 40 lists the approximate number of service need to be serviced. An increase in the levels of
hours before a major overhaul for different G3600 noise and vibration indicates that rotating parts
Engine applications. require service.

Table 40 Note: It is possible for oil analysis to indicate a

Estimated Service Hours Before a Major Overhaul
decrease of wear metals in the lube oil. The cylinder
liners may be worn so that polishing of the bore
Fuel Compression Ratio
Service occurs. Also, the increased use of lube oil will dilute
Hours the wear metals.

Monitor the engine as the engine accumulates

Wellhead gas or service hours. Consult your Caterpillar dealer about
9.2:1 100000
natural gas
scheduling a major overhaul.

75000 to Note: The driven equipment may also require service

Natural gas 10.5:1
80000
52000 to
Bio-gas 9.2:1
54000
The need for a major overhaul is determined by
several factors:
• An increase of oil consumption
• An increase of crankcase blowby
• A decrease and variation of cylinder compression
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.
The engine does not require an overhaul if the
engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder
compression.
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.
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:

Other factors must also be considered for determining

a major overhaul:
112 SEBU7563-07
Maintenance Section
Overhaul (Top End)

Inspect – Inspect the components according to Table 42

the instructions that are in Caterpillar reusability Estimated Service Hours Before a Top End Overhaul
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index Fuel Compression Ratio Service
of Publications on Reusability or Salvage of Used Hours
Parts”. The guidelines were developed in order to Wellhead gas or 9.2:1 25000
help Caterpillar dealers and customers to avoid natural gas
unnecessary expenditures. New parts are not
required if the existing parts can still be used, Natural gas 10.5:1 15000
reconditioned, or repaired. If the components are Bio-gas 9.2:1 10000 to
not in the reusability guidelines, refer to the Service 14000
Manual, “Specifications” module.

Rebuild – The component can be reconditioned in Top end overhauls are normally scheduled according
order to comply with reusability guidelines. to the projection of exhaust valve stems. This
measurement provides an accurate indication of the
Replace – The service life of the part is exhausted. rate of valve wear. This measurement can be used to
The part may fail before the next maintenance predict when a cylinder head requires replacement.
interval. The part must be replaced with a part that
meets functional specifications. The replacement Measure the projection of the exhaust valve stems at
part may be a new part, a CAT remanufactured part, the first 1000 service hours. This measurement is the
a rebuilt part, or a used part. Some worn components baseline. The baseline is a reference for subsequent
may be exchanged with your Caterpillar dealer. measurements. Continue to periodically measure
Consult your Caterpillar dealer about repair options the projection.
for your engine.
Plan for the top end overhaul as the valve stem
Table 41 projection approaches the maximum limit. Perform
the top end overhaul when the valve stem projection
Major Overhaul(1) has increased by a total of 2.3 mm (.09 inch). Do not
Procedure Component allow the projection of the exhaust valve stems
to exceed this limit.
Inspect Camshafts
Replace
Connecting rods Note: Generally, cylinder heads wear out at different
rates. In some cases, servicing the cylinder heads at
Crankshaft different times may be the most economic decision.
Rebuild Inlet air piping This depends on the valve stem projection of the
individual cylinders. However, this decision must
Replace Aftercooler include the costs of additional downtime that is
Camshaft lifters caused by this procedure. Perform an economic
analysis in order to determine if cylinder heads should
Exhaust manifolds be serviced as a group or divided into smaller groups.
Gear train bearings
Note: The generator or the driven equipment may
Oil cooler also require service when the engine overhaul is
(1) In addition to these procedures, perform the procedures for performed.
both the top end overhaul and the in-frame overhaul.

Top End Overhaul Information

i02602081
A top end overhaul involves servicing the cylinder
Overhaul (Top End) heads and turbochargers. Also, some other engine
components are inspected.
SMCS Code: 7595-020-TE
Top end overhauls require more tools than preventive
Scheduling a Top End Overhaul maintenance. The following tools are needed for
restoring the engine to factory specifications:
Table 42 lists the approximate number of service
hours before a top end overhaul for different G3600 • Torque wrenches
Engine applications.
• Dial indicators
• Accurate measurement tools
SEBU7563-07 113
Maintenance Section
Overhaul Considerations

• Cleaning equipment Replace – The service life of the part is exhausted.

The part may fail before the next maintenance
• Rebuilding equipment interval. The part must be replaced with a part that
meets functional specifications. The replacement
Caterpillar dealers are equipped with these tools. part may be a new part, a CAT remanufactured part,
Caterpillar dealers can provide a flat rate price for a rebuilt part, or a used part. Some worn components
a top end overhaul. may be exchanged with your Caterpillar dealer.
Consult your Caterpillar dealer about repair options
Unexpected problems may be found during a top for your engine.
end overhaul. Plan to correct these problems, if
necessary. Table 43
Top End Overhaul
• Buildup in the cylinders from excessive oil
consumption Procedure Component
Inspect/Replace Seals for the gas admission
• Plugging of the aftercooler from coolant that is valve
poorly maintained Rod bearings
Prechambers
• Degradation of the oil cooler from hydrogen sulfide Drive coupling
in the fuel Rebuild Gas pressure regulator
Inspect the following components according to Starting motor
the instructions that are in Caterpillar reusability Turbochargers
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index Replace Cylinder heads and
of Publications on Reusability or Salvage of Used gaskets
Parts”. Oil temperature regulators
Your Caterpillar dealer can provide these services Spark plug extenders
and components. Your Caterpillar dealer can ensure Water temperature
that the components are operating within the regulators
appropriate specifications.

If you elect to perform an overhaul without the i02250409

services of a Caterpillar dealer, be aware of the
following recommendations. Overhaul Considerations
The following definitions explain the terminology for SMCS Code: 7595-043
the services that are performed during an overhaul:

Inspect – Inspect the components according to Overhaul Information

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.
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
114
Maintenance Section
Overhaul Considerations
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:
• 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.
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
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
• 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.
SEBU7563-07
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.
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
SEBU7563-07 115
Maintenance Section
Prechamber - Clean/Inspect

• Crankshafts i02602727

• Cylinder heads Prechamber - Clean/Inspect

• Oil Pumps SMCS Code: 1106-571

• 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.
g01302648
Illustration 98
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.
116 SEBU7563-07
Maintenance Section
Prechamber Check Valves - Clean

i02602093 i02602222

Prechamber Check Valves - Prechamber Check Valves -

Clean Replace
SMCS Code: 1550-070 SMCS Code: 1550-510

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

Note: Use of a platform may be necessary to reach Note: Use of a platform may be necessary to reach
the prechamber check valves. the prechamber check valves.

Note: Refer to the engine’s Disassembly and Note: Refer to the engine’s Disassembly and
Assembly manual for instructions on removal and Assembly manual for instructions on removal and
installation of the check valves. installation of the check valves.

1. Remove check valve assembly (3) and gasket (5). 1. Remove check valve assembly (3) and gasket (5).

2. Discard gasket (5) and O-ring (4). Disassemble 2. Keep plug (1) for reassembly. Discard the other
the check valve by unscrewing the end cap. parts. Obtain new parts for reassembly.

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).
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

4. Do NOT overtighten the plug for the check valve.

Tighten to 15 N·m (11 lb ft).
Prelube Pump - Inspect
SMCS Code: 1319-040

Inspect the prelube pump for the following conditions:

• Cracks
• Pin holes
• Proper operation
• Wear
SEBU7563-07
Inspect the prelube pump for leaks. Replace all of the
seals if a leak is observed.
Inspect the wiring for the following conditions:
• Damage
• Fraying
Ensure that the wiring is in good condition.
Inspect the electrical connections. Ensure that the
electrical connections are secure.
If repair or replacement is necessary, refer to the
engine’s Disassembly and Assembly manual. Consult
your Caterpillar dealer for assistance.
Air Prelube Pump
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.
Electric Prelube Pump
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.
117
Maintenance Section
Starting Motor - Inspect
Electric Starting Motor
Note: Problems with the electric starting motor can
be caused by the following conditions: malfunction of
the solenoid and malfunction of the electric starting
system.
Inspect the electrical system for the following
conditions:
• Loose connections
• Corrosion
• Wires that are worn or frayed
• Cleanliness
Make repairs, if necessary.
Air Starting Motor
Personal injury or death can result from improp-
erly 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 tis-
sue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of
injury.
Inspect all of the components in the air circuit for
the starting motor. Inspect all of the air lines and
connections for leaks.
If the teeth of the starting motor pinion and/or the
flywheel ring gear are damaged, the air circuit for
the starting motor must be examined in order to
determine the cause of the problem.
Removal and Installation of the
Starting Motor
Refer to the Service Manual, “Disassembly and
Assembly” module for information on removing the
starting motor and installing the starting motor.
Consult your Caterpillar dealer for assistance.
118 SEBU7563-07
Maintenance Section
Turbocharger - Clean

i01765784 2. Open air valve (1) in order to remove deposits

that may be in the connecting pipe. After three
Turbocharger - Clean minutes, close air valve (1). Close gate valve (4).
(Cleaning with Dry Particles) 3. Open purge valve (2) in order to relieve any
SMCS Code: 1052-070 pressure from the container. Close purge valve
(2).
Note: Use of a platform may be necessary to reach
the turbocharger. 4. Remove cap (3). Pour 0.5 L (0.5 qt) of the particles
into the container. Tighten cap (3).
If the engine has more than one turbocharger, each
turbocharger requires cleaning. 5. Ensure that purge valve (2) is closed. Reduce
the output of the engine so that the exhaust
Note: The drain openings in the exhaust housing temperature before the turbine is less than 577 °C
of the turbocharger are closed during the cleaning (1070 °F).
procedure. Some of the particles will be expelled
through the exhaust stack. The particles that are 6. Open gate valve (4). Open air valve (1).
expelled will be burned.
7. After 60 to 90 seconds, close air valve (1). Close
The materials that are listed in Table 44 are gate valve (4).
recommended for use with this cleaning procedure.
8. Open purge valve (2) in order to relieve any
Table 44 pressure from the container. Close purge valve
(2).
Materials for Cleaning 3600 Engine Turbochargers
Material Particle Size
i00908991
Nut shell 1.7 mm
(1/16 inch) Turbocharger - Inspect
Formed carbon 1 mm (1/32 inch)
SMCS Code: 1052-040
Granulated carbon (70% hardness) 1.2 to 2 mm
(3/64 to 5/64 inch) Periodic inspection and cleaning is recommended
for the turbocharger.
Granulated dry rice 1.7 mm
(1/16 inch)
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.

g00833073
Illustration 101
(1) Air valve
(2) Purge valve
(3) Cap
(4) 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).
SEBU7563-07
NOTICE
Turbocharger bearing failures can cause large quan-
tities 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 ex-
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc-
curred.
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.
119
Maintenance Section
Turbocharger - Inspect
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
for the inlet air (plugged air filters), which causes
the turbocharger to slobber.
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.
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.
5. Inspect the bore of the turbine housing for
corrosion.
6. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.
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.
120 SEBU7563-07
Maintenance Section
Turbocharger Cleaner Tube - Replace

i01765785 The actual measurement of the valve recession

inside of the cylinder head is difficult to obtain.
Turbocharger Cleaner Tube - Two simpler methods are used to determine valve
Replace recession:

SMCS Code: 1052-510 • 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

g00790542
Illustration 102 Maintenance Manual, “Valve Data Sheet” (Reference
(1) Air valve Materials Section). Record the measurements on
(2) Purge valve the sheets.
(3) Gate valve
(4) Tube
• Measure the projection of the inlet and exhaust
valve stems and the exhaust valve rotators at
Note: Use of a platform may be necessary in order to the first 1000 service hours. This measurement
reach the cleaner tube. is the baseline. The baseline is a reference for
subsequent measurements.
1. Stop the engine.
• Measure the projection of the inlet and exhaust
2. Ensure that air valve (1) and gate valve (3) are valve rotators when the engine valve lash is
closed. checked. Continue this periodic measurement until
the projection of the valve rotator has increased by
3. Open purge valve (2) in order to relieve any a total of 1.6 mm (.063 inch). This is 70 percent of
pressure from the container. the maximum limit. Measure the projection of the
valve stems when this occurs. This measurement
4. Remove tube (4). Discard the used tube. will determine the actual wear of both the valves
and the valve seats.
5. Install a new tube.

6. Close purge valve (2).

• After 70 percent of the maximum limit has been
reached, measure the projection of the exhaust
valve stems at every 500 hours of operation.
i00682053
• Plan for the top end overhaul as the valve
Valve Stem Projection - stem projection approaches the maximum limit.
Perform the top end overhaul when the valve stem
Measure/Record projection has increased by a total of 2.3 mm
(.09 inch). Do not allow the valve recession to
SMCS Code: 1105-082 exceed this limit. The valve head can break.
This will cause severe damage in the combustion
Valve Recession – The valves and the valve seats chamber and the turbocharger.
are worn over time. This causes the valves to recede
into the cylinder head. This condition is called “valve Consult your Caterpillar dealer for assistance.
recession”.

The exhaust valves and valve seats show the

greatest wear due to high operating temperatures.
The top end overhaul interval is normally scheduled
according to exhaust valve recession.
SEBU7563-07 121
Maintenance Section
Walk-Around Inspection

i01492446

Walk-Around Inspection
NEVER use a flame to check for gas leaks. Use a
SMCS Code: 1000-040 gas detector.

An open flame can ignite mixtures of air and fuel.

Inspect the Engine for Leaks and This will cause explosion and/or fire which could
for Loose Connections result in severe personal injury or death.

A walk-around inspection should only take a few

minutes. When the time is taken to perform these
• Check the fuel system for leaks. Look for loose fuel
line clamps.
checks, costly repairs and accidents can be avoided.

For maximum engine service life, thoroughly inspect

• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
the engine room before starting the engine. Look for
items such as leaks, loose bolts, loose connections
and trash buildup. Make repairs, as needed.
• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
• Inspect the ground straps for good connections
and for good condition.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
• Check the condition of the gauges. Replace any
gauge that is damaged. Replace any gauge that
can not be calibrated.
NOTICE
For any type of leak, clean up the fluid. If leaking is ob- • Inspect the exhaust system for leaks. If a leak is
served, find the source and correct the leak. If leaking found, make repairs.
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. i00524084

Water Pump - Inspect

NOTICE
Accumulated grease and/or oil on an engine or deck is SMCS Code: 1361-040
a fire hazard. Remove this debris with steam cleaning
or high pressure water. 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
• Ensure that cooling lines are properly clamped. damage to the engine.
Check for leaks. Check the condition of all pipes.
Visually inspect the water pump for leaks. If leaking
• Inspect the water pumps for coolant leaks. of the water pump seals is observed, replace all of
the water pump seals. Refer to the Service Manual
Note: The water pump seal is lubricated by coolant for the disassembly and assembly procedure.
in the cooling system. It is normal for a small amount
of leakage to occur when the engine cools and the Inspect the water pump for wear, cracks, pin holes
parts contract. and proper operation. Refer to the Service Manual or
consult your Caterpillar dealer if repair is needed or
Excessive coolant leakage may indicate the need replacement is needed.
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.
122 SEBU7563-07
Reference Information Section
Customer Service

Reference Information Latin America, Mexico, Carribean

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

Europe, Africa, and Middle East

i02097871
Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000; 4450 CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
USA and Canada Fax: 22-849-4544
When a problem arises concerning the operation of Far East
an engine or concerning the service of an engine, Caterpillar Asia Pte. Ltd.
the problem will normally be managed by the dealer 7 Tractor Road
in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level without additional assistance, use the phone Hong Kong
number that is listed below to talk with a Field Phone: 852-2848-0333
Service Coordinator: Fax: 852-2848-0440
1-800-447-4986 Japan
Shin Caterpillar Mitsubishi Ltd.
The normal hours are from 8:00 to 4:30 Monday SBS Tower
through Friday Central Standard Time. 10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
3. If your needs have not been met still, submit the Japan
matter in writing to the following address: Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Caterpillar Inc.
Manager, Customer Service, Engine Division Japan
Mossville Bldg AC Caterpillar Power Systems, Inc.
P.O. Box 610 SBS Tower (14th floor)
Mossville, Illinois 61552-0610 4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Please keep in mind: probably, your problem will Phone: 81-3-5797-4300
ultimately be solved at the dealership, using the Fax: 81-3-5797-4359
dealership’s facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a Australia and New Zealand
problem is experienced. Caterpillar of Australia Ltd.
1 Caterpillar Drive
Outside of the USA and of Canada Private Mail Bag 4
Tullamarine, Victoria 3043
If a problem arises outside the USA and outside Australia
Canada, and if the problem cannot be resolved at the Phone: 03-9953-9333
dealer level, consult the appropriate Caterpillar office. Fax: 03-9335-3366
SEBU7563-07 123
Reference Information Section
Customer Service

i01028392

Ordering Replacement Parts

SMCS Code: 4450; 7567

When replacement parts are required for this

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

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

Quality Caterpillar replacement parts are available

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

When you order parts, please specify the following

information:

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

When a Caterpillar engine requires maintenance

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

Discuss the problem with the dealer. Inform the

dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
124
Reference Information Section
Reference Materials
Reference Materials
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
SEBU7563-07
• Maintenance log
i02408969
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:
• Demonstration of compliance with the required
maintenance practices and maintenance intervals
• Determination of operating costs
• Establishment of maintenance schedules for other
engines that are operated in the same environment
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.
Keep records for the following items:
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. Keep the
following documents as proof of maintenance or
repair for warranty:
• Dealer work orders and itemized bills
• Logs of engine performance
• Maintenance logs
• Owner’s repair costs
• Owner’s receipts
• Trend charts
SEBU7563-07 125
Reference Information Section
Reference Materials

i02209903

Maintenance Log
SMCS Code: 1000; 4450

Table 45
Engine Model Customer Identifier
Serial Number Arrangement Number
Service
Service Item Date Authorization
Hours
126 SEBU7563-07
Reference Information Section
Reference Materials

i00769479

Valve Data Sheet

SMCS Code: 1000

Table 46
Engine Model Serial Number Service Hours Authorization
Cylinder Valve Location Current Stem Rotator
Cylinder Wear
Pressure Measure Baseline Baseline
1 Pushrod Side
Exhaust Manifold
2 Pushrod Side
Exhaust Manifold
3 Pushrod Side
Exhaust Manifold
4 Pushrod Side
Exhaust Manifold
5 Pushrod Side
Exhaust Manifold
6 Pushrod Side
Exhaust Manifold
7 Pushrod Side
Exhaust Manifold
8 Pushrod Side
Exhaust Manifold
9 Pushrod Side
Exhaust Manifold
10 Pushrod Side
Exhaust Manifold
11 Pushrod Side
Exhaust Manifold
12 Pushrod Side
Exhaust Manifold
13 Pushrod Side
Exhaust Manifold
14 Pushrod Side
Exhaust Manifold
15 Pushrod Side
Exhaust Manifold
16 Pushrod Side
Exhaust Manifold
SEBU7563-07 127
Reference Information Section
Reference Materials

i02602385 • Application and Installation Guide, LEBW4977,

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

Lubricants • Special Publication, LEKQ9360, “Internal

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”
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”

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

(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”
• 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”
128 SEBU7563-07
Reference Information Section
Reference Materials

• Application and Installation Guide, LEBW4974, Engine Manufacturers Associaton

“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”
Two North LaSalle Street, Suite 2200
Chicago, IL, USA 60602
E-mail: ema@enginemanufacturers.org
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

• 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”
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.

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

8T-2700 Blowby/Airflow Indicator Group” (ISO)
1, rue de Varembé
• Special Instruction, SEHS8984, “Using the Case postale 56
1U-8860 Large Engine Blowby Pickup Group” CH-1211 Genève 20
Switzerland
• Special Instruction, SEHS9031, “Storage Telephone: +41 22 749 01 11
Procedure for Caterpillar Products” Facsimile: +41 22 733 34 30
E-mail: central@iso.ch
• Special Instruction, SEHS9162, “Spring Isolator Web site: http://www.iso.ch
Group Installation and Adjustment Procedure”
European classifications are established by the
• Specifications, SENR3130, “Torque Specifications” Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).
Additional Reference Material
CIMAC Central Secretariat
The “Engine Fluids Data Book” can be obtained from
Lyoner Strasse 18
the following locations: local technological society,
local library, and local college. If necessary, consult 60528 Frankfurt
Germany
EMA at the following address:
Telephone: +49 69 6603 1567
Facsimile: +49 69 6603 1566
SEBU7563-07 129
Reference Information Section
Reference Materials

i00382622

Warranty Information
SMCS Code: 1000

Engine Protection Plans

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

Consult your Caterpillar dealer for information on a

plan that is tailored in order to fit your requirements.
130
Index Section
Index
A Control Panel......................................................... 40
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 ................................................
B Engines That Are Not Equipped With a Sight
Barring Device - Lubricate ..................................... 67
Electric Barring Device....................................... 68
Manual Barring Device....................................... 68
Battery Electrolyte Level - Check .......................... 69
Before Starting Engine .................................... 17, 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............................... 69
Adjusting the Alternator Belt .............................. 69
Adjusting the Fan Drive Belt .............................. 70
Inspection........................................................... 69
Replacement...................................................... 70
Burn Prevention..................................................... 14
Batteries............................................................. 14
Coolant............................................................... 14
Oils..................................................................... 14
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.........
SEBU7563-07
Advisor II ........................................................... 40
“DESIRED SPEED” Potentiometer .................... 45
64 “EMERGENCY STOP” Button ........................... 43
64 Indicators ........................................................... 44
64 “MANUAL PRELUBE” Switch and “PRELUBE
64 ACTIVE” Indicator ............................................ 44
10 Mode Control Switch.......................................... 44
50 Control Panel - Inspect .......................................... 72
50 Record the Data and Review the Data .............. 72
53 Cooling System Coolant (NGEC) - Change .......... 72
65 Clean the Cooling System ................................. 73
65 Cleaning a Cooling System that has Heavy
65 Deposits or Plugging ........................................ 73
66 Drain the Cooling System .................................. 72
67 Fill the Cooling System ...................................... 74
67 Cooling System Coolant Level - Check ................. 74
67 Add Coolant ....................................................... 74
Engines That Are Equipped With a Sight
Gauge .............................................................. 74
Gauge .............................................................. 74
Cooling System Coolant Sample (Level 1) -
Obtain .................................................................. 75
Cooling System Coolant Sample (Level 2) -
Obtain .................................................................. 75
Cooling System Level Switch - Inspect ................. 76
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add.................................................. 76
Add the SCA, If Necessary ................................ 77
Test the Concentration of the SCA..................... 76
Cooling System Water Temperature Regulator -
Replace................................................................ 77
Crankcase Blowby - Measure/Record ................... 78
Crankshaft Vibration Damper - Inspect ................. 78
Removal and Installation.................................... 79
Crushing Prevention and Cutting Prevention ........ 16
Customer Assistance........................................... 122
Outside of the USA and of Canada.................. 122
USA and Canada ............................................. 122
Customer Service ................................................ 122
Cylinder Pressure - Measure/Record .................... 79
Cylinders - Inspect (Inspect the Combustion
Chamber)............................................................. 80
D
Driven Equipment - Check..................................... 81
47 Check the Alignment.......................................... 81
48 Every 10,000 Service Hours .............................. 81
48 Every 5000 Service Hours ................................. 81
48 Driven Equipment - Inspect/Replace/Lubricate ..... 81
70
72
SEBU7563-07
E F
Electrical System ................................................... 18
Grounding Practices .......................................... 18
Electrohydraulic Actuator - Inspect........................ 81
Electrohydraulic Actuator - Recondition ................ 82
Electrohydraulic System - Check/Adjust................ 84
Check the Pressure Relief Valve ....................... 84
Electrohydraulic System - Inspect ......................... 84
Check the Oil Level............................................ 84
Inspect the Lines, Connections, and
Components..................................................... 84
Electrohydraulic System Oil - Change................... 84
Electrohydraulic System Oil Filter - Change.......... 85
Emergency Stopping ............................................. 52
Emergency Stop Button ..................................... 52
Engine Air Cleaner Element (Single Element) -
Clean/Replace ..................................................... 86
Cleaning the Air Cleaner Elements.................... 86
Crankcase Air Cleaner....................................... 88
Servicing the Air Cleaner Elements ................... 86
Engine Air Cleaner Service Indicator - Inspect...... 88
Test the Service Indicator................................... 89
Engine Air Precleaner - Clean ............................... 89
Engine Crankcase Breather - Clean...................... 90
Engine Mounts - Check ......................................... 90
Engine Oil - Change .............................................. 90
Change the Engine Oil....................................... 91
Oil Change Interval ............................................ 90
Engine Oil Filter - Change ..................................... 92
Inspect the Used Oil Filter Elements.................. 94
Replacing the Engine Oil Filters During Engine
Operation ......................................................... 93
Replacing the Engine Oil Filters With the Engine
Stopped............................................................ 92
Engine Oil Level - Check ....................................... 95
Engine Oil Sample - Obtain ................................... 95
Obtain the Sample and the Analysis.................. 96
Engine Oil Temperature Regulator - Replace........ 96
Engine Operation................................................... 51
Oil Consumption ................................................ 51
Operating the Engine and the Driven
Equipment ........................................................ 51
Partial Load Operation ....................................... 51
Engine Protective Device Connections - Inspect... 96
Engine Protective Devices - Check ....................... 98
Visual Inspection................................................ 99
Engine Speed/Timing Sensor - Clean/Inspect....... 99
Engine Starting ................................................ 17, 46
Engine Stopping .............................................. 17, 52
Engine Valve Lash - Inspect/Adjust ....................... 99
Check the Timing of the Crankshaft and
Camshaft.......................................................... 99
Engine Valve Lash ........................................... 100
Gas Admission Valve ....................................... 100
Valve Bridge..................................................... 100
Engine Valve Rotators - Inspect .......................... 100
Exhaust Bypass - Recondition............................. 101
Exhaust Shields - Inspect .................................... 101
131
Index Section
Features and Controls ........................................... 33
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................................................................. 101
G
Gas Admission Valve - Recondition .................... 102
Gas Admission Valve Seals - Inspect/Replace.... 102
Gas Pressure Regulator - Inspect/Replace ......... 103
Gas Shutoff Valve - Inspect ................................. 103
General Hazard Information .................................. 12
Asbestos Information ......................................... 13
Containing Fluid Spillage ................................... 13
Dispose of Waste Properly ................................ 14
Fluid Penetration................................................ 13
Pressurized Air and Water ................................. 13
General Information............................................... 19
H
Hoses and Clamps - Inspect/Replace ................. 104
Replace the Hoses and the Clamps ................ 104
I
Ignition System Spark Plugs - Check/Adjust ....... 105
Cleaning the Spark Plug .................................. 107
Inspecting the Spark Plug ................................ 106
Installing the Spark Plug .................................. 107
Removing the Spark Plug ................................ 106
Ignition System Spark Plugs - Replace ............... 108
Ignition Systems .................................................... 16
Important Safety Information ................................... 2
Inlet Air System - Inspect..................................... 108
Inlet Gas Manifold and Piping - Inspect/Replace.. 109
L
Lifting and Storage ................................................ 31
132
Index Section
M R
Maintenance Interval Schedule (G3600 Engines That
Have a 10.5:1 or an 11:1 Compression Ratio and
Use Natural Gas) ................................................. 60
Maintenance Interval Schedule (G3600 Engines
That Have a 9.2:1 Compression Ratio and That
UseWellhead or Natural Gas).............................. 58
Maintenance Interval Schedule (G3600 Engines That
Use Bio-Gas) ....................................................... 62
Maintenance Log ................................................. 125
Maintenance Records.......................................... 124
Maintenance Section ............................................. 54
Manual Stop Procedure......................................... 52
Model View Illustrations......................................... 20
Model Views and Specifications ............................ 20
Monitoring System................................................. 34
Integrated Combustion Sensing Module
(ICSM).............................................................. 38
Mounting and Dismounting.................................... 16
O Safety Section ......................................................... 6
Operation Section.................................................. 31
Ordering Replacement Parts ............................... 123
Overhaul (In-Frame) ............................................ 109
In-Frame Overhaul Information......................... 110
Scheduling an In-Frame Overhaul ................... 109
Overhaul (Major)................................................... 111
Major Overhaul Information .............................. 111
Scheduling a Major Overhaul............................ 111
Overhaul (Top End) .............................................. 112
Scheduling a Top End Overhaul ....................... 112
Top End Overhaul Information .......................... 112
Overhaul Considerations ...................................... 113
Overhaul Information ........................................ 113
P Table of Contents..................................................... 3
Plate Locations and Film Locations....................... 29
Engine Identification........................................... 29
Information Plate................................................ 29
Serial Number Plate........................................... 29
Prechamber - Clean/Inspect................................. 115
Prechamber Check Valves - Clean....................... 116
Prechamber Check Valves - Replace................... 116
Prelube Pump - Inspect ........................................ 116
Air Prelube Pump.............................................. 117
Electric Prelube Pump ...................................... 117
Product Description ............................................... 22
Engine Service Life ............................................ 23
Product Identification Information .......................... 29
Product Information Section .................................. 19
Product Lifting........................................................ 31
Engine Lifting with a Generator.......................... 31
Product Storage..................................................... 32
Generator Storage ............................................. 32
Programmable System Parameters ...................... 33
SEBU7563-07
Reference Information ........................................... 29
Reference Information Section ............................ 122
Reference Material .............................................. 127
Additional Reference Material.......................... 128
Coolants........................................................... 127
Fuels ................................................................ 127
Lubricants ........................................................ 127
Miscellaneous .................................................. 127
Reference Materials ............................................ 124
Refill Capacities..................................................... 54
Refill Capacities and Recommendations............... 54
Cooling System.................................................. 55
Fuel .................................................................... 54
Hydraulic Actuator System................................. 54
Lubrication System ............................................ 54
S
Safety Messages ..................................................... 6
Specifications ........................................................ 24
Drives and Gear Trains ...................................... 25
Engine Specifications......................................... 24
Reference Weights ............................................ 28
Starting Motor - Inspect ........................................ 117
Air Starting Motor .............................................. 117
Electric Starting Motor....................................... 117
Removal and Installation of the Starting Motor .. 117
Starting the Engine ................................................ 48
Automatic Starting.............................................. 49
Manual Starting.................................................. 49
Purging Unburned Gas ...................................... 48
T
Turbocharger - Clean (Cleaning with Dry
Particles)............................................................. 118
Turbocharger - Inspect ......................................... 118
Turbocharger Cleaner Tube - Replace ................ 120
V
Valve Data Sheet................................................. 126
Valve Stem Projection - Measure/Record............ 120
W
Walk-Around Inspection ...................................... 121
Inspect the Engine for Leaks and for Loose
Connections ................................................... 121
Warranty Information ........................................... 129
Engine Protection Plans................................... 129
Water Pump - Inspect .......................................... 121
Welding on Engines with Electronic Controls ........ 19
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
©2006 Caterpillar
All Rights Reserved Printed in U.S.A.