; CATERPILLAR seevessoat Sess | Operation ancl | Maintenance | Manual G3612 and G3616 Engines (Engine) 1YGI-Up 4CG1-Up (Engine)‘onnseo92 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 sitvations before an accident occurs. A person rust 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 “WARNING” as 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, adjusiments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obiain the complete and most current information before you start any job, Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.@ Table of Contents Satety Section Warning Signs and Labels General Hazard Information Burn Prevention Fire Prevention and Explosion Prevention wn... Crushing Prevention and Cutting Prevention Mounting and Dismounting Ignition Systems... Belore Starting Engine... Engine Starting Engine Stopping Electrical System Product Information Section ee Product Identification Information Operation Section Engine Liting and Storage Engine Features and Controls Engine Starting Engine Operation Engine Stopping... Maintenance Section Torque Specifications Lubricant Specifications, Fuel Specifications, Cooling System Specifications e Refill Capacities " 13, 13 ot 15 16 16 16 16 18 25 87 28 40 45 46 48 51 88 62 69 Maintenance Interval Schedule (G3612 and G3616 Engines wih @ 92:1 Compression Ratio Using Wellhead Gas or Natural Gas) 70 3 Table of Contents Maintenance Interval Schedule (G3612 and G3616 Engines With a 0.511 or an 11:1 Compression Ratio Using Natural Gas) ce .rcnrnnnnnnsene 72 Maintenance Interval Schedule (63612 and G3616 Engines Using Bi0-GaS) ...rnnnnnnnnnne 7 Reference Information Section Customer Service 198 Relerence Materials — 140 Index Section Index 146 34074 Safety Section Warning Signs and Labels Safety Section Warning Signs and Labels SMCS Code: 1000; 7405, There may be several specific warning signs on your engine. The exact location and a description of the warning signs are reviewed in this section. Please become familiar with all warning signs, Ensure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warning signs. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning signs. The warning signs that are loosened could drop off of the engine. Replace any warning sign that is damaged or missing. 1 @ warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Caterpiiar dealer can provide new warning signs. Do not operate or work on this engine uniess you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. The warning labels that may be attached on the engine are illustrated and described below. Pinch Point (Linkage) ustraton + (1) Air choke actuator (2) Fuel contol actuator (3) Exhaust bypass actuator The warning labels for the pinch point (linkage) are focated on the covers of the following components: air choke actuator (1), fuel control actuator (2), and ‘exhaust bypass actuator (3). llustration t shows electronic actuators, Some engines have hydraulic actuators. The hydraulic actuators are mounted in he same locations as the electronic actuators. OOTESTES ‘The movement of the linkage can form a pinch Point. This can cause personal injury. Keep hands away from the linkage.5 Safety Section ‘Warning Signs and Labels, Oil Filter (Engines That Have a Control Valve For the Oil Filters) ‘ustration 2 Pr (1) Warring labet {2} Contrct valve The warning label for the oil filers is located on the oil filter covers, re : Filter contains hot pressurized fluid when engine is running, Follow instructions on control valve to avoid injury if rapid air movement exists to blow fluid. Stop engine to avoid fire. Oil Filter (Engines That Do Not Have a Control Valve For the Oil Filters) Inustation 3 NEE The warning label for the oil filters is located on the oil filter AW Coe q0no29 Filter contains hot pressurized fluid when engine is running. To avoid personal injury, stop engine before re- moving filter cover,6 Safety Section ‘Warning Signs and Labels Engine Lifting (Label On the Number One Camshaft Cover and On the Number Two Camshaft Cover) Engine Lifting (Label On the Number Three Camshaft Cover and On the Number Four Camshaft Cover) IWustration 4 poeneTa| istration 4 shows a label that is located on the loft side ofthe ‘engine. An Manica label is located on te apposite side ot the ‘engin. (1) Label on the camshat cover of the number two cylinder Warning labels for engine lifting are located on the camshaft cover of the number one cylinder and on the camshaft cover of the number two cylinder, tustraton 5 gooesseao tustration 5 shows label that s located on the tet sce ofthe tengine. An idetica label is fosated on the opposite side of the engine. (1) Labet on tne camshatt cover of the number four evindr Warning labels for engine lifting are located on the camshaft cover of the number three cylinder and on the camshaft cover of the number four cylinder. Pn oes Improper lift rigging can allow unit to tumble causing injury and damage. If improper equipment is used to lift the engine, injury and damage can occur. Use cables that are properly rated for the weight. Use a spreader bar and attach the cables according to the information on the warning label, yes Improper lift rigging can allow unit to tumble causing injury and damage. If improper equipment is used to litt the engine, injury and damage can occur. Use cables that are properly rated for the weight. Use a spreader bar and attach the cables according to the information| on the warning label7 Safety Section Warning Signs and Labels Barring Device | Iustraton 6 oe The warning for lifting the base is located on the base. stration 7 cos The warning label for the barring device is located (on the guard of the barring device Improper lift rigging can allow unit to tumble causing injury and damage. If improper equipment is used to lift the engine, injury and damage can occur. Use cables that are properly rated for the weight. Use @ spreader bar and attach the cables according to the information fon the warning label rT GUARDS MUST BE mW PLACE PRIOR TO OPERATING BARRING DEVICE MOTOR. REMOVE ALL HAND Tools PRIOR TO OPERATING BARRING DEVICE MOTOR. ORNS Guards must be in place prior to operating barring device motor. Remove all hand tools prior to operating barring device motor. The guard covers gears that rotate, Hands can be rapped in rotating gears. This can cause personal injury. Tools can be trapped in rotating gears. This, can cause property damage. Ensure that no tools are in the barring device and ensure that the guard is secure before the barring device is operated:8 Safety Section Warning Signs and Labels Drain Coolant Crankcase Covers Wustration 8 noize The warning label for coolant is located on the ‘expansion tank or on the heat exchanger. The warning label for coolant is also located on the covers of the outlets for the cooling system, WNT | DRAIN COOLANT BEFORE REMOVING | ontasrae Drain coolant betore removing covers. When the engine is at operating temperature, the engine coolant is hot. The engine coolant is also under pressure, The radiator and/or the heat exchanger contain hot coolant, All lines to the heaters or to the engine contain hot coolant. Contact can cause severe burns, Imustration 9 nas ‘The warning label for the crankcase covers is located on the crankcase covers FLASH FIRE MAY RESULT IN PERSONAL IWOURY, IF CRANKCASE COVERS ARE REMOVED WITHIN FIFTEEN MINUTES AFTER EMERGENCY SHUT DOWN, DO NOT RESTART ENGINE UNTIL CAUSE FOR SHUT DOWN HAS BEEN CORRECTED. Flash fire may result in personal injury, if crankcase covers are removed fifteen minutes after emergency shut down. Do not restart engine until cause for shutdown has been corrected.SoS ae Mustration 10 yo0296979 The warning label for olectrical distribution (generator) is located on the covers of the generator 36085 Do not connect generator toa utility electrical dis- tribution system unless itis isolated from the sys- tem. Electrical feedback into the distribution sys- tem can occur and could cause personal injury or death. Open and secure main distribution system switch, or if the connection is permanent, install a double throw transfer switch to prevent electri- cal feedback. Some generators are specifically approved by a utility to run in parallel with the distribution system and Isolation may not be required. Always check with your utility as to the ipplicable circumstances. 9 Safety Section Warning Signs and Labels CSA Hazardous Atmosphere (Junction Box) A warning label for the Canadian Standards Association (CSA) hazardous atmosphere is located 9m the junction box. PE See A._AVERTISSEMENT Do not disconnect equipment unless power has been disconnected or the area is known to be non-hazardous Approval by the CSA is a requirement for engines thai operate in hazardous locations, Volatile flammable gases are present in these locations. The gases are normally confined within closed systems. The gases can only escape if the system accidentally breaks down. The CSA warning is intended to prevent a hazardous atmosphere from igniting, Volatile flammable ges that is contacted by a spark will cause an explosion. This could result in personal injury or death, Also, property could be damaged10 Safety Section Warning Signs and Labels, Do not disconnect electrical equipment unless the power has been disconnected. Otherwise, ensure thal the aimosphere is not hazardous. Electrical equipment includes the following components: ignition system, engine contro! system, witing harnesses, and sensors. CSA Hazardous Atmosphere (Control Panel) Imustration 12 pT A warning label for the Canadian Standards ‘Association (CSA) hazardous atmosphere is located on the control panel PT A_AVERTISSEMENT sd | Do not disconnect equipment unless power has been disconnected or the area is known to be non-hazardous Approval by the CSA is a requirement for engines thal operate in hazardous locations, Volatile flammable gases are present in these locations. The gases are normally confined within closed systems. The gases can only escape if the system accidentally breaks down. The CSA warning is intended to prevent a hazardous atmosphere trom igniting Volatile flammable gas that is contacted by a spark will cause an explosion. This could result in personal injury or death, Also. property could be damaged, Do not disconnect electrical equipment unless the power has been disconnected, Otherwise, ensure thal the atmosphere is not hazardous. Electrical ‘equipment includes the following components: ignition system. engine contra} system, wiring harnesses, and sensors. CSA Installation of Transformers ustraon 13. (1) Warring label on transformer The warning labels for the Canadian Standards Association (CSA) installation of transformers are located on the transformers. A_WARNING a | | Cn, mT ORIED IO Fuser 5 | oars Coil must be mounted without flange gasket.1" Safety Section General Hazard Information Approval by the CSA is a requirement for engines thal operale in hazardous locations. Volatile flammable gases are present in these locations The gases are normaliy confined within closed systems. The gases can only escape if the system accidentally breaks down, The CSA warning is intended to prevent a hazardous atmosphere trom igniting Volatile flammable gas that is ignited will cause an explosion. This could result in personal injury or death. Also, property could be damaged. Ita fire should occur within tube (3), the flame could possibly burn through a gasket. This would create 2 gap under flange (2). The gap would enable the flame to ignite @ hazardous atmosphere. To meet the approval of the CSA, the transiormer (coil) must be installed without @ gasket under flange (2), This provides a connection that limits the potential for an explosion. General Hazard Information SMCS Code: 1000 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. Inustation 14 poe 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 fitings '* Pressure taps © Breathers Drain plugs. Use caution when cover plates are removed. Gradualiy loosen but do not remove the last two bolts or nuts that ate located at opposite ends of the cover plate or the device. Belore removing the last two bolts or nuts, pry the cover loose in order to relieve any spring pressure or other pressure. ‘¢ Wear a hard hat, protective glasses, and other protective equipment, as required, ¢ When work is performed around an engine that is operating, wear protoctive devices for ears in order lo 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 thal 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. ‘¢ Roport ail necessary repairs Unless other instructions are provided, perform the maintenance under the following conditions. ‘* The engine is stopped © The protective locks or the controls are in the applied position '* 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.12 Safety Section General Hazard Information # Do not attempt any repairs or any adjustments to the engine while the engine is operating # Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment. * For initial start-up of a new engine or for starting 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 and/or the ignition system. '* Start the engine from the operator’s position or from the control panel that is in the local engine room, California Proposition 65 Warning Some engine exhaust constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm: Pressure Air and Water Pressurized air and/or water can cause debris andjor hot water to be blown out. This could result in personal injury. When pressure air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi) Always wear eye protection for cleaning the cooling system Fluid Penetration ‘Always use a board or cardboard when the engine ‘components are checked for leaks. Leaking fluid that 's under pressure can cause serious injury or possible death. This includes loaks that are the size of a pin hole. If fluid is injected into the skin, seek treatment immediately. Seek treatment from a doctor that is familiar with this type of injury. Fluid Spillage Care must be used in order to ensure that the fluids are contained during the inspection, the maintenance, the testing, the adjusting, and the repair of the engine. Make provision {o collect, the fluid with a suitable container before any compartment is opened or before any component is disassembled. Refer to the Special Publication, NENG2500. This publication explains the items that are needed for collecting and for containing fluids that are used in Caterpillar engines. Dispose of fluids according to local regulations. Asbestos Information Caterpillar equipment and replacement paris that are shipped from Caterpillar are asbestos free. Caterpillar recommends the use of only genuine Caterpillar replacement parts. Use the following guidelines when any replacement parts that contain asbestos or debris that contains asbestos are handled, The asbestos in these components is usually sealed ‘or bonded in a resin, Handling these materials normally is not hazardous unless airborne dust that contains asbestos is generated Do not inhale dust that might be generated when components that contain asbestos fibers are handled, Inhaling this dust can be hazardous to your health, If dust which may contain asbestos is present, follow these guidelines: ‘¢ Never use compressed air for cleaning ‘¢ Avoid abrasion of materials that contain asbestos. ‘¢ Use @ wet method to clean up asbestos debris. A vacuum cleaner thal is equipped with a high efficiency particulate air filter can also be used, '* Use exhaust ventilation when parts that contain asbestos are machined. '* Wear an approved respirator if there is no other way to control the dust ‘* Comply with applicable rules and regulations for the work place. In the USA, use the Occupational Safety and Health Administration requirements. These OSHA requirements can be found in “29 CFR 1910.1001 ‘¢ Obey environmental regulations for disposal of asbestos13 Satety Section Bum Prevention Stay away from areas that might have asbestos particles in the ai, Lines, Tubes, and Hoses Do not bend or strike high pressure ines. Do not install lines, lubes, or hoses thal are damaged. Repair any fuel lines, oil lines, tubes, or hoses that are loose or damaged. Leaks can cause fires. Inspect all fines, tubes and hoses carefully, Do not use bare hands to check for leaks. Always use a board or cardboard for checking engine components for leaks. Tighten all connections to the recommended torque Check for the following conditions: ¢ End fitings that are damaged or leaking ‘¢ Outer covering that is chated or cut ¢ Wire that is exposed in reinforced hose ¢ Outer covering that is ballooning locally ¢ Flexible part of the hose thal is kinked or crushed ‘* Armoring thal is embedded in the outer covering Ensure that all of the clamps, the guards, and the heat shields are installed correctly in order to help prevent vibration, rubbing against other paris, and ‘excessive heal during operation. Burn Prevention SMCS Code: 1 Do not touch any part of an operating engine Allow the engine to coal before any maintenance is performed on the engine. Rolieve all pressure 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. When pressure is feleved rapidly, the hot coolant can turn into steam, Any contact with hot coolant or with steam can cause severe butns. Allow cooling system components to cool before the cooling system is Grained. Check the coolant level only after the engine has been stopped Do not step on the engine in order to remove the filler cap. Use a ladder, if necessary. Ensure that the filler cap is cool before removing the filler cap. Remove the fillor cap slowly in order 10 rolieve. pressure Cooling system conditioner contains alkali, Alkali an cause personal injury. Do not allow alkali 10 contact the skin, the eyes, of the mouth Oils Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin Keep all of the exhaust manifold and turbocharger shieids in place in order to protect components from oil spray if there is a failure of a line, a tube, or Batteries Electrolyte is an acid, Electrolyte can cause personal injury. Do not allow electrolyte 1o 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 Batteries give off combustible gases which can explode. Ensure proper ventilation for batteries that are in an enclosure. Never discannect any charging Unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases to ignite. Do not smoke when batteries are serviced, Always thaw a frozen battery before jump starting lery. Frozen batteries can explode. Fire Prevention and Explo: Prevention SMCS Code: 1000 A flash fi may result in personal injury if the crankcase covers are removed within fifteen minutos after an omergency shutdown,14 Safety Section Crushing Prevention and Cutting Prevention Fire may result from lubricating oil or from fuel that is sprayed on not surfaces. Fire may cause personal injury and property damage. Inspect all lines and tubes for wear or for deterioration. The lines must be routed, supported, and clamped securely. Tighten all connections to the recommended torque. Leaks, can cause fires. Determine whether the engine will be operated in {an environment that allows combustible gases to be drawn in through the air inlet system. These gases could cause the engine to overspeed. This could result in bodily injury, property damage, or damage to the engine. It the application involves the presence of combustible gases, consult your Caterpillar dealer in order to obtain additional information concerning suitable protection devices. Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire. All fuels, most lubricants, and some coolant mixtures are flammable, Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel fumes and gasoline fumes is extremely explosive Do not smoke while the engine is refueled, Do not ‘smoke in the refueling area Store all fuels and all lubricants in properly marked ‘containers. Store the protective containers in a safe place. Do not smoke in battery charging areas. Batteries give off flammable fumes which can explode. Do not smoke in areas that contain flammable material Store cily rags and other flammable material in protective containers. Do not weld on pipes or tubes that contain flammable fluids. Do not flame cut pipes or tubes: that contain flammable fluids. Before pipes or tubes. are welded or flame cut, clean the inside and clean the outside of the pipes or tubes thoroughly with nonflammable solvent Do not allow flammable materials to accumulate on the engine. Do not expose the engine to flames. Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a lube, or a seal failure. Exhaust shields must be installed correctly, Dispose of oil according to local regulations. Oil filters and fuel filters must be properly installed. The housing covers must be tightaned to the proper torque when the housing covers are reinstalled. Batteries must be kept clean. The covers (it equipped) must be kept on the colts. Use the recommended cables, connections, and battery ox covers when the engine is operated Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires betore the engine is operated. Repair all trayed electrical wires before the engine Is operated Wiring must be kept in good condition, properly routed, and securely attached. Routinely inspect the wiring tor wear or far deterioration. Loose witing, unattached wiring, or unnecessary wiring must be eliminated. All wires and all cables must be of the recommended gauge. Do not use a wire or a cable that is smaller than the recommended gauge. The wires and cables must be connected to a fuse or to a circuit breaker, if necessary. Do not bypass luses andjor circuit breakers. Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly maintained battery cables will help prevent arcing or sparking, Fire Extinguisher Ensure that fire extinguishers are available. Be familiar with the operation of the fire extinguishers. Inspect the fire extinguishers and service the fire exlinguishers regularly. Service the fire extinguisher according to the recommendations on the instruction plate. so0st882 Crushing Prevention and Cutting Prevention SMCS Code: 1000 ‘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. Alter the maintenance is performed, reinstall the guards. Keep objects away trom moving fan blades {if equipped). The fan blades will throw objects and the fan blades can cut objects.15 Safety Section ‘Mounting and Dismounting When objects are struck, wear protective glasses in order to avoid injury to the eyes Chips or other debris may tly off abjacts when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris, sore Mounting and Dismounting SMCS Code: 1000 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 andjor 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 hanchoids. Use two feet and one hand or use one foot and two hands, Do not use any controls es handhoids. Do not stand on components which cannot support your weight, Use an adequate ladder or use a work platform. Secure the climbing equipment so thal the equipment will not move. Do not carry tools or supplies when you are climbing. Use a hand line or other means for carrying equipment up to the work area, soennase Ignition Systems ‘SMCS Code: 1550 Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring, Electronic Ignition Do not inspect the vaive mechanism or tho transformers while the engine is operating. Personal injury or death may result, The ignition system will be damaged if the ignition harness is removed during engine operation. if the mode control switch is in the AUTOMATIC. or START position and the wiring harness is connected, the ignition system may discharge and a spark plug will ignite. The spark plug will ignite any gas that has accumulated in that cylinder. The crankshaft and the driven equipment can move. Personal injury may result. The driven equipment could be damaged. Gas that has accumulated in the exhaust system can also be ignited, ‘Turn the mode control switch to the STOP or OFFIRESET position before connecting the wiring harness. When the mode control switch is in the ‘STOP or OFFIRESET position, the ignition system is disabled Magneto ‘The storage capacitor in a breakerless magneto can be charged by turning the magneto by hand. The storage capacitor can be charged even when the wiring hamess is disconnected from the magneto. I the mode control switch is in the AUTOMATIC ‘or START position and the wiring hamess is being connected, the storage capacitor may discharge and a spark piug will ignite, The spark plug will ignite any gas that has accumulated in that cylinder. ‘The crankshall and the driven equipment can move Personal injury may result, The driven equipment could be damaged. Gas that has accumulated in the exhaust sysiem can also be ignited. Before connecting the wiring harness to a breakerless magnoto, discharge the storage capacitor to the ground. Use the following procedure fo discharge the siorage capacitor: 4. Attach one end of a wire to the magneto housing 2. Contact the other end of the wire to the Connector pins for the wiring harness that is on the magnelo, You will hear a “snap” when the storage capacitor discharges. 3. Ground all of the connector pins This will ensure that no charge is in the magneto. Some breakerless magnetos have more than one storage capacitor, ‘Tum the mode control switch to the STOP or OFFIRESET position before connecting the wiring harness. When the mode control switch is in the ‘STOP or OFF/RESET position, the ignition system is disabied16 Safety Section Before Starting Engine 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 (ree of personnel. Ensure that the engine is equipped with a lighting system thal is suitable for the conditions. Ensure that all ights work propery 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 shutott 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 intial start-up of a new engine or an engine that has Deen 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 adjusiments. ‘osreana Engine Starting ‘SMCS Gode: 1000 a warning tag is attached to the engine start switch oF to the controls, DO NOT start tne engine (or move the controls. Consult with the person that attached the warning tag before the engine is started Al 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 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) andjor the lube oil heater (if equipped) is working properly, check tne water temperature gauge and the oil temperature gauge during the 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. soess007 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 Siop Button for normal engine stopping After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been correcte: On the initial start-up of @ 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, of shutting off the ignition system. 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.v7 Safety Section Electrical System Check the electrical wires dally for wires that are loose or frayed, Tighten all laase electrical wires belore 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 crankshalt journal surlaces, 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 *-” baltery terminal with a wire that is adequate to carry the full charging current of the alternator, For the starting motor, do not altach the batlery negative terminal to the engine block, Ground the engine block with a ground strap that is furnished by the customer. Connect this ground strap fo the ground plane. Use a separate ground strap to ground the battery negative terminal for the control system to the ground plane il rubber couplings may 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18 Product Information Section Model Views. Product Information Section Model Views soo8eses Model View Illustrations ‘SMCS Code: 1000 The illustrations show various typical features of G3600 Engines. The illustrations do not show all of the options that are available. tsteation 15, coos (1) Gas shutott valve (5) Crankcase breather (2) Banting doves (2) Fut control actuator {6} ranstormer 10) Ot oval gauge (G) Exhaust bypass actuator (7) Ol iter (19) Ol iter (4) Uiting eye! {) dunction box (12) Ol drain19 Product Information Section Model Views tuator (15) Staring motor nkcase explosion reli valve20 Product Information Section Model Views: IMysteation 17 (17) Air inlet (18) Exraust (19) Jacket water pure oeo100 Engine Description SMCS Code: 1000 The G3600 Family of Engines are designed to provide power for the following applications: ‘© Direct drive chiller ‘* Electrical power generation Gas compression ‘¢ Industrial air compression ¢ Petroleum ‘The engines incorporate advanced technology that is essential for obtaining these qualities: ‘¢ High output = Low emissions ‘¢ High thermal efficiency (20) aftercooler and ol cooler pura (21) Frywneet housing (22) Crankshaft vibration damper porns) (29) Prelute pump 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 fuel system of these engines does not use a carburetor, A control valve allows the fuel to enter the gas manifold, The control valve is actuated by an actuator. The fuel pressure in the manifold is, regulated by the actuator and the control valve. Fuel flows from the manifold through an orice. Some of the gas is routed through an adjustable needle valve and into a prechamber. The fuel in the prechamber is ignited by the spark plug. This provides the ignition for the airfluel mixture in the cylinder. The rest of the gas is routed through a valve (gas admission valve). The gas admission valve is actuated by the camshaft. This allows fuel to enter the inlet port in the cylinder head. The gas is mixed with air in the cylinder head.Air for combustion flows from the turbocharger to a cchoke (air inlet). The air inlet choke is actuated by an actuator. The air travels through the aftercooler to the air plenum and into the cylinder head inlet port. The inlet manifold pressure is controlled by the air inlet choke and the exhaust bypass valve An electronic control system determines the air sure thal is required 10 maintain the correct uel ratio. The electronic control system controls the air inlet choke and the exhaust bypass valve. The electronic control system controls the ignition timing. The control system monitors changes in the load. The control system moaifies the timing in response to the change in the load, The timing can also be modified in order to compensate for Getonation that is detected The engine has two cooling circuits. 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 centrifugal pump (gear type) pulls the jacket water 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 wat temperature regulator and to a heat exchanger. 7 coolant is returned to the engine. For engines with @ standard cooling system, the lube oil and the air for combustion are cooled in a separate circuit, A pump pulls the coolant from the heat exchanger. Some of the coolant goes 10 the oll cooler. Most of the coolant goes to the aftercooler, The coolant returns to the heat exchanger. The lube oil is supplied by a gear type pump. The temperature of the lube ail is regulated. The oil is fillered belore the ail is circulated 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, iuels, and coolantiantireezes, For the engine maintenance that is required, see this, Operation and Maintenance Manual, ‘Maintenance Interval Schedule” (Maintenance Section). 21 Product Information Section Model Views Engine Specifications Table 1 - “G3612 Engine Specifications Operating em 750 t0 1000 Low ile «pm 550 Cylinders and 50 degree vee 12 arrangement foe 300 mm (11.8 inch) |sc ees Aspiration ’ Compression ratio 924 1051 ta Displacement per cylinder 21.2 L (1204 in’) 254.4 L (15,528 in’) 9 mvs (172 fUmin) Total displacement Mean velocity of the pistons at 900 rpm Mean velocity of the pistons at 1000 rpm 10 mis (1969 fumin) Flywhee! rotation Counterclockwise (standard) Fuel ‘See this Operation and Maintenance Manual “Fuel Recommendations” (Maintenance Section) ‘iso, see the Application and Installation Guide. Method of starting Performance of the cooling Air starting motors, See the Application and Installation Guide Maximum allowable 3 kPa (12 inches of H.O) exhaust back pressure Maximum allowable inlet air restriction 3.7 kPa (15 inches of HO) | Air cleaners Remote 0.64 mm (.025 inch) Valve lash (gas admission valve)" : " Inlet valve lash | 0.50 mm (.020 inch) 1.25 mm (.050 inch) (This measurement is for newer engines. For earier engines, the valve lash is set by uring an adjusting sorow and ‘counting the “ceks" Exhaust valve lash22 Product Information Section Model Views Iustation 18 {63612 Engine cyindar numbers (A) Gas admission valves () Inet valves (©) Exhaust valves (©) Front Table 2 G3616 Engine Specifications Operating pm (Tae 2, cos (62616 Engine Speciications ‘Maximum atowatie inlet) 3.7 ¥Pa (18 inches of HO) | aeatton Ar cleaners Remote Vana an sn | 08 rm 05 et Inlet vave lash —==——0.50 mm (.020 inch) Exhaust vale fash 1.25 mm (050 inch (1 This moasurement is for newer engines. For earlier engines, the valve lash is sot by turning an adjusting screw and counting the “cleks" +1000 Low idle rpm Cylinders and arrangement Bore Stroke Aspiration Compression ratio | Displacement per cylinder isplacement Mean velocity of the pistons at 900 rpm Total Mean velocity of the pistons at 1000 rpm Flywheel rotation (standard) Fuel Method of starting Performance ofthe cooling system Maximum allowable exhaust back pressure 550 50 degree vee 16 200 mm (11.8 inch) Mustration 19 coca’ 300 mmm (17.8 inch) 63616 Engine cylinder numbers = (8) Gas aamission valves a (8) a ves ) Exhaust valves 924 (0) Front 1051 oo a A ———____ Drives and Gear Trains 212 L (1294 in) 399.2 L (20,704 ir? Front Drives 9 mis (172 fumin) 10 rms (1969 fmin) Counterclockwise ‘See this Operation and Maintenance Manual, Fuel Recommendations" (Maintenance Section), ‘Also, soe the Application ‘and Installation Guide, Air starting motors tusvation (qo0R aa ‘See the Application peeeale and Installation Guide, ‘SAE standard engine crankshatt rotation (1) Jackot water pur 3 kPa (12 lches of H.O) {2) Ateroter ana cooler pump (8) OF pump (continued)23 Product information Section Model Views Tle « “Front Gear Train Gear Number Of Teeth 41) Crankshaft | 96 (2) tater 6a (9) ler or (4) Jacket water pump 38 | : (8) Aftercooler and oil cooler Pump: 38 (6) Auxiliary pump 43 Mustration 21 Oona 63 SAE stand engine crankshatrtaon ewe ce Engine Rear Gear Train {6} Or omer $$ —________— — (7 On not Table 3 Front Drives Component Jacket water pump Atercooler and oil cooler pump |otpane (0 The speed of the component is sted for an engine that is ‘operating at 1000 rpm. For an engine that is operating at 800 spn. ruliply the speed ofthe component by 9. For an engine that's operating at 800 rpm, mutiply the speed ofthe component by 8 Engine Front Gear Train tustravon 22 255208 SAE standard engine crankshaft rotation (2) Crankshatt (2) tater (6) later (a) Jacket water pump (5) Afleteooler and ok cooler pum (6) Auxiiay pump (7) 04 pump ‘mustravon 23 ‘SAE standard engine crankshaft tation (1) Crankshatt (2) Large cluster idler {G) Smal stor ier (4) Camshat (5) ioe" Oa? Table 5 i Rear Gear Train Gear Number OF Test | icra 31 tage deride (4) Camshatt 81 | (5) Wier 1 at24 Product Information Section Model Views. Reference Weights hate 6 Approximate Engine Weights Dry weight of | 63612 Engine | G3616 Engine the engine wth siachnents 25.084 ig | 29.892 4g ($5,300 8) (65,900 1) ranie 7 Approximate Weights Of Serviceable Parts Component csst2 | Gaeie Engine | Engine Cylinder block 6005 kg | 9625 ko (497rb) (21.219) Bearing cap 185g (144 1) | 65 hg (1441) Crankshat 2001 kg | $800 ke (4600); _(6878 b) Flywheel assembly 491 kg aig | (rose) | (4082 fy | Crankshaft vibration 185kg 183 Kg damper (403 1b) (403 1b) | Cylinder head 196 kg 196 kg ascombly am) | (432m) Cylinder liner 110 kg 110 kg | eas) | 23) Piston assembly | 48.kg (106 ib) 48 hg (106 f) Piston la 19 kg (2) | 19 kg (42) {Piston rod assombly | 7 kg (126 b) | 57 kg (126 b) Tubocharger (one) «401 Kg | AOL HQ | Coe) ‘Atercooler core) 94 kg (207Ib) | 125 4g | 250) Front housing 258 Ko | 258. Kg (36916) | (669.8) Fear housing 350 kg) 350 Kg | 2b | cab Used air cleaner V2 kg (64 Ib) 29 kg (64 Ib) element i (©) The weight listed is for a one-stage altercooler. A two-stage fteroooler and a deep core aftersoole ae also avalale Tobie 8 |” Approximate Weights Of Package Generator Sets item | 3612 Engine | G3616 Engine Engine! 25,084 kg | 29,802 kg | (58,300 Ib) (65.200 fb} Generator 15.655 kg | 15,855 kg (34954) | (34,964) Module 1650 kg 1650 kg (2638 1B) (638 1B) Mounting base | 12.700 kg 12,700 kg (28,000 18) (28,000 b) Couping | 97 kg (2154 i | 97 ka (2154 fo) Tota 55266 4g | 61.074 kg | (2h045 bm) | (194.648 1) (0) The weights ofthe engines that are listed includes atachmonts that are mourted on the engines. The engine Weights are ory woignts,25 Product Information Section Product Identification Information Product Identification Information Engine Identification ‘SMCS Code: 1000 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 that is 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, corrse7s Serial Number Plate ‘SMCS Code: 1000 OPATERPILLAR® GAT® ustravon 24 ooze The Serial Number Plate is on the side of the cylinder block above one of the crankshaft inspection cavers. The following information is stamped on the Serial Number Plate: engine serial number, model, and arrangement number. Information Plate SMCS Code: 1000 station 25 The Information Plate is on the side of the cylinder biock above one of the crankshalt 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 Reference Numbers ‘SMCS Code: 1000 Information for the following items may be needed to order parts. Locate the information for your engine. Record the information in Table 9. Make a copy of this list for a record, Retain the information forluture reference.26 Product Information Section Product Identification Information Record for Reference Table 9 Serial Number - | Arrangement Number Modification Number Performance Specification [PowerRating Personality Module (Revision) Low fdle rpm ! | High Idle rem | Full Load «pm Lube Oil Capacity (total) Ar Cleaner Element Supplemental Coolant Adve Cooling System Capacity (total) TbechrwerOperation Section Engine Lifting and Storage Engine Lifting : SMCS Code: 1000 stration 26 oot NOTICE When it is necessary to remove a component at an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. Eyebolts and brackets should never be bent and should only be loaded in tension. 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 abject that is being lifted Some removals require lifting fixtures in order to obtain proper balance. Some removals require lilting fixtures in order to be handled properly To remove the engine ONLY, use the lilting eyes that are on the engine. Lifting eyes are designed and installed for the specific engine arrangement. Alterations to the liking 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. Consul your Caterpillar dealer for information regarding fixtures for proper engine liking, 27 Operation Section Engine Lifting and Storage Engine Lifting with a Generator NOTICE Do not use the engine lifting eyes to remove the engine and generator together. A lifting plate is provided with the package generator set, Instructions for lifting the package generator set are stamped on the lifting plate Consult your Caterpillar dealer for information regarding proper fixtures and lilting devices. Engine Storage SMCS Code: 1000 It 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 ail 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, “General Coolant Information” (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 fone month, @ 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28 Operation Section Engine Features and Controls. Engine Features and Controls 6282 Control Panel SMCS Code: 7451 Engine Supervisory System The engine supervisory system is specifically designed for Caterpillar G3600 Engines. The engine supervisory system integrates several engine contol systems. The engine supervisory system optimizes each controlled parameter in order to ensure maximum engine performance The engine supervisory system consists of the following components: Control panel Junction box # Actuators « Potentiometers ‘¢ Relays, solenoids, sensors, and switches Wiring The engine supervisory system includes three systems that are integrated Starv/Stop/Prelube System ~ This system controls the starting of the engine, the stopping of the engine, and the prelube pump, Engine Monitoring And Protection System — This system provides a display of parameters of engine ‘operation. The system generates warnings when ‘one or more parameters are outside acceptable limits. The system can stop the engine if the engine ‘operation reaches @ setpoint that is programmed for shutdown. The system can prevent the engine from starting if certain paramoters are outside of acceptable limits Engine Control System ~ This system governs the engine. This system controls the airfuel ratio, the ignition timing, and the limiting of power. Some of the components within the engine supervisory system perform more than one function. For example, the engine control module is involved with these activities: « Starting # Monitoring © Controlling # Stopping The components of the control panel are briefly described in this section. For more detailed information on the engine supervisory system, see the Service Manual, “Systems Operation/Testing and Adjusting” module, Control Panel Wustration 27 (1) Caterpittar mentoring system (2) Timing contot mocute “FUEL ENERGY CONTENT potentiometer Engine contra mod “SPEED CONTROL" potentiometer (6) Status control module (7) Mode contro! smtcn (6) Pyrometers {0) "EMERGENCY STOP” buton (10) “MANUAL PRELUBE” switch29 Operation Section Engine Features and Controls jo Ptien om Mustration 28 (1) Mode contrat stch (2) "EMERGENCY STOP" button () "MANUAL PRELUBE" switch Mode Control Switch Mode control switch (1) has four positions: = "AUTO" ° “START © “STOP © “OFFIRES! “AUTO” ~ When the mode control switch is in the "AUTO" position, the system is configured for remote operation. When the romote start/stop initiate contact closes, the prelube system will operate and the engine will start. When the remote startistop initiate contact opens, the engine will shut off. I the coo! down cycle is programmed, the engine will operate for the cool down period before the engine slops. The cool down cycle can be programmed for a0 to 30 minute period “START” — When the mode control switch is tuned {0 the “START” position, the prelube system will operate. When the prolube pressure is sufficient, the engine will start, The engine will operate until the engine supervisory system receives a shutdown signal The following methods cause a shutdown signal: # The remote start/stop initiate contact opens when the mode control switch is in the "AUTO" position @ The mode control switch is tured to the “STOP” position. ¢ The moce 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 engine supervisory system. “STOP" - When the mode control switch is turned to the "STOP" position, 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. Ater the engine stops, a postiube cycle will operate. The power to the control panol is maintained when the mode control switch is in the "STOP" position, Tho “STOP" mode 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, the engine is immediately shut off and the diagnostic lights of the status control module are reset. Power is removed {rom the control panel and the actuators alter the engine completes the postlube cycle This method for stopping bypasses the normal stopping procedure. This method for stopping is not recommended “EMERGENCY STOP” Button NOTICE Only use the “Emergency Stop" button in order to stop the engine in an emergency situation. Do nat use the “Emergency Stop" bution for normal engine stopping. To prevent damage to the engine, use the mode control switch or use the remote startstop initiate contact for normal engine stopping, The fuel and the ignition are immediately shut off when "EMERGENCY STOP” button (2) is pressed, No postiube cycle occurs The “EMERGENCY STOP” button and the mode control switch must be reset before the engine will start, To resel the “EMERGENCY STOP" button, turn the button clockwise, To reset the mode control switch, turn the switch to the OFF/RESET position. Note: More than one “EMERGENCY STOP" button may be available for use.30 Operation Section Engine Features and Controls “MANUAL PRELUBE” Switch “MANUAL PRELUBE” switch (3) enables the operator to prelube the engine. Lubrication is required prior to rotation of the crankshail. This includes crankshaft rotation in order to service the engine. Rotating the crankshaft before prelube may cause damage fo the crankshalt bearings if the surfaces of the bearings are dry. All G3600 Engines require lubrication prior to start-up. The engine supervisory system will not permit the engine to start untl sufficient prelube pressure has been achieved. The actuators will be powered up alter the engine has been prolubed Note: The engine control module is programmed to provide engine lubrication after the engine is shut off. The typical duration of the postlube is 60 seconds. Engine Monitoring and Protection System Status Control Module The status control module includes the following features: + Control of starting the engine and stopping the engine # Basic engine protection # A display of the status of certain parameters + Shutdown indicators «© Diagnostic information When the status control module receives a signal to start the engine, the module activates the fuel system and the starting motor. When the engine rpm reaches the crank termination speed, the starting motor is disengaged. The module will sequentially display the following parameters in two second increments: service hours, engine rpm, battery voltage, engine oil pressure, and engine oil tomperature, The module also monitors the engine for faults ‘The engine will operate until the module receives @ shutdown signal OD abou Sit Iwustration 29) poer86s Status contol module (1) Liquid Crystal Display (LOD) (2) Swen {@) LOW OM PRESSURE” LED (4) “OVERCRANK” LED (5) ‘OVERSPEED" LED (6) HIGH OWL TEMPERATURE” LED (7) "EMERGENCY STOP" LED (@) “AUXILIARY” LED Liquid Crystal Display (LCD) ~ International Standards Organization (ISO) symbols for the foliowing parameters are tocated under LCD (1). The LCD provides a digital display of the status of these parameters, When the status of a parameter is displayed, an arrow at the bottom of the LCD points the corresponding ISO symbol. The display can be in metric units or English units. Hour meter — When the arrow points to this symbol, the hours of engine operation are displayed Engine speed — When the arrow points to this symbol, the engine rpm is displayed. System battery voltage — When the arrow Points to this symbol, the voltage of the electrical system's battery is displayed.Engine oil pressure — When the arrow points to this symbol, the engine oil pressure is cisplayed. Engine oil temperature - When the arrow points to this symbol, the engine oil Temperature is displayed The parameters are displayed sequentially. To lock the display onto one af the parameters, press switch (2). To resume the sequential display, press the switch again. The LCD is also used to display diagnostic codes A diagnostic indication signifies that the system has detected the failure of components that are associated with the status control module. When a diagnostic code is displayed, the arrow that indicates the display of the parameters will be missing, A flashing "diAG’ will be displayed. I more than one diagnostic cade is present, the diagnostic codes will be displayed in sequence. Table 10 is a list of the diagnostic codes that can be generated by the status control module and a brief explanation of the codes. For more detailed information on diagnostic codes and troubleshooting, see the Service Manual, “Troubleshooting” module. ratte 10 a Display OF Diagnostic Codes | For The Status Control Module Code Indication 01; Theis no signal rom the engine speed | 02 | Ther is no signal tom the of prossure [Netgear aneaucer 03 ‘There is a problem with the signal from the | rode comet awh 0% Theis a oss of ho stpoins Inthe memory OF ie satus contol mod." | 65 |The engine has shut down wihout a signal Tom the satus conte mode’? 08 | Theres an ineral axe ofthe status contol mnode othe wage supply is unsadi G7” | There isan enor in the progtameing ol tho Sus cont mele 68 Thore aprobiem win the ol temperature (continued) a Operation Section Engine Features and Controls (Table 10, conta} isplay Of Diagnostic Codes For The Status Control Module code Indication 02 There is a problem with the oil pressure sensor. 10 the engine is operating, he engine wil shut down. Tho engine wil rot star, 12 Ifthe engine i not operating, the engine may be unable 10 2 ha engine is not operating, the engine will not start ‘The status control module has six fight emitting diodes (Nlusiration 29) that indicate an engine shutdown. The shutdowns that are associated with the indicators are described below. Overcrank ~ If the engine fails to start within a programmed amount of time, the status control module will deactivate the starting sequence, LED (4) will flash. The mode contro’ switch must be turned to the "OFFIRESET” position belore another attempt to start the engine can be made, “LOW OIL PRESSURE” ~ If the engine oii pressure decreases below the setpoint, the fuel to the engine will be shut off. LED (3) will flash, There are two setpoints for low oil pressure, The setpoints depend on the engine rpm. One selpoint is for engine rpm that is below the oil slep speed setting. The other setpoint is for engine rpm that ig abave the oll step speed setting “OVERSPEED" - If the engine rpm “HIGH OIL TEMPERATURE” ~ If the engine oil temperature exceeds the selpoint, the fuel will be shut off, LED (6) will flash, “EMERGENCY STOP” ~ LED (7) wil flash if the “EMERGENCY STOP" button is used to stop the engine “AUXILIARY” — LED (8) is available as a custom shutdown indicator Note: Hf a fault accurs and the contol for the fue! does nol shut down the engine, the ignition is shut off five seconds after the fault has occurred.32 ‘Operation Section Engine Features and Controls Caterpillar Monitoring System The Caterpillar monitoring system monitors parameters of engine operation. The parameters are displayed on digital gauges and a digital display. The panel also has indicators thal illuminate when faults are detected. The monitoring system receives information from sensors. The monitoring system communicates the information to the engine control module. | 2esgtso @Q BL ete se mene ge 0 srr GI 2 gone sence (; occ Be? FogRe Soren gg OE SENSIS wear Breet Ge asst nee Imran 90 peas Ccatritrmortoing sym (3) Sat gauges (4) Large gage (y-DIMER ant (2)"GAGE GROUP SELECT’ switch (5) en (8) Fault indicators {6} Kdeniication of the small gauges (lm) “DIMMER” switch (7) enables the operator to contro! the brightness of the lighting for the contro! panel. ‘The brightness is reduced when the switch 1s toggled. After the dimmest ight has been reached, toggle the switch in order to return the display to the maximum brightness. Large gauge (4) is a tachometer. This gauge always indicates the engine rpm, Two sets of parameters can be displayed on the six small gauges (1). The display will be in either metric units or English units. Identification for the two sels of parameters are listed on film (3). The fiim includes the ISO symbols of the parameters ‘and the units that are displayed on the gauges. Digital splay (6) "GAGE DATA SELECT" ewiteh (6) Identification o the fault ncicators (tim) The information that is displayed on the six small ‘gauges is controlled by "GAGE GROUP SELECT” switch (2), To display the parameters that are listed ‘on the left side of the film, move the switch to the left. To display the parameters that are listed on the right side of the film, move the switch to the right. ‘The information that is displayed on digital display (8) is controlled by "GAGE DATA SELECT” switch (6). This switch enables the operator to view a digital display of the parameters that are listed on fim (3). The upper number in the digital display indicates the parameter that is displayed. Toggling the "GAGE DATA SELECT” switch causes the next gauge to be displayed33 ‘Operation Section Engine Features and Controls Ii the "GAGE GROUP SELECT” switch is toggled, the digital display will change to the gauge that corresponds with the position, For example, if gauge "1 AIR TEMPERATURE” was selected and the "GAGE GROUP SELECT” switch is toggled, the digital display will show the data for gauge “7 OIL FILTER DIFFERENTIAL’. Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine the normal operating range by observing the gauges over a period of time Noticeable changes in gauge readings can indicate potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within specifications, Determine and correct the cause of any significant change in the readings. Consult your Caterpillar dealer for assistance. inlet air is too high during full speed and load operation, the engine may misfire. Also, detonation ee “1 AIR TEMPERATURE” ~ This gauge “2 COOLANT TEMPERATURE” ~ This (Sp, "3 FUEL CORRECTION" - This gauge (BB) Faeates ot corocion nc ets aoplod by he arhl ao cont ton ‘An indication to the lett side of the gauge signifies the following condition. The same condition is signified by a digital display of less than 100, '¢ The fuel exhibits a lower fuel energy content than indicated by the setting of the “FUEL ENERGY CONTENT" potentiometer. ‘An indication to the right side of the gauge signifies the following condition, The same condition is signified by a digital display that is greater than 100. ‘¢ The fuel exhibits a higher fuel energy content than indicated by the setting of the “FUEL ENERGY CONTENT" potentiometer. When the load is greater than 50 percent tor more than three minutes, the air/luel ratio is automatically contralied. The control is based on the following factors: ¢ The setting of the "FUEL ENERGY CONTENT” potentiometer ¢ Duration of combustion that is measured in the cylinders This automatic control is called “leedback’ mode. When the engine is in this mode. a red circle around the gauge is ON. When the engine is in prechamber calibration mode (or magneto calibration mode, the automatic control is nol used. The red circle around the gauge is OFF and the fuel correction factor is secured at 100 percent when the engine is in this mode. These modes can only be accessed through the digital diagnostic tool. The magneto calibration mode is used only for setting the initial calibration of the magneio. The magneto calibration mode is used only with a load of less than 50 percent of raled torque. The prechamber calibration mode is used only for setting the needle valves for the prechamber and for some troubieshooting ieee (air inlet manitold) after the aftercooler. “4 AIR INLET PRESSURE" ~ This gauge “5 ENGINE OIL PRESSURE” - This gauge indicates the prossure of the engine oil. The pressure will be highest after a cold engine is started. The pressure will decrease as the engine warms up, The pressure will increase when the engine rom is increased. The pressure will stabilize when the engine rpm is stable, Note: If the mode control switch is in the "AUTO" of “START” position, the prelube cil pressure is Indicated by a green ring around the ol! prossure gauge. A ring that is continuously displayed indicates sufficient prelube pressure. A ring that is flashing indicates that the prelube pressure is NOT sufficient,34 Operation Section Engine Features and Controls “6 ENGINE LOAD” - This gauge indicates a percentage of the engine's full rated torque. The calculation of the percentage is based on these factors: flow of fuel, engine rom, {uel energy content, and fuel correction factor. This, gauge flashes if the torque exceeds the maximum, limit that is programmed into the control strategy. @) 7, OIL FILTER DIFFERENTIAL” ~ This gauge indicates the difference in pressure between the inlet side and the outlet side of the engine ail filters. As the oil fiter elements, become plugged, the pressure will increase. AIR RESTRICTION LEFT - This gauge indicates the air restriction for the left air inlet. This gauge indicates the difference in air pressure between the inlet side (ambient air pressure) and the engine side (turbocharger inlet) of the air fiter element. The air restriction is measured from the turbocharger air inlet. AS the air fiter element becomes plugged, the difference in pressure between the two sides of the air cleaner element will increase. Normal air restriction is 1.25 kPa (5 inches of H.O), “9 CRANKCASE PRESSURE” - This gauge indicates the pressure that is inside the crankcase. The typical crankcase pressure is 0.125 kPa (5023 inches of H.0) Changes in the crankcase pressure may indicate problems with the following components: crankcase ventilation system, pistons, piston rings, and cylinder liners. “10 COOLANT OUTLET PRESSURE” - This gauge is usually blank. Some applications use the gauge in order to display the outlet pressure of the engine coolant. “11 AIR RESTRICTION RIGHT” ~ This gauge indicates the air restriction for the right air inl G “12 STARTING PRESSURE” - This gauge (€BF indicates the air pressure that is available = — for starting the engine, Fault Indicators ‘The monitoring system has 12 fault indicators (illustration 30). The indicators are identified by the film that is located beneath the fault indicators on he panel. This enables the operator to investigate the faults, Table 11 is a list of the fault indicators and a brief explanation of each faull35 Operation Section Engine Features and Controls, e Table 11 Fault “F1 CHECK GAGES" “F2 CHECK FLUID LEVELS") “F3 AUXILIARY EQUIPMENT “F4 FUEL SUPPLY SYSTEM" “FS AIR INLET SYSTEM™ “F6 EXHAUST SYSTEM" “F7 MODULESMWIRING™® “F8 COMBUSTION FEEDBACK SYSTEM “F9 IGNITION SYSTEM"" "F10 SENSORS/DEVICES" “F11 STARTING SYSTEM" °F12 DETONATION SYSTEM" Fault Indicators For The Caterpillar Monitoring System Indication (One or more gauges indicate that a parameter is outside of the normal range. (One oF more tuid levels are below an acceptable level. (One or more problems exist in the interlace for the driven equipment. ‘One or more problems exist in the system that controls the fuel ‘One or more problems exist in the system that controls the inlet air ‘One or more problems exist in the exhaust system. ‘One or more problems exist with specific control modules andlor the wiring, | ‘One or more problems exist in the controls for the feedback from the combustion system. ‘One oF more problems exist in the ignition system. ‘One or more problems exist on specific control devices. This includes sensors, actuators, et, _One oF more problems exist in the engine starting system. ‘One or more problems exist in the system that detects detonation. (0 Note the dlagnestic codes that are splayed on the engine control module. eer to the Service Manual, “Troubleshooting? module Pyrometer The digital pyrometer is an electronic instrument that is designed to monitor exhaust temperatures. ‘The pyrometer uses “K” type thermocouple probes. The pyrometer can display the temperatures of ‘The exhaust porl and the exhaust temperatures are shown on dispiay (1). Channel °0" is displayed when the control panel is powered up. Channe! *0" displays the exhaust stack temperature. "PUSH TO ADVANCE” button (2) enables the operator to select, the temperatures from the different exhaust ports, nine points in the exhaust system. The nine points include the exhaust stack and eight exhaust ports. G3612 and G3616 Engines use two pyrometers. ‘One pyrometer is for the lelt side and one pyrometer is for the right side of the exhaust system, Oe anh Hustravon 31 Pyrometer (1) Display (2) "PUSH TO ADVANCE button (3) “PUSH TO READ” tution (a) Adjustment serew (sotpount) ‘The temperature of channel “0” is continuously compared against the setpoint for high exhaust slack temperature. If the setpoint is exceeded, the pyrometer will close an output switch to the ground This instructs the engine control module to shut down the engine ‘The setpoint is established during the engine commissioning, To adjust the selpoint, use the following procedure: Note: Do not increase the setpoint above 600 (1112 °F) without approval from the factory. 1. Press "PUSH TO ADVANCE” button (2) until channel *0" is displayed 2. Press "PUSH TO READ" button (3) in order to dispiay the setpoint. Note: A switch on the back of the pyrometer enables the operator to select a display of Celsius or Farenheit degrees 3. Turn adjustment screw (setpoint) (4) until the temperature that is desired for the setpoint is reached36 ‘Operation Section Engine Features and Controls To increase the temperature of the setpoint, turn the adjustment screw clockwise. To decrease the temperature of the setpoint, turn the adjustment screw counterclockwise. Engine Contro! System Operator Inputs. The engine control module monitors the fuel energy content for the airfuel ratio control and for limiting the power. The engine control module relies on. information from sensors, buffers, and the seiting of the "FUEL ENERGY CONTENT” potentiometer. The information is necessary in order to maintain the air/fuel ratio and the foliowing conditions: ‘* Combustion that is consistent '* Control of emissions '» Optimum performance ‘The duration of combustion is measured in each, cylinder. Each cylinder has a sensor for combustion and a buffer. The pulse of the ignition starts the timer for the butler. The flame travels in the cylinder from the spark plug to the sensor for combustion, A signal from the sonsor stops the timer, The duration of combustion is an excellent method of measuring the aififuel ratio, A rich mixture of fuel provides a fast duration of combustion. A lean mixture of fuel provides slower duration of ‘combustion. During normal operation, the engine control module will calculate the air/uel ratio. The airtuel ratio can bbe rich or lean in order to suit the fuel, The engine control module calculates @ new inlet manifold air pressure that will provide the ideal airfuel ratio for the engine speed and load. The exhaust bypass. valve is repositioned in order to maintain the calculated iniet manifold air pressure. Under the following circumstances, the airffuel ratio is maintained only by measuring the fuel flow ‘and the setting of the "FUEL ENERGY CONTENT" potentiometer: * Operation at less than 50 percent of the rated torque ‘¢ The engine is in prechamber calibration mode or magneto calibration mode. SPEED FUEL ENERGY CONTROL, CONTENT Iustravon 32 senaez108 (1) “SPEED CONTROL” (2) FUEL ENERGY CONTENT" potentiometer Note: Remote control of the “FUEL ENERGY CONTENT” and the "SPEED CONTROL” is available. Use of the remote control disables the potentiometers on the control panel “FUEL ENERGY CONTENT” potentiometer (2) enables the operator to adjust the setting for the low heat value of the lue! thet is being used. The engine control module will display the setting. The solting provides a starting point for airfuel ratio Control. The selling is used until information about the duration of combustion is available. Alter the engine has operated for twwee minutes at 2 load that is greater than 50 percent, the engine Control module will maintain the proper aitfluel ratio by using the actual duration of combustion in the cylinders. This occurs unless the engine is in prechamber calibration mode or magneto calibration mode. Note: The low heat value is based on data from a {uel analysis. To determine the low heat value of the fuel, the data from the fuel analysis must be input into the Caterpillar PC Software, LEKQ6378, "Methane Number Program “SPEED CONTROL" potentiometer (1) allows the ‘operator to select the engine rpm that is needed, Low idie speed is 550 rpm. Rated speed can be as high as 1000 rpm. Engine Control Module The engine control module performs the following functions: # Controling tne airfuel ratio ‘© Governing the engine rpm '* Monitoring operation7 Operation Section Engine Features and Controls «# Protecting the engine « Starting the engine Stopping the engine Most of the functions of the engine supervisory system ate routed through the engine control module. The module controls most of the operations of the engine supervisory system, The control strategy of the module contains many of the setpoints for the protective system, Mustraion 33 oo Engine control module (1) Display (2) LED indicators (3) DISPLAY SELECT” wren The engine contiol module uses display (1) and LED indicators (2) to provide status and diagnostic information, Diagnostic codes are shown on display (1), Identification of the indicators is adjacent to the indicators. if an indicator is ON continuously, the corresponding diagnostic code is displayed. If an indicator is flashing, the corresponding diagnostic code is available, but not presently displayed. For example, if the engine control module is indicating a continuously green “STATUS” mode, but the red “SENSOR FAULT” LED is flashing, a fault is present but not currently displayed. "DISPLAY SELECT” switch (3) must be toggled in order to display the diagnostic cade. The “DISPLAY SELECT” switch enables the operator to view the information on the display. When the switch is toggled, the next parameter is displayed The parameters are displayed in the following order: # Desired engine rpm # Fuel energy content # Diagnostic codes in order of occurrence Write down all diagnostic codes that are displayed. The display of the diagnostic code is cleared when the “DISPLAY SELECT” switch toggled or when power is removed from the lectronic control module. Log the diagnostic codes before clearing the codes. Logging the diagnostic codes will help to soive en problems. For detailed information regardi diagnostic codes, see the Service Manual, “Troubleshooting” module, The eight engine control module indicators and a brief explanation of the indicators are listed in Tabie 1238 Operation Section Engine Features and Controls LED Display On The Engine Control Module LED Color Indicati ‘STATUS" Green | Status information is displayed “COMMUNICATION LINK Green | The engine control module is communicating properly with the Timing ACTIVE Control Module, “COMMUNICATION LINK 2 Yellow | The engine control module is communicating properly with the gauges ACTIVE” i of the monitoring system, the ports for the digital diagnostic tool, the customer communication module, and the detonation mixing control “CAUTION MODE" Red One of more problems exist, The code that indicates the exact nature of the condition will be displayed {A problem with one of the sensors has been detected. One or more problems exist. The code that indicates the exact nature of the condtion will be displayed ‘A problem with one of the actuators has been detected. The code that indicates the exact nature of the problem will be displayed. ‘SENSOR FAULT" | Rea “ACTUATOR FAULT | “SYSTEM FAULT | Ret] | A problem with one of the control systems has been detected. The code that indicates the exact nature of the problem willbe displayed. | ape 1 | CONTROL MODULE FAULT” Red | A problem with one of the control modules has been detected. The code | I that indicates the exact nature of the problem will be displayed. The display will normally indicate either the desired engine rpm or the fuel energy content for the engine operation. If diagnostic cades are presont, the appropriate engine control module indicator and the corresponding Caterpillar monitoring system fault indicator (*F1" through “F12") are illuminated. See llustrations 33 and 30 Using the "DISPLAY SELECT” will reveal the Giagnostic code. Toggling the “DISPLAY SELECT” switch will cause the display to indicate any other diagnostic codes in the order of occurrence. Hf the engine control module shuts down the ‘engine because of a fault, the condition which caused the shutdown wil FLASHING diagnostic code which do not cause an ens warning codes. A display of a warning code does not flash. Correct the cause of the warning code in order to avoid problems with operation. be indicated by a If the engine control module initiates an engine shutdown, a “RST REQD™ message will also be present on the engine contra! module, To view the message, toggle the “DISPLAY SELECT" switch, This message indicates that the sysiom must be reset before the engine can be started, To reset the system, turn the mode control switch to the *OFF/ RESET" position. This will also clear the message, Use of the mode control switch o the remote start! slop initiate contact causes the status control module to shut down the engine. The status control module sends a signal fo the engine control module, The engine control module will display “SHUT ON” when the signal from the status control module is received A “SHUT DN” display indicates one of the following ‘occurrences: '* The engine has completed a normal shutdown thal was initiated by an external signel. ‘# The mode control switch is in the "STOP" position. This code will be cleared when the engine is started, Resetting the engine control module is not required If @ diagnostic code has been acknowledged but the status control module continues to send a shutdown signal, the yellow "CAUTION MODE indicator will lash, The diagnostic code will appear during a scroll of the display until the shutdown signal is removed A display of "PC CAL" indicates that the engine is in prechamber calibration mode or magneto calibration mode,29 Operation Section Engine Features and Controls Th 19 Control Module The timing control module maintains the ignition timing that is determined by the engine control module, The timing control module also protects the engine from unacceptable levels of detonation The timing control module provides the engine control module with information about timing and detonation. The engine control module sends a signal to the timing control module for the engine timing thal is desired. The signal can be retarded it detonation is sensed. The engine will be shut down if high levels of detonation persist Ly fs ances ystation 94 (1) Display forthe engine control modus {2} Light emiting diode (LED) indicators for the ting control meduie (@) DISPLAY SELECT: switch The timing control module uses sensors to monitor ‘components of the timing system. if a component fails or if @ wiring harness fails, the timing control module will illuminate an indicator (2). Identification for the nine indicators is adjacent to the indicators. The diagnostic code can be displayed on display for the engine control module (1). To view the Giagnostic code, toggle "DISPLAY SELECT” switch @. Write down all diagnostic codes that are displayed. The display of the diagnostic code is cleared when the “DISPLAY SELECT” switch is toggled or when power is removed from the electronic control module. Log the diagnostic. codes before clearing the codes. Logging the diagnostic codes will help to solve engine problems. For detailed information regar iagnostic codes, see the Service Manual, “Troubleshooting” module. The nine indicators that are on the timing control module are listed in Table 13. LED Display On The Timing Control Module LED - ~~ Color “CONTROL OW Groen “DETONATION ENGINE SHUTDOWN Red “MAGNETO OUT OF CALIBRATION’ Red “NO RH DETONATION SENSOR SIGNAL” Red “NO LH OETONATION SENSOR SIGNAL" Red |-No SPEED SENSOR SIGNAL Red [NO CRANK ANGLE SENSOR SIGNALYY Row [-NO MAGNETO INTERFACE SIGNAL‘ | Red NO COMMUNICATION SIGNAL" fed (0 This fault wil not cause an engine shutdown. ithe engine is shut ofthe condtton must be clearad before the engine is ‘allowed to start, For more detailed explanations of the faults that are generated by the timing control module, see the Service Manual, "Troubleshooting" module.40 Operation Section Engine Starting Engine Starting Before Starting Engine : SMCS Code: 1000 Perform the required dally maintenance and other periodic maintenance betore starting the engine. This can prevent major repairs aa later dale. See 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 @ thorough inspection before starting the engine, Make @ 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 cleat. Air Inlet System ‘» Ensure that the air inlet piping and the air filters, are in place, ‘* Ensure that all clamps and connections are secure. 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. sary. information on the proper coolant to use, see this Operation and Maintenance Manual, “Cooling System Specifications’ (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 thal 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, Lubrication System Wustration 35 (Oi level gauge (2) "ADO" mark (2) FULL! mark ‘¢ Check the engine crankcase oil level, Maintain the oil level between the “ADO” and “FULL " marks on the “ENGINE STOPPED" side of the cil level gauge. For information on the proper oil to use, see this Operation and Maintenance Manual, “Lubricant Specifications" (Maintenance Section).a Operation Section Engine Starting ‘# Check for leaks at the following components: crankshait seals, crankcase, ail filers, oil gallery plugs, 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, OF the red piston locks in the visible position. Fuel System ‘¢ Inspect the {uel lines for loose fittings and leaks, Ensure that the fuel lines are properly clamped. ‘* Ensure that the fuel is supplied fo the engine at the correct pressure for the application. Many engines use a fuel pressure of 310 = 14 kPa (45 + 2 psi) Some engines use a variable fuel pressure that is based on the engine load. For the proper fuel pressure, see the report from the engine commissioning, Starting System tustraton 30 (1) Barring device (2) Latricator (9) Ar supply valve * Ensure that barring device (1) is fully disengaged. Drain moisture and sediment from the air tank and from any other air piping Check the oil level in lubricator (2). Keep the lubricator at least half full, Add oi. if necessary. Use nondetergent “10W" oil for temperatures that are greater than 0 °C (32 ‘F). Use air tool oil for temperatures thal are below 0 °C (32°F) # Check the air pressure for starting. Starting motors with vanes require air pressure in a range ‘of 620 to 1550 kPa (90 to 225 9s). Ar turbines require air pressure in a range of 210 to 620 KPa (30 to 90 psi, ‘* Open air supply vaive (3) 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 contro’ system, Cold Weather Starting SMCS Code: 1000: 1250 See Gas Engines Application and Installation Guide, LEKQ7255 for more information on the folowing topic '* Recommendations for the size and installation of jackot water heaters and oil heaters # Requirements for cranking torque and air starting motors at various temperatures Consult your Caterpillar dealer for more information Cn the starting aids that are available for cold weather starting Jacket Water Heaters Jacket water heaters are available as optional equipment. Jacket water heaters are recommended for improving startabilty 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.42 Operation Section Engine Starting NOTICE Heating elements that are in direct contact with the lubricating oil can cause coking of the oi To aviod coking of the oil when the oil is heated, follow these recommendation: The temperature of the heating surface must not exceed 150 °C (300 °F). The maximum heat density of the heating surface must not exceed 1.24 wlom (awiin’). Oil viscosity affects the amount of torque that is needed fo crank the engine. Oil temperatures below 10 °C (50 °F) reauire cranking torque that is excessive. Oil heaters are recommended for heating the lube oil to 10 °C (60 °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 andjor a higher air pressure 's 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.waler separator removes vapor from compressed ait 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. veononzn Starting the Engine SMCS Code: 1450 Engine exhaust contains products of combustion which may be harmful to your health. Aiways 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 startup 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. Note: Using the “EMERGENCY STOP" button will shut off both the fuel and the ignition Unburned gas in the inlet manifold andlor in the exhaust manifold can ignite when the engine is started. Personal injury and/or property damage can result. Use this procedure to clear the engine and the exhaust system of unburned gas: Before starting an engine that was stopped by terminating the ignition system, turn the gas supply OFF. Crank the engine for approximately 48 seconds in order to clear any unburned gas from the engine and the exhaust system. 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). 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. I the mode 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 rom when the oil pressure is sufficient. Manual Starting 1. Ensure that fuel is supplied to the engine. Ensure thal no gas is leaking43 Operation Section Engine Starting 2. Ensure that the driven equipment is unloaded. . For generator set engines, open the main cireult breaker, b. For industrial engines, unioad the compressor ‘or pump. Disengage the clulch (it equipped). Place the transmission andjor other attachments for the power take-off in NEUTRAL, So || @ AUTO @ OFF /RESETC@ By START Seton? tustaton 37 seicesb8 (1) "SPEED CONTROL” potentiometer (2) "FUEL ENERGY CONTENT” potentometer {G) Mode contol switch in the “START” postion 3. Verity that "SPEED CONTROL" potentiometer (1) is set to an rpm that is appropriate. Verity that the "IDLEIRATED" display (if equioped) indicates “IDLE’ 4, Verily that “FUEL ENERGY CONTENT” otentometer (2) is set fr the fuel that is being set NOTICE Do not engage the starting motor when flywheel is turning. Do not start the engine under load. It the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allow the starting motor to cool before using it again. 5. Turn mode control switch (3) to the “START” position, NOTICE ‘The engine must be prelubed betore the crankshaft is rotated, Damage can resultif the crankshaft is rotated on dry bearing surfaces, Note: The prelube oi pump will operate for approximately 30 seconds. When the ail pressure is sufficient, the status control mociule will initiate the engine start-up. I the module detects a signal to prevent the engine irom starting, the appropriate indicator will illuminate, & 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. When all systems are normal, the rpm may be increased. Ensure that the oil pressure and the fuel pressure are in the normal ranges. After the engine has slarted and the warm-up is complete, the engine ‘can be operated at low rpm and low load. The engine will reach normal operating temperature faster if he engine is operated at low rpm and with 2 low power demand. This procedure is more effective than idling the engine with no load. The ‘engine should reach normal operating temperature ina tew minutes. Starting Failure Note: If the cycle crank feature is enabled, the status control module will allompt to start the engine for the programmed period. If the engine fails 10 start within the programmed period, the module will execute an overcrank faull, The *OVERCRANK” indicator on the medule will illuminate. The module must be reset before the engine can be started. To reset the module, turn the mode control switch 10 the "OFF/RESET” position, HW the engine fails to start alter cranking for 30 seconds, stop cranking. Perform the following procedure: 1. Tum the mode control switch to the “OFF/RESET" position, 2. Turn the gas supply OFF.44 Operation Section Engine Starting 3. Allow the starting motor to 600! for two minutes. Crank the engine for approximately 15 seconds in order to disperse any unburned gas from the engine and the exhaust system 4, Allow the starting motor to cool for two minutes. Turn the gas supply ON. Repeat the starting procedure, After Starting Engine SMCS Code: 1000 Note: For new installations and engines that are recently rebuilt, carefully monitor the engine in order to detect any unusual engine performance. Check the gauges 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 rom until the oil pressure gauge indicates a minimum of 160 kPa (23 psi) at low idle rpm. 1. Increase the engine rom. ‘The minimum rpm for operating an engine with a load is 750 rom. The maximum rpm for operating an engine with a load is 1000 rpm. 1. For engines with a “SPEED CONTROL" potentiometer or a remote speed control, turn the control to the engine rpm that is desired b. For engines with an "IDLE/RATED" switch. toggle the switch to the "RATED" position Ensure that the gauges are in the normal ranges for the engine rpm. Note: It may be necessary to apply some load in ‘order to attain normal operating temperatures. 2. After verifying that the engine systems are normal, engage the driven equipment. Apply the load according to the requirements for temperatures that are listed in Table 14. Table 14 Required Temperatures For Applying The Load ‘Minimum Percent of Jacket Water Rated Torque Temperature Before Loading 0 to 49% 38°C (100°F) | 10°C (50°F) 50 to 100% | 80°C (122°F) | 50°C (122 °F) Continue to check the gauges and the driven. equipment. Continue to operate the engine at a load according to the operating temperatures that are listed in Table 14 For information on partial load operation, see this Operation and Maintenance Manual, “Engine Operation” topic (Operation Section). 3, Adjust the load, as needed.45 Operation Section Engine Operation Engine Operation ‘oor7sr0 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 Ite of the engine. Observe the gauges frequently while the engine is operating. Record the data from the gauges in a log reguiatly. Compare the data to the specifications for normal engine operation. Comparing the data over lime will help 10 determine the normal readings for each gauge. Comparing the data over time wil help to detect changes in engine performance. Investigate any significant change in the gauge readings. Monitor the engine operation and take action when discrepancies are found. Operating the Engine and the Driven Equipment ‘Tho 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 gauges and the driven equipment frequently while the engine is operating under a load. Partial Load Operation Extended operation at low idle or al a reduced load will cause increased oil consumption and carbon buildup in the cylinders. Carbon buildup results in the following effects: * Power loss '¢ Poor performance ‘¢ Accelerated wear of components Caterpillar Engines can be operated at very light loads (torques) for limited times with no harmful effects. Table 15 lists the limits for hours of operation at various torques. After the time limit for reduced load operation has expired, operate the engine for a minimum of two hours at a torque that is more than 70 percent. For example, an engine is operating at 20 percent Gf the rated torque. 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 al ‘east two hours al @ load factor of more than 70 percent To keep engine maintenance al a minimum, follow the guidelines that are listed in Table 15 Table 15 ‘Time Limits For Low Load Operation |_Engine Torque Time | 0 to 29% 1/2 hour | 30 t0 49% 2 hours | s0 10 100% _ ‘0 Time represents the hours of operation atthe speciied load 1) Alter the time has elapsed, oparate the engine above 70 percent load for a minimum of two hours46 Operation Section Engine Stopping Engine Stopping so062088 Emergency Stopping ‘SMCS Code: 1000 NOTICE Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure. Ensure thal any system that provides external support to the engine is secured after the engine is sloped. Turn off the auxiliary systems for engine operation after the engine is stopped. NOTICE Do not start the engine unti the problem necessitating the emergency stop has been located and corrected. Emergency Stop Button Ca lustation 36 (1) Emergency slop button {2) Mode contrl sitchin the “OFFIRESET" positon The emergency stop button is in the OUT position for normal engine operation. For an emergency stop, push emergency stop bution (1). 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 bution will return to the OUT position Tho contro! panel must also be reset before the engine wil start. To reset the control panel, turn mode control switch (2) to the "OFFIRESET” position, ‘enaroesa Manual Stop Procedure ‘SMCS Code: 1000 NOTICE Stopping the engine immediately atter it has been working under load can result in overheating and accelerated 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. 4. Disengage o 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 equiped). Place the transmission andior other attachments for the power take-olf in NEUTRAL. Note: Extended idling can cause excessive oil consumption and related problems. See this Operation and Maintenance Manual 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 caoldown period before stopping the engine, 1a If the engine has been operated at a low load, operate the engine at low idle for approximately 30 seconds before stopping the engine. b. I the engine has been operated at a high load, operate the engine at low idle for approximately five minutes before stopping the engine 3. Use one of the following methods in order to, stop the engine:47 Operation Section Engine Stopping Mustration 39 Mode contol switch in the “STOP® postion ‘a. Turn the mode control switch to the “STOP” position b. If the mode control switch is in the "AUTO" Position, open the remote start/stop initiate contact, If the cooldown feature is utilized, the engine will operate for a programmed period of time betore 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 60 seconds. The power to the contro) panel will be maintained The engine will coast to a stop. Ensure that any system that provides external support to the engine 's secured aiter the engine is stopped. Turn off the auxiliary systems for engine operation after the engine is stopped, 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, periorm minor adjustments, Repair any leaks and lighten loose bolts. ‘¢ Nole the service hour meter 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 Coolant Specifications of this manual. Failure to do so can cause engine damage. «¢ Allow the engine to cool. Check the coolant level ¢ If treezing temperatures are expected, check the coolant for protection against freezing. The coaling system must be protected against freezing to the lowest expected outside temperature. Add the proper coolantiwater 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48. Maintenance Section Torque Specifications Maintenance Section Torque Specifications ‘osc? General Torque Information ‘SMCS Code: 7553 FOG Mismatched or incorrect fasteners can result in damage or malfunction, or possible injury. Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners. Exceptions to these torques are given in the Service Manual, it necessary, Prior to installation of any hardware, ensure that ‘components are in near new condition. Bolts and threads must not be worn or damaged. Threads must not have burrs or nicks. Hardware must be free of rust and corrosion. Clean the hardware with a noncorrosive cleaner. Do not lubricate the fastener threads except for the rust preventive. The rust Preventive should be applied by the supplier of that component for purposes of shipping and storage. Other applications for lubricating components may also be specified in the Service Manual Standard Torque for Metric Fasteners SMCS Code: 7553 Table 16 Metric Nuts and Bolts ‘Thread Size Reaee Standard Torque 1223Nm(9+2 bn) 28.27 Nm (21251) Mio 55£ 10. Nm (41 = 7 bf m2 100 # 20 Nim (75 + 15 bf) mia 160 + 30 Nem (120 = 22 bf) ute 240 = 40 Nim (175 = 30 Ib fh) M20 460 = 60. Nm (9402 441A) £800 + 100 Nim (590 + 75 1b ft) | M30 | 1600 = 200 Nem (1180 + 150 Ib ft) M36 £2700 += 800 Nim (2000 + 220 Ib ft) Metric Taperiock Studs Tg $6 Sana fee Mi2 | 65 + 10 Nm (48 + 7 Ib ft) Mi6 [110 20 Nem (80 + 15 bf) Meo | 170+ 30 Nm (125 2 22 bt) Mes) 400 + 60 N-m (300 + 44 Ib ft) M30 t 750 + 80 N-m (550 + 60 Ib ft) M36 1200 = 150 Nem (880 + 110 Ib ft)Standard Torque for Inch Fasteners SMCS Code: 7553 Table 18 ee Inch Nuts and Bolts Muse! Standard Torque wa 122 3.Nm (9 +2 bf 5n6 25 = 6 Nm (18 +4 fof) 47 = 9Nm (85 +7 Ib tt) 7H6 70 #15 Nem (50 + 11 tb ft) 1” 105 2 20 Nim (75 + 15 ft) one 160 2 80 Nem (120 = 22 fb t 216 © 40 Nem (160 = 90 Ib ft) 370 + 50 Nm (275 = 97 tb ft | _620 = 80 Num (460 = 60 Ib 1) 1 900 = 100 N-m (660 = 75 bf) 118 1900 = 150 Nom (960 = 110 fo ft) 114 "1800 = 200 Nom (1320 = 150 tb ft) 138 £2400 + 300 N-m (1780 + 220 16H) 112 13100 # 360 N-m (2280 Table 19 Inch Tapertock Studs Milt eead Standard Torque 14 82 3Nm6+2If) 5n6 1725 Nm (132 4M) 308 35 = 5 Nem (26 x 4 Ib) 7h6 45 + 10. Nem (93 = 7 Ib f) ve 65 2 10 Nm (48 = 7 1b f) 1 88 110 2 20 Nem (80 = 15 Wf) | 3a 170 £30 Nem (125 = 22 10M) rz 260 + 40 Nim (190 + 90 1b) 1 400 + 60 N:m (900 = 44 tb ft) 118 525 + 60 Nem (890 = 44 Ib ft) aw 750 = 60 Nem (550 2 60 Ib ft) 138 950 # 125 Nim (700 + 90 bf) 112 11200 + 150 N-m (880 = 110 Ib ft) 49 Maintenance Section Torque Specifications Standard Torque for Worm Drive Band Hose Clamps SMCS Code: 7553 ustraven «0 Table 20 Initial Installation f Width of Clamp torque On New Hose 7.9. mm (31 inch) | 09 2 0.2Nm (8 =2 bin) 413.5 mm (SS inch) 4.5 20.5 Nm (40 2 4 bin) | 1.9mm (.63 inch) | 7.5 20.5 Nem (65 + 4 Ib in) Reassembly or Retightening Torque 7.9 mm (31 inch) 07 202Nm(6+2Idin) | 113.5 mm (53 inch) 3.0.4 0.5 Nim (27 4 4 Ib in) 15.9 mm (69 inch) | 4.5 # 0.5 Nem (40 + 4 Io in) Width of Clamp Standard Torque for Constant Torque Hose Clamps SMCS Code: 1000; 7553 Use @ constant torque hose clamp in place of any standard hose clamp. Ensure that the constant torque hose clamp is the same size as the standard hose clamp. Due to extreme temperature changes, the hose will heat set. Heat setting can cause nose clamps to loosen, Loose hose clamps can result in leaks, There have been reports of component failures that have been caused by hose clamps that have loosened, The constant torque hose clamp will help prevent these failures yo, gmneroaat51 Maintenance Section Lubricant Specifications Lubricant Specifications Lubricant information SMCS Code: 1000; 7581 Engine oil performs several functions: + Kooping the engine clean ‘¢ Preventing rust and corrosion # Acting as a coolant # Reducing friction and wear Engines that uso gaseous fuel require oils that are formulated with additives that are specific to these engines, No performance specilications are available to define the performance levels that are required by engines that use gaseous fuels. Field tests must be used in order to define oils that are acceptable. To aid in oll selection, guidelines are provided in Supplement, SEBU6400, “Caterpillar Gasoous Fueled Spark Ignited Engines Lubrication Specifications" Grease is classified by the National Lubricating Grease Institute (NLGI). The classification is based on the "ASTM D217-68 Worked Penotration characteristics, The characteristics have a number for consistency that is defined. For information on grease, see this Operation and Maintenance Manual, “Lubricating Grease” topic (Maintenance Section}. Engine Oil SMCS Code: 1000; 7581 Caterpillar Oils Caterpillar Oils have been developed and tested in ordor to provide the full performance and service life that has been designed and built into Caterpillar Engines. These oils are offered by Caterpillar Gealers for continued use when the engine oil is changed. Consult your Caterpillar dealer for more information on these oils Due to significant variations in the quality and in. the performance of commercially available oils, Caterpillar makes the following recommendation: « Caterpillar Natural Gas Ent (ow) Caterpillar NGEO has been tested throughout the world in demanding environments. Caterpillar NGEO has beon tested in engines thal use all types cof gaseous fuel. The formulation of the oil has Deen proven to be superior to many brands of ail that are locally available. (NGEO) For maximum service life of the engine and the engine oil, use Caterpillar NGEO with low sultur gaseous fuels that contain less than 0.43 mg H.S/MJ (45 ug H-S/Btu). Caterpillar NGEO may also be used with high sulfur natural gas and with bio-gas. Bio-gas is formed in langfils and sewage gas digesters. The use of these fuels may require a shorter oil change interval Caterpillar NGEO is formulated and blended with special additives in order to provide protection agains! oxidation and nitration. Caterpillar NGEO aiso has thermal stability. Caterpillar NGEO also provides the following benefits: ‘¢ Reduction of the formation of carbon and sludge # Resistant to foaming ‘* Protection against corrosion ‘¢ Protection of valves and valve seats « Improved cleanliness of pistons # Protection against scoring of the pistons and scuffing of the pistons # Protection against cylinder liner wear Table 21 lists the oil properties of Caterpiliar NGEO (40W), The properties are based on ASTM test specifications52 Maintenance Section Lubricant Specifications Table 21 Caterpillar NGEO Properties Characteristic ASTM Test SAE 40W API Gravity “Doze | 8 | Flash Point *D 0092 248 PourPont | OMT) tS | | cSt Viscosity sposss | 1305 | at 40" C (104° F) cStViscosty Cts) |S | at 100° C (212° F) Viscosity Index “0 0867 a7 Percent Weigh of “poere | 0a8 | Sulfated Ash Total Base Number “D 2896" Commercial Oils Commercial oil specifications do not exist for Caterpillar Engines that operate on gaseous fuels. The performance of lubrication oil for gas engines is determined by a field test. Successtul field operation has been achieved with oils that meet the following guidelines: ‘* Caterpillar recommends the use of oils that are formulated specifically for heavy-duty gas engines. Do not use ails that are specially formulated for gasoline engines or for diesel engines, Caterpillar recommends the use of olls that have @ sulfated ash content between 0.40 and 0.60 percent, The oil must demonstrate adequate protection for ‘4 minimum of 7000 hours in a field test under controlled conditions. NOTICE Failure to follow these oil recommendations can ‘cause shortened engine service life due to deposits and/or excessive wear. NOTICE Caterpillar recommends the use of oils that are formulated specifically for heavy duty spark ignited gaseous fueled engines. Oils that are formulated for gasoline engines only or for diesel engines only should not be used, 7000 Hour Field Test Caterpillar recommends oils for gas engines that meet the requirements of the 7000 hour field test. The 7000 hours of field service must be documented, Standard andjor Low Emission engine configurations may be used for the test. The field test must be performed in an engine configuration that is similar to the engine that will use the oil that is proposed. The field test must be performed at a power level that is at least equal to the power that Is required by the engine that will use the oil that is proposed. Field tests may identify commercial brands of oil with successful results. Caterpillar will not endorse oF approve of a brand of oll based on those results, Tne oll company can use the results of the field test 8 a proof of the oi’s performance. The oil company is responsible for the performance and the quality of the oll, and for any changos in the formulation of the oil. Before purchasing a lubrication oil for a gas ‘engino, discuss the claims of performance for the oll with the oil supplier. For additional information on field tests, see Supplement, SEBUS400, “Caterpillar Gasoous Fueled Spark Ignited Engines Lubrication Specifications” Sour Gas and Bio-Gas Applications Note: For more information, see this Operation and Maintenance Manual, "Fuel Recommendations’ topic (Maintenance Section). Many gaseous fuels contain sulfur compounds. These compounds are primarily composed of hydrogen sulfide (H.S). Gaseous fuels are considered "sweet" if the level of sulfur compounds is less than 0.43 mg H.S/MJ (.45 ug H.S/Btu}. Gaseous fuels with more than 0.43 mg H-S/MJ (45 ug H.S/Biu) are considered “sour” gas. Sour gas can reduce the service life of an engine and the engine oil. When the sulfur compounds are combined with water, acids are produced in the engine oil. These acids attack the metals in the engine crankcase. This causes corrosive wear. To reduce the effects of these sulfur compounds, Caterpillar recommends the use of devices that treat the fuel, If the sour gas cannot be treated in order to reduce the level of sulfur, additional measures must be taken in order to protect the engine. To reduce the harmiul effects of sour gas, Caterpillar recommends the following guidelines: Use a “low energy fuel engine” configuration. ‘¢ Maintain the temperature of the jacket water (outlet) at 110 °C (230 °F)53 Maintenance Section Lubricant Specifications ‘¢ Reduce the oil change interval according to the results of oii analysis. Caterpillar does not recommend the use of engine oils with a nigh concentration of sulfated ash in order to reduce the harmiul effects of sour gas. High levels of sulfated ash may produce excessive deposits on the valves and on the turbine wheel of the turbocharger. These deposits will reduce the service life of tne engine. These deposits wil also increase the cost of maintenance, For additional information on gaseous fuels and on trealment of the fuel, see the following publications: ‘* Application and Installation, LEKQ7256, *Fuels/ Fuel Systems" '* Application and Installation, LEKQ7260, "Low Energy Fuels’ # Maintenance Management Schedules, ‘SEBUG127, “Schedules for Industrial and EPG Spark Ignited Gas Engines’ For information regarding condemning limits of the lubrication oi, refer to this Operation and Maintenance Manual, “S'O'S Oil Analysis” topic (Maintenance Section). Lubricant Viscosity SAE 40W is the only grado of ail viscosity that is recommended for Caterpillar G3600 Engines. Table 22 lists the minimum ambient temperature for slarting a cold engine, and the maximum ambient temperature during engine operation. Table 22 Engine Oil Viscosity Caterpillar Ambient Temperature NGEO 7 Grade of Minimum Maximum Viscosity SAE 40 50 (41°F) (122° F) Aftermarket Oil Additives SMCS Code: 1000, 7581 Caterpillar does not recomment the use of aftermarket additives in oil. It is not necessary lo use aftermarket additives in order to achieve the engine's maximum service life or rated performance. Fully formulated, finished oils consist of base ols and of commercial additive packages. ‘These additive packages are blended into the base ils at precise percentages in order to help provide finished oils with performance characteristics that meet industry standards. There are no industry standard tests that evaluate the performance or the compatiblity of aftermarket additives in finished oil. Aftermarket additives may ot be compatible with the finished oil's additive package, which could lower the performance of the finished oil. The aftermarket additive could fail to mix with the finished oil. This could produce sludge in the crankcase. Caterpillar discourages the use of aftermarket additives in finished oils Hydraulic Oil SMCS Code: 5095 Applications Systems Hydraul Hydrostatic Transmissions lar Hydraulic Oil (HYDO) Caterpillar Hydraulic Oil is formulated with a balanced additive system. The system includes the following agents: detergents, rust inhibitors, antiwear agents, and defoamers. Caterpillar Hydraulic Oil offers protection against mechanical wear, against rusiing, and against corrosive wear in hydraulic systems and in hydrostatic transmission systems. Caterpillar Hydraulic Oil should be used 10 achieve maximum file and maximum performance from hydraulic system components and trom hysirostatic transmissions. Caterpillar Hydraulic Oil is recommended in most hydraulic systems and in most hydrostatic systems. Cater] Caterpillar Hydraulic Oil It a different viscosity is required due to ambient temperatures, the following Caterpillar oils can be used!54 Maintenance Section Lubricant Specifications © Caterpillar Muitigrade Diese! Engine Oil (DEO) + Caterpillar Single Grade Diesel Engine Oil (DEO) + Caterpillar TransmissioniDrive Train Oil (TOTO) *# Caterpillar Multipurpose Tractor Oil (MTO) Commercial Oils It Caterpillar oils cannot be used, the following commercial classifications can be used in hydraulic systems and in hydrostatic transmission systems: ¢ CG-4 engine oils that have a minimum zinc additive of 0.09 percent (900 ppm) © CF-4 engine oils that have a minimum zine additive of 0.09 percent (900 ppm) © OF engine oils that have a minimum zine additive of 0.09 percent (200 ppm) Caterpillar Biodegradable Hydraulic Oil (HEES) Caterpillar has a biodegradable hydraulic oil that is available for use in machine hydraulic systems. This, fluid is recommended for the hydraulic systems when environmental compliance is required or dested | BIO Machines with this symbol are filed wi biodegradable hydraulic oil. This symbol is located on the hydraulic tank, This fluid is formulated from a saturated HEES (Hydraulic Environmental Ester Synthetic) synthetic base stock and selected additives. Use this oil only in hydraulic systems, Do not use the oil in compartments with brakes and clutches. Do not use BIO HYDO (HEES) oil in machine hydraulic systems with jacket water cooling such as large track-lype tractors of off-highway trucks. BIO HYDO (HES) is recommended for operation at tank temperatures of -32 to 100°C (-25 to 212°F) . While the oil is in the specified range of temperatures, the ol has a viscosity that is similar 0 SAE 10W or to ISO VG 46. Caterpillar BIO HYDO (HEES) may become darker in color throughout the service life of the oil. Analysis is required to determine the quality of the oil ‘The maximum recommended water content for hydraulic systems that are filled with Caterpillar BIO. HYDO (HEES) is 0.10 percent. If the water levels ‘exceed 0.10 percent, the water should be removed the oil should be replaced Consult your Caterpillar dealer for additional information on this product and on the potential use. Commercial Biodegradable Hydraulic Oil H Caterpillar BIO HYDO (HEES) is not used. commercial oils which meet the Caterpillar BF-1 specifications should be used, S-0-S Oil Analysis SMCS Code: 1000; 7542 Caterpillar recommends the SOS oil analysis program in order to monitor the condition of the oil and the maintenance requirements of the engine. The SOS program complements the preventive maintenance program. The $-0'S oil analysis includes these tests:55 Maintenance Section Lubricant Specifications ¢ The Wear Rate Analysis monitors wear by detecting, identifying and assessing the amount of engine wear metal and type of engine wear metal that is in the oil. The Increase in the rate of engine wear metal in the oil is as important as the quanlity of engine wear metal in the oil For this reason, regular sampiing at specified intervals is necessary in order to establish wear rates for each compartment that is lubricated by oll, Intermittent sampling does not allow woar rate trond lines to be established. Engine wear melals in the oll sample are compared {0 established Caterpillar norms in order to. determine acceptability. Potential failures can be identified when the wear rate andjor the contaminants exceed the established trend, Tesis are conducted in order to detect contamination of the oil by water and/or glycol The Oil Condition Analysis determines the loss of the oil's lubricating properties. An infrared analysis is used to compare the properties of new oil to the proporties of the used ail sample. This analysis allows technicians to determine the amount of deterioration of the oil during use. The test results of the oil samples will then be used as a basis for determining the oil change interval for the engine. The results of the $-O'S oil analysis may enable the engine to operate longer between oil changes without the risk of damage Obtain each oil sampie when the oil is warm and well mixed in order to ensure that the sample is representative of the oil in the engine crankcase. il analysis is essential in order to determine satisfactory performance of the oil. Refer to Special Publication, PEDP7036, “S-O-S Fluid Analysis" for more information Consult your Caterpillar dealer for complete information and assistance about the program. Condemning Limits of the Oi! Oil analysis is the only method of determining it an ail is protecting the engine. The cil analysis is compared to limits that have been established through experience The condemning limits for lubrication oll were developed from experience with engine operation and from the analysis of used oil. The limits provide Quidelines for determining the uselul service life of the engine oil. Table 23 lists the limits for the service He of the oil Table 23 8.05 Oil Analysis Condemning Limits Parameter Limit 100% as defined by 5.0 ol analysis, Oxidation Nitration | 100% as defined by S.0S oll analysis: Water | 0.88% maximum Glycot 0% Silicon (Bio-gas engines) 25 pom Based on Caterpillar horms and on the trend of the Wear Rate Analysis! Wear Metals Additional Oil Analysis Viscosity at 100°C (212°F) Increase of 9 by “ASTM Daas St from new oil Total acid number (TAN) | 3.0 maximum or 2.0, by "ASTM Desa” {greater than new oi! Total base number by 50% of new oll TEN “ASTM 02896" (0 base tend can be established trom the results of three oi analyses cca Lubricating Grease ‘SMCS Code: 1000; 7581 Caterpillar provides grease in order to cover a variety of applications and extreme temperature conditions. Consult your Caterpillar dealer for part numbers and for available sizes of containers, Note: Some greases may not be used with other greases. When a commercial grease 's used, ensure that the grease is compatible with the grease that is currently used in the system. If the commercial grease is not compatible, the system must be purged. If any questions arise concerning he compatioilty of a grease, consult the supplier56 Maintenance Section Lubricant Specifications Multipurpose Greases Multipurpose Lithium Complex Grease (MPG) Multipurpose Lithium Complex Grease (MPG) is general purpose lithium complex grease for medium duty applications, This product has good characteristics al high temperatures such as a dropping point over 260°C (500°F). MPG contains unleaded oxireme pressure additives, antiwear inhibitors and corrosion inhibitors thal provide extra protection in the following applications: * Construction Agricultural '* Automotive MPG meets the requirements for extended service intervals of automotive chassis points and for extended service intervals of wheel bearings with disc brakes in automobiles, in vans, and in light trucks. This product meets the NLGI certfication of *GC-LB". MPG js also available in NGLI grade No. 2. Normal operating temperatures for this product are -28 to 149°C (~18 to 300°F) This product is also available as a while lithium complex grease Multipurpose Lithium Complex Grease with Molybdenum (MPGM) Multipurpose Lithium Complex Grease with Molybdenum (MPGM) is a general purpose lithium complex grease that is used for light-duty applications and for medium duty applications. The MPGM is available in NLGI grade No. 2 or NLGI grade No. 0. The MPGM is fortified with @ molybdenum disulfide and polymer for ‘extra lubrication and protection. MPGM contains unleaded additives. MPGM also contains antivwear inhibitors, oxidation inhibitors, and corrosion inhibitors that are for protection and lubrication in many environments. The MPGM is formulated with @ base fluid that has high viscosity. The MPGM has the following features: «© Increased protection against water washout Increased retention ‘* Resistance to heavy loads This product is recommended for heavily loaded pin joints and for journal bearings. This product mects the certification of "GC-LB". Normal operating temperatures for this product are ~28 to 149°C (18 to 300°F) for the NLGI No. 2. Normal operating temperatures for this product are -18 to 149°C (@ to 300°F) for the NLGI No. 0. Note: If MPGM is not available, use @ multipurpose type grease which contains three to five percent molybdenum. Special Purpose Grease (SPG) Bearing Lubrication (SPG) Bearing Lubricant (SPG) is a NLGI No. 2 lubricating grease with a polyurea thickener. This grease is recommended for high temperature antitriction bearings in the following applications: electric starter motors, alternators, tan drives, and generators, The Bearing Lubricant (SFG) has an effective operating range of ~29 to 17°C (-20 to 350°F) Water and Temperature Resistant Grease ‘The Water and Temperature Resistant Grease is designed for use whenever the following conditions are a concern: water washout, severe corrosion, ang high operating temperatures. The Water and ‘Temperature Resistant Grease provides extreme pressure, antiwear, oxidation, and corrosion protection. The Water and Temperature Resistant Grease is an environmentally friendly grease which does not contain antimony, sulfur, barium, zinc, lead or phosphorous, The Wailer and Temperature Resistant Grease has excellent shear stability and can also resist a breakdown in the presence of water. The Water and Temperature Resislant Grease works well in the following applications # Construction # Agricultural # Automotive « Industrial # Marine This product meets the NUGI cerifcation of “GC-LB", Normal operating temperatures for this product are ~40 to 204°C (-40 to 40°F).Caterpillar Premium Grease Desert Gold Desert Gold is a heavy duty, premium synthetic, extreme pressure lubricating grease developed for the most extreme operaling environments. Desert Gold is formulated with a high viscosity, synthetic base fluid, high molecular weight polymers and molybdenum disulfide, as well as a high viscosity index and high dropping point. Desert Gold wil protect equipment against heavy shock loads Desert Gold protects against corrosion in extreme heat, in moist conditions, or in dusty conditions. This product has excellent characteristics of adhesion and of stability. Desert Gold provides longer protection than other greases. Desert Gold is an environmentally friendly grease which does ot contain antimony, sulfur, barium, zinc, lead, of phosphorous. Normal operating temperaiures are 6 to 230°C (21 to 450°F). Desert Gold can operate, at higher temperatures for shorter time periods. Desert Gold has additional extreme pressure protection for highly loaded pin joints, Arctic Platinum Arctic Platinum is a super-premium extreme pressure lubricating groase developed for lubrication in below zera temperatures to moderate operating temperatures. Arctic Platinum is available in grades 000, 00, 0, 1, and 2 to ensure pumpability in central lube systems in a variety of ambient temperatures from -60 to 18°C (-76 to 65°F) Arctic Platinum has a high drop point and contains five percent molybdenum disulfide for protection ‘against extre heavy loads. Arctic Platinum provides excellent protection against corrosion and against oxidation, Arctic Piatinum is an environmentally friendly grease whicn does not contain antimony, sully, barium, zinc, ar phosphorous. Arctic Platinum is designed for 1ong fife lubrication of horizontal pivot and lowor link bearings, of steering cylinders, of kingbolt bearings, of upper hitch fink beerings and of ejector carrier roller bearings. This grease is extra tacky for retention on excavator carbody bearings. Arctic Platinum has additional extreme pressure protection for highly loaded pin joints, 57 Maintenance Section Lubricant Specifications58 Maintenance Section Fuel Specifications Fuel Specifications snseores Fuel Recommendations SMCS Code: 1000 General Fuel Information Gaseous fuels consist primarily of hyérocarbons (combinations of hydrogen and carbon) and some inert gases. Pipeline natural gas has been used for many years. Other types of tuels such as welthead, bio-gas, and manufactured gas need to be reviewed for acceptabilly Each commercial fuel gas is a mixture of gases. Some of the gases are combustible and some of the gases are inert. The compositions of these gas mixtures have extreme variations, Caterpillar Gas Engines will operate successfully on a broad range of gaseous fuels. Adjustments must be made to the fuel system when the fuel is changed. Consult your Caterpillar dealer about the proper adjustments, Permissible fuels must be analyzed in order to determine the following characteristics: © Composition # Specitic gravity # Heat value # Methane number A fuels potential for detonation is indicated by a methane number. The methane number of any gas {fuel) can be determined withthe following method 1. Obtain a fuel analysis of the gas 2. Enter the data from the fuel analysis into he Caterpillar Software Program, LEKQ6378, “Methane Number Program” This software program calculates the fuel's methane number, The methane number is used for determining the following parameters: ‘¢ Compression ratio ‘* Fuel system components Ignition timing # Rated load For a detailed explanation of methane numbers, see Application and Installation Guide, LEKQ?: Fue'siFuel Systems Dry Natural Gas Dry natural gas is a mixture of methane, ethane, propane, and butane, Dry natural gas may also have traces of heavier hydrocarbons. The Low Heat Value (LHY) of a gas is the high heat value (HHV) rminus the heat that is required to vaporize the water that is formed by combustion, For more information on heat values, see Applicatior and Installation Guide, LEKQ7256, “Fuels/Fue Systems" ‘The heat value of dry natural gases may vary. This depends on the composition of the gas. Dry natural gas usually has an LHV that is between 33,53 to 34.65 kuJL (900 to 930 Bust), Caterpillar Gas Engines are adjusted al the factory with a cry natural gas that is within this range. For dry natural gas, the acceptable limit of hydrogen sulfide is 0.43 mg H.S/MJ (.450 ug H.S/BIU}. Sour Gas Note: For sour gas, Caterpillar recommends engine arrangements that are similar to arrangements for lanai gas. Sour gas refers to fuels that contain more than 0.43 mg H.S/MJ (.450 tig H,S/8tu). The following gases are within this category: +» Some weltheed gases * Landfil ges «# Digester gas “Sweet” gas pertains to fuels that have less than 0.43 mg H.S/MV (.450 pg H,SIBIu). The use of gases that have hydrogen sulfide can damage the engine, Products of combustion (water vapor and sulfur oxides) form sulturous acid and sulfuric acid, Sulfur reacts easily with “bright” metals such as copper. Therefore, oll coolers are usually the first components that are affected by the acids. Other engine parts that are altacked by the acids include the following components: «Valves, © Vaive guides59 Maintenance Section Fuel Specifications '* Piston rings, e « Piston pin bushings ‘¢ Cylinder liners ¢ Exhaust manifolos * Aftercoolers Analyze the gas betore use. If the gas has more than 0.43 mg H.SIMV (.450 ug H-S/BtU), treat the gas in order to reduce the content of hydrogen. sulfide, Various devices can reduce the content of hydrogen sulfide, Examples are chemically active fiters, reactive beds, and solutions. The performance of the devices deteriorates as the reactive chemicals are depleted, The devices must be serviced or replaced in order to maintain effectiveness. Take the following precautions even if the gas is, treated in order to reduce the level of hydrogen sufide. This will help to protect the engine against intervais when the devices for treating the fuel deteriorate, Even brief intervals of operation with high sultur fuels can damage the engine, unless, r } precautions are taken ‘¢ Maintain the temperature of the coolant outlet 10 ‘a minimum of 110 °C (230 °F). Do not allow the fise in temperature across the engine to exceed 8.3 °C (15 "F). A rise in temperature of 5.6 °C. (10°F) is preferable, Lower jacket water temperatures permit water vapor and hydrogen sulfide to condense on the cylinder liners. Higher temperatures will reduce this condensation ‘* Establish an oil analysis program in order to ensure that the oil change intervals are not extended beyond the condemning limits of the ool, The oil analysis will also be able to detect, other problems that may occur. Wellhead Gas (Field Gas) Wellhead gas is natural gas that has not boon processed. The composition of gases from the ‘wellheads in different gas fields varies. The composition of the gas from different wellneads within the samo gas field can vary. As a result, the gas from one source may be acceptable for use but the gas from a diferent source may not be acceptable. For this reason, a fuel analysis from each source is required to determine if the fuel is acceptable for a particular Caterpillar Engine. Lo Note: The composition of the gas from a field can change over time. Allow some adaptability for this change during the life of the project. Wellhead gas has minimal processing before entering the fuel manifold. This fuel is commonly Used in engines thal power gas compressors. The engines burn the same gas that is compressed in order to be transferred through pipelines Some gas fields contain significant amounts of hydrogen sulfide. In these cases, follow the precautions that are recommended for using sour (gas. Obtain a fuel analysis and determine the ‘methane number. Many wellhead gases have some heavier hydrocarbons such as pentane, isobutane and lier “gasolines’. These heavier hydrocarbons ‘cause detonation and other problems. For more information on hydrocarbons, see Application and Installation Guide, LEKQ7256, "FuelsiFuel Systems” Consult your Caterpillar dealer before operating the ‘engine with fuel that nas more than one percent of hydrocarbons that are heavier than butane. Bio-Gas Bio-gas is generally classified as oither gas that is produced from landfills or gas that is produced ‘irom digester gas facilities. Although these gases are both the result of organic decomposition, the compasitions are different, Landfill Gas The decomposition of organic material produces fandfill gas. The composition of landfill gas depends. con the materials that are in the landfill. The gas is collected through @ grid of pipes that are laid out within the lanfil The collection of landfil gas was prompted by ecological concerns. Landfill gas contains methane and other pollutants. These harmful pollutants are consumed in order to produce useful energy. Caterpillar offers a variety of engines that can be operated successiully with landfill gas. Fuel analysis is required in order to provide guidelines for treatment of the fuel. When 20 application that uses landfill gas initiates operation, the operation anc maintenance that is recommended by Caterpillar must be followed,60 ‘Maintenance Section Fuel Specifications Landfill gas may contain the following contaminants that can cause harmful effects on engines: © Chlorine * Fluorine « Siloxanes * Sulfur ‘© Water vapor The sulfur compounds in landfill gas cause the same engine problems as sulfur in sour gas. When landfill gas is used, follow the precautions that are: recommended for Using sour gas. Landfills can contain chlorine and fluorine compounds in the form of form volatile organic compounds and chlorofiuorocarbons. When these substances are burned in engines, corrosive hydrochloric acid and hydrofluoric acid can be produced. Landfill gas can corrode both the equipment that handles the gas and the engine, Vapor is produced by combustion. If that vapor condenses in the crankcase, a solution that is potentially corrosive to the engine can form, Landfill gas and digester gas can contain siloxanes. Slloxanes are formed when silica ions attach to the methane hydrocarbon chain. These gaseous ‘compounds enter the combustion chamber with the tel. This enables silica type deposits to form in the cylinders. Because the engine oil contains some calcium, deposits in the combustion chamber are generally a combination of silicon and calcium with some other trace elements. These substances can coagulate in the combustion process and form larger particles. The larger particles can be abrasive to exhaust valve faces and valve seats. This causes the valves to become pitted and indented. The particles can also build up on the vaive seat. The buildup can ‘cause guttering of the valves, Deposits also form on the pistons and on the bottom deck of the cylinder heads. Detonation can loosen the deposits. The deposits that are loosened can be trapped between the valve and the valve seat. The valve will be held open, Guttering of the valve wil result The formation of deposits depends on the following factors: '* Composition of the fuel ‘* Operating conditions © Type of lubrication oil ‘Most landfill applications will generate some deposits in the combustion chamber and the turbocharger. Siloxanes are a major contributor to these deposits. The fuel requires treatment in order to remove the siloxanes. For information (on equipment for processing landfill gas, see Application and Installation Guide, LEKQ7260, “Low Energy Fuels’ Note: The amount of silicon in the fuel can be Measured with a test that was developed by Caterpillar and Bio-Engineering Services, The test kit enables a sample of the fuel to be analyzed. The fuel can also be analyzed for other harmful contaminants such as chiorines, fluorines, sulfur, and halides. Details can be obtained from the following address: Bio-Engineering Services 36 Virginia Street Southport, Merseyside PR8 6RU England Telephone: 44 (0) 1704-53004 Fax: 44 (0) 1704-50160 During normal combustion, some exhaust gas and unburned fuel is forced past the piston rings and into the crankcase. The contaminants in this blowby are vented away from the crankcase by positive crankcase ventilation, The contaminants are diluted and purged. The formation of water in the crankcase can result in an acid solution which allows corrosion to occur A high jacket water temperature helps to prevent the condensation of water in the crankcase. For landfill gas, the engines have a high temperature jacket water cooling system as standard equipment The standard water temperature regulators (outlet) begin to open at 110 °C (230 °F). Because of the higher jacket water temperatures, the oil must be cooled by other means. In engines that use landfil gas, the oil is cooled by the water in the separate circuit ‘aftercooling system To protect the service life of the engine, itis necessary to follow the guidelines for operation and maintenance that are recommended by Caterpila. For engines that use landfil gas, practice the following recommendations in addition to the precautions for using sour gas: ¢ Exhaust gases are likely to contain acids. If the engine installation has a device thal uses the heat from the exhaust, maintain a minimum exhaust gas temperature of 204 °C (400 °F). This will prevent condensation in the device,61 Maintenance Section Fuel Specifications Landfill gas requires regular, careful maintenance of the spark plugs. Misfire causes the engine to run rougn, The cylinder temperatures are reduced, Cooler cylinders allow deposits to build up faster in the combustion chamber, the exhaust manifold, and the turbocharger. Exhaust port temperatures can indicate the performance of the spark plugs. An exhaust port temperature that decreases more than 66 *C (150 °F) below the average operating temperature may indicate the misfire of a spark plug. Clean the spark plug Inspect the spark plug and set the electrode gap. Replace the spark plug if the performance is in question ‘* Caterpillar Natural Gas Engine Oil (NGEO) is recommended for engines that use landfill gas, NGEO has 0.45 percent sulfated ash, The use of an oil that has a high concentration of sulfated ash will result in excessive deposits in the combustion chamber. Because of the inconsistent composition of landfill gas, oil may react differently to 2 particular landfill gas. Use the $-O'S oil analysis program to determine proper oll change intervals, For now installations, sample the oil frequently in order to establish a consistent program for oil changes, Initially, sample the oil on a daily Dasis. The properties of landfill gas can change rapialy ‘Therefore, it is necessary to continue 10 monitor the oil on a weekly basis or two times per month in order fo ensure adequate protection. Note: For more information on landfill gas. and digester gas, see Application and Installation Guide, LEXQ7260, ‘Low Energy Fuels” Digester Gas A variety of materials can produce digester gas: * Sewage # Animal waste ‘¢ Liquid effluent irom vegetable oil mills and alcoho! mills Digester gas has properties that are similar 10 the properties of landfill gas, Digester gas usually has some sulfur and siloxanes. However, digester gas does not usually contain the chlorotlorocarbons that are found in landfill gas. The same precautions for treatment of the uel and protecting the engine are required. Until experience proves otherwise, the same maintenance recommendations are used. Gaseous Fuel ers The customer is responsible for supplying clean, dry fue! to the engine. Fuel fillers are no less important than air filters to protect gas engines from dirt ang debris. A proper fuel filter removes impurities that can damage the internal components of the engine. ‘The gas must be supplied to the engine at a pressure thal is acceptable. For optimum operation, Use a fuel filter that is properly sized for the gas pressure, For many gas engines, fuel fillers are provision of the design for the application. These devices are included in the normal maintenance of the plant. Therefore, Caterpillar does not include a standard fuel filer as a part of each gas engine. However, fuel filers are available from your Caterpillar dealer. Consult your Caterpillar dealer about the requirements fer filtering your engine’s fue!62 Maintenance Section Cooling System Specttications Cooling System Specifications General Coolant Information SMCS Code: 1350; 1395 Many engine feilures are related to the ceoling system. The following problems are related to cooling system failures # Overheating # Leakage of the water pump # Plugged radiators or heat exchangers «© Pitting of the cylinder liners These failures can be avoided with proper cooling system maintenance. Cooling system maintenance '8 as important as maintenance of the {uel system and the lubrication system. Quality of the coolant is as important as the qualily of the fue! and the lubricating oil Coolant is normally composed of three elements: ¢ Water # Additives # Glycol Water NOTICE Never use water alone without Supplemental Coolant Additives (SCA) or without inhibited coolant. Water alone is corrosive at engine operating temperatures. Water alone does not provide adequate protection against boiling or freezing, Water is used in the cooling system in order to transfer heat, Distilled water or deionized water is recommended for use in engine cooling systems. DO NOT use the following types of water: '» Hard water Water that is softened with salt © Salt water It distiled water or deionized water is not available, use water with the characteristics that are listed in Table 24 Table 24 ‘Acceptable Characteristics Of Water For Use In Engine Cooling Systems | Characteristic crore | oa GOR gay | “Beat! oe ee Ten Tq OBE gay | Di Total Solids | yg MO,MOL | -D8680 For a water analysis, consult one of the following sources: Caterpillar dealer # Local water utility company Agricultural agent @ Independent laboratory Ad Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives: or insufficient amounts of additives enable the following conditions to occur: '* Corrosion ‘¢ Formation of mineral deposits = Rust + Scale ‘¢ Corrosion and erosion from cavitation of the cylinder liner ‘¢ Foaming of the coolant Many additives are depleted during engine operation. These additives must bo replaced periodically. This can be done by adding Supplemental Coolant Additives (SCA) to Diesel Engine Antifeeze/Coolant (DEAC)63 Maintenance Section Cooling System Specifications Additives must be added al the proper concentration. Overconcentration of additives can cause the inhibitors to drop out-ol-solution. The deposits can enable the following problems to occur: ¢ Formation of gel compounds ¢ Reduction of heat transfer ¢ Leakage of the water pump seat # Plugging of radiators, coolers, and small passages Glycol Glycol in the coolant helps to provide protection against the following conditions: * Boiling « Freezing ‘* Cavitation of the water pump and the cylinder liner For optimum performance, Caterpillar recommends 50/50 mixture of a water/glycol solution. Note: Caterpillar engines with air-to-air aftercooling Fequire a minimum of 30 percent glycol in order to help prevent water pump cavitation, Most conventional heavy-duty coolanvantifreazes use ethylene glycol. Propylene glycol may also be used. In a 50/50 mixture with water, ethylene and propylene glycol provide similar protection against freezing and boing, See Tables 25 and 26 thins Etnylene Ghee Prsteton Aganet | Concentration % Glycol% Water | Freezing Boiling | 50/50 86°C (-83°F) | 106°C (22°F) 6040 | -81°C{-60°F) | 108°C (26°F) | NOTICE Do not use propylene glycol in concentrations that ex- ceed 50 percent glyco! because of propylene glyco!'s, reduced heat transfer capability. Use ethylene glycol in conditions that require additional protection against bolling or freezing. ante 26 Propylene Glyco! Concentration Protection Against % Glycol Water Freezing Boiling 29°C : 50/50 ae | 108°C (229°) To check the concentration of glycot, use the 1U-7298 Coolant Test Kit for °C or use the 10-7297, Coolant Test Kit for °F The testers give readings that are immediate and accurate. The testers can be used with ethylene or propylene glyco! Coolant Recommendations SMCS Code: 1350; 1305 NOTICE Do not use a commercial coolanVantifreeze that only meets the ASTM D3306 or D4656 specification. This type of coolanVantifreeze is made for light duty automotive applications. ' ‘Two types of coolants are recommended for use in Caterpillar G3600 Engines Preferred — Caterpillar Diesel Engine Antilreeze/ Coolant (DEAC) or a commercial heavy-duty coolantantifreeze that meets “ASTM D4985" or “ASTM D5345" specifications Acceptable ~ a mixture of Caterpillar Supplemental Coolant Additive (SCA) or a commercial SCA and water Caterpillar recommends a mixture of 50 percent water and 50 percent glycol for optimum performance of the coolant/antifreeze. Note: Caterpillar DEAC does not require a treatment with an SCA at the initial fil. Commercial heavy-duty coolanVantifreeze that meets “ASTM D4985" or "ASTM D545" specifications REQUIRE a treatment with an SCA at the initial fil In those engine applications that do not require protection from boiling or freezing, a mixture of SCA and water is acceptable, Caterpillar recommends a six percent to eight percent concentration of SCA in those cooling systems. Distilled water or deionized water is preterred. Water which has the recommended properties may be used. See this Operation and Maintenance Manual, “General Coolant Information” topic (Maintenance Section).64 Maintenance Section Cooling System Specifications Table 27 is a list of the coolants that are recommended and the sorvice life of the coolants. To achieve this service life, the coolants must be properly maintained. The maintenance program includes $-0-S coolant analysis. Table 27 Coolant Service Life Service Lite Coolant Type 20,000 Service Hours or Three Years 20,000 Service Hours ‘or Three Years Caterpillar DEAC ‘Commercial Heavy-Duty CoolanvAntitresze that meets “ASTM D5345° Commercial Heavy-Duty CoolanvAntifreeze that meets "ASTM D4985" Caterpillar SCA and Water ‘Commercial SCA and Water 20,000 Service Hours ‘or Three Years. 10,000 Service Hours or Two Years ‘8000 Service Hours or One Year (1 The service life of the coolant may be adjusted according to ‘he rosulls of SOS coolant analysis (Level I) comoroce Diesel Engine Antifreeze/ Coolant (DEAC) SMCS Code: 1350; 1352; 1395 Caterpillar recommends the use of Diesel Engine Antifreeze/Coolant (DEAC) in cooling systems that use conventional heavy-duty antireeze/ coolant. DEAC is a coolantfantireeze with these characteristics: Alkaline type # Single-phase * Ethylene glycol DEAC contains inorganic corrosion inhibitor’s and antifoam agents. Premixed DEAC is mixed with, Gistilled water in a SO/SO concentration. Containers of DEAC are available in several sizes, Consult your Caterpillar dealer for the part numbers. DEAC is also available as a concentrate. Caterpillar recommends mixing the concentrate with distilled water or with deionized water. If distilled water is not available or deionized water is not available, use water with the properties that are listed in the table that can be found in the Operation and Maintenance Manual, “General Coolant information (Maintenance Section). Commercial Heavy-Duty Coolant/Antifreeze and SCA SMCS Code: 1350; 1395 It Caterpillar DEAC is not used, select a coolant/ antifreeze with low silicate content for heavy-duty applications that meets "ASTM 05345” or “ASTM 04985" specifications, When a heavy-duty coolantlantireeze is used, the cooling system should be treated with three to six percent Caterpillar SCA by volume. Reter to the Operation and Maintenance Manual, “Conventional CoolantiAntitreeze Cooling System Maintenance” in the Maintenance Section for more information It Caterpillar SCA is not used, select a commercial SCA. The commercial SCA must provide a minimum of 1200 mgfL ar 1200 ppm (70 grains/US gal) of nitrates in the final coolant mixture. Coolant/antifreezes for heavy-duty applications that meet “ASTM D5345” or “ASTM D4985' specifications require treatment at the inital fil and on a maintenance basis. When concentrated coolants are mixed, Caterpillar recommends mixing the concentrate with distilled water or with deionized water. If distilled water or deionized water is not available, refer to the table in the Operation and Maintenance Manual, "General Coolant Information” in the Maintenance Section. nereooe Supplemental Coolant Additive (SCA) ‘SMCS Code: 1350; 1352; 1395 In engine cooling systems that use Supplemental Coolant Adcitive (SCA) and water alone, Caterpillar recommends the use of SCA. The use of SCA helps ‘engines to prevent the following conditions trom oceurting © Corrosion ‘¢ Formation of mineral deposits '* Cavitation of cylinder liner '* Foaming of the coolantCaterpillar Diesel Engine Antiireeze/Coolant (DEAC) 's formulated with the correct level of Caterpillar SCA, When the cooling systern is originally filed with DEAC, adding more SCA is not necessary Containers of SCA are available in several sizes Consult your Caterpillar dealer for the parl numbers Conventional Coolant/ Antifreeze Cooling System Maintenance ‘SMCS Code: 1350; 1352: 1995 NOTICE Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the proper operating temperature. Cooling system problems can develop without water temperature regulators. Check the cooian/antifreeze (glyco! concentration) in order to ensure adequate protection against boiling or freezing, Caterpillar recommends the use of a refractometer for checking the glycol concentration. Use the 1U-7298 Coolant Tester (°C) cor use the 1U-7297 Coolant Tester (°F), The testers give readings that are immediate and accurate. The testers can be used with ethylene or with propylene glycol Adding the SCA to Conventional Coolant/Antifreeze at the Initial Fill Note: Caterpillar DEAC DOES NOT require an addition of SCA when the cooling system is initially filed Commercial heavy duty coolantantifreezes that meet “ASTM D4985" or “ASTM D5345° specifications DO REQUIRE an addition of SCA. al the initial fil, The size of the cooling system determines the amount of SCA that is required Use the equation that is in Table 28 to determine the amount of Caterpillar SCA that is requited when the cooling system is initially filed with "ASTM D4986" or “ASTM D5345" heavy duty coolant/anbifree. 65 Maintenance Section Cooling System Specifications Table 28 Equation For Adding The SCA To Conventional CoolanvAntifreeze At The Initial Fill V x 0045 = x Vis the total volume of the cooling system, X is the amount of SCA that is required, Table 29 is an example for using the equation that is in Table 28, Table 29 Example Of The Equation For Adding The SCA To Conventional CoolantAntifreeze At The Initial Fill Total Volume | Multiplication | Amount of of the Cooling Factor SCA that is | System Required (X) 946 L x 0,085, 43 (250 US gal) (11 US ga) Adding the SCA to Conventional Coolant/Antifreeze For Maintenance Heavy duty coolant/antifreeze of all types DO REQUIRE periodic additions of an SCA Test the coolant/antifreeze periodically for the concentration of SCA. For the interval, see this ‘Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section). SCA test kits are available from your Caterpillar dealer. Test the concentration of SCA or submit a coolant sample to your Caterpillar dealer. See the Operation and Maintenance Manual, "S-O-S Coolant Analysis” topic (Maintenance Section). Additions of SCA are based on the results of the lest or based an the results of the coolant analysis. The size of the cooling system determines the amount of SCA that is needed Use the equation that is in Table 30 10 determine the amount of Caterpillar SCA that is required, i necessary: Tatte 90 Equation For Adding The SCA To Conventional CoolanvAntifreeze For Maintenance Vv x 0014 = x Vis the total volume of the cooling system X is the amount of SCA that is required Table 31 is an example for using the equation that is in Table 30.66 Maintenance Section Cooling System Specifications Tae 31 Example Of The Equation For Adding The SCA To Conventional Coolant/Antifreeze For Maintenance Total Volume | Multiplication | Amount of | of the Cooling Factor SCA that is ‘system (V) Required (X) | oat | x 0014 eu (280 US gal) (4 US gal) Note: Specilic engine applications may require. maintenance practices to be periodically evaluated in order to properly maintain the engine's cooling system, Table 32 lists part numbers and quantities of SCA that is available from your Caterpillar dealer. Table 2 a “ Caterpillar Liquid SCA Part Number Quantity 80-3680 19.L (6 US gal 5P-2907 208 L (55 US gal) Cleaning the Cooling System Caterpillar Cooling System Cleaner dissolves mineral scale, corrosion products, light oil contamination and sludge. ‘# Clean the cooling system after used coolant is drained or before the cooling system is filled with new coolant. ‘¢ Clean the cooling system whenever the coolant is contaminated or whenever the coolant is foaming, ‘orosec0 Water/Supplemental Coolant Additive (SCA) SMCS Code: 1350; 1352; 1395 Do not use water alone as an engine coolant Supplemental Coolant Additive (SCA) helbs 10 prevent the following conditions fram occurring: + Corrosion # Formation of mineral deposits ¢ Cavitation of the cylinder liner ‘* Foaming of the coolant if Caterpillar SCA is not used, select a commercial SCA. The commercial SCA must provide a minimum of 2400 ma/L or 2400 ppm (140 grains/US gal) of nitrates in the final coolant mixture ‘The quality of the water is a very important factor in this type of cooling system. Disllled water or deionized water is recommended for use in cooling systems. Ii dislled water or deionized water is ot available, use water that meets the minimum requirements that are listed in this Operation and Maintenance Manual, “General Coolant Information (Maintenance Section). A cooling system that uses a mixture of only SCA and water requires more SCA than a cooling system thal uses a mixture of glycol and water. The SCA and water requires six to eight percent of SCA Adding the SCA to Water at the Initial Fill Use the equation that is in Table 33 to determine the amount of Caterpillar SCA that is required at the initial fill. This equation is for a mixture of only SCA and water. Table 33 | Equation For Adding The SCA ‘To Water At The Initial Fill V x 007 = X Vis the total volume of the cooling system, | 2 a Q a xs ) YS AN \ {| \ \, > 1) |p JZ A ue em ia wh Imastation 50 001107265 “Typical nydrautc fuel control actuator (1) Rod en Replace rod ends (1) of the linkage for the actuator.80 Maintenance Section Aftercooler Condensation - Drain ocsra67 Aftercooler Condensation - Drain SMCS Code: 1063-543 ‘The aftercooler is similar to a radiator. Coolant passes through the tubes in the aftercooler core. Inlet air that is warmed by the turbochargor compressor is directed through the aftercooler core. The air is cooled in the attercooter, Condensation can form in the passages of the altercooler system. Drain plugs are provided for draining the condensation iustation 52 TES 'A ain plug is located on the right side near the rear ofthe engin. (1) Plug ‘SOO EE ustrabon §3 ‘A drain plug is located on the let sido near the front of the engine. (2) Pug Remove plugs (1) and (2). Drain the moisture into suitable container. Install the plugs. sceosso4 Air Starting Motor Lines Screen - Clean ‘SMCS Code: 1451-070 oan lystration 54 aes (1) Plug (2) Seren 1. Ensure that the air supply to the air lines is OFF. 2. Remove plug (1). retully remove screen (2). Clean the screen with nonflammable solvent. Inspect the screen for damage. I the screen is damaged, replace the damaged screen with a new screen, 4. Install clean, dry screen (2). Clean plug (1). Install the plug. Refer to this Operation and Maintenance Manual, “Torque Specifications” (Maintenance Section)at Maintenance Section Air Starting Motor Lubricator Bowl - Clean Air Starting Motor Lubricator Bowl - Clean SMCS Code: 1451-070 1. Ensure that the air supply to the lubricator is OFF. Air Starting Motor Lubricator Oil Level - Check SMCS Code: 1451-595 NOTICE Never allow the lubricator bow! to become empty. The air starting motor will be damaged by a lack of lubrication. Ensure that sufficient oil is in the lubricator bowl tustation 55 (1) Plug (2) Bow! (5) Drain Note: Always dispose of fluids according to local regulations 2. Open drain (3), Drain the oil into a suitable container. Dispose of the used oil 3. Remove bow! (2). Clean the bow! with warm, water 4. Dry the bowl. Inspect the bowl for cracks. If the bow! is cracked, replace the damaged bow! with a new bow! 5. Install the bowl. Close drain (3) 6. Remove plug (1). Fill bow! (2) with oil, Use nondetergent “10W" oil for temperatures that are greater than O°C (32°F). Use air tooi oil for temperatures that are below 0°C (32°F). Install oil filer plug (1) 7. Mi necessary, adjust the lubricator in order to release two drops of oil per 30 seconds. For instructions, see this Operation and Maintenance Manual, “Air Starting Motor Lubricator Oii Level Check” topic (Maintenance Section) Inustation 56 (1) Dome 12) Krab (3) Sight gauge (4) Plug 41. Observe the oil level in sight gauge (3). Ifthe 0} level is less than 1/2, add oil fo the lubricator bowl 2. Ensure that the air supply to the lubricator is OFF. 3. Remove plug (4). Pour oil into the lubricator bow! Use “10W" oil for temperatures that are greater than 0°C (32°F). Use air too! oil for temperatures. that are below 0°C (32°). 4, Install 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 agai82 Maintenance Section Air Tank Moisture and Sediment - Drain 2. Operate the air starting motor. Observe the drops of oi! 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 two drops of oll por 30 seconds. To increase the rate, tun knob (2) counterclockwise. To decrease the rate, turn the knob clockwise Air Tank Moisture and Sediment - Drain SMCS Code: 5505-543 Moisture and sediment in the air starting system can cause the following conditions: Freezing © Corrosion of internal paris ‘* 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. 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 vaive83 Maintenance Section Alternator - Inspect cosas Alternator - Inspect SMCS Code: 1405-040, 1405 Inspect the alternator for the following conditions: + Loose connections + Proper charging of the battery Observe the ammeter during engine operation in ‘order to ensure oroper battery performance andor proper performance of the electrical system Make repairs, if necessary. See the Service Manual for service procedures. Consult your Caterpillar dealer for assistance, ove: Alternator Belt - Inspect/ Adjust/Replace SMCS Code: 1257-025: 1957-036; 1357-039 1357-040; 1357-081. 1357-510; 1357; 14 1405-039-BE. 1405-510-BE, 1405 036 Inspection Inspect the alternator belts for wear and for cracking, Replace belts thal are not in good condition Check the belt tension according to the information in the Service Manual, “Specifications’ module. Siippage of loose belts can reduce the efficiency Of the driven components. Vibration of loose bells can cause unnecessary wear on the following components: «Bells * Pulloys Bearings: If the belts are too tight, unnecessary stress is, placed on the components. This reduces the service life af the components. Adjustment Iustration $7 031272 (1) Adjusting nuts {2} Mounting bot 1, Remove the belt guard 2. Loosen mounting bolt (2). 3. Tur adjusting nuts (1) in order to increase or decrease the bell tensiona4 Maintenance Section Barring Device - Lubricate 4, Tighten adjusting nuts (1). Tighten mounting bolt (2). For the proper torque, see the Service Manual, “Specifications” module, 5. Install the belt guard, Ht new belts are installed, check the belt tension again after 30 minutes of engine operation at rated rpm. Replacement For applications that require multiple drive belts, replace the belts in matched sets. Used belts are stretched. Replacing only one belt of a matched set will cause the new belt to carry an excossive load The additional load on the new belt could cause the new belt to break. 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. Imustation 58 Rear view of a baring device with an electric motor Note: Prelube of the engine is required betore the ‘crankshaft is rotated for normal maintenance. ‘The barring device provides a means for siowiy turning the flywheel in order to service the engine. ‘The barring device can also be used to prevent rotation of the crankshaft, When the barring device is in the engaged position, the engine starting system is disabled. When the barring device is not used, the barring device must be fully disengaged from the flywhoot and secured in the disengaged position. Reler 10 the Service Manual for information on operation of the barring device NOTICE Do not operate the engine starting motor until the barring group pinion gear is fully disengaged from the flywheel ring gear. Serious damage to the engine could result85 Maintenance Section Battery ~ Recycle Note: Illustration 59 and Illustration 60 show the locations of the grease fittings for two typical barring devices. Some engines may be equipped with different barring devices, Mustravon $9 STE Fight sie section viow of a baring device without an electic motor (1) Grease tittng (2) Vent 1. Ensure that the barring device is locked in the disengaged position 2. Lubricate grease fiting (1) with MPGM until the grease is visible at vent (2) tm Imustration 60 oes (1) Grease tting (2) Gear end 1. Ensure that the barring device is lacked in the disengaged position, 2. Lubricate grease fitting (1) with MPGM until the grease is visible at gear end (2). Battery - Recycle SMCS Code: 1401-561 1. Always recycle a battery. Never discard a battery. 2. Always roturn used batteries to one of the following locations, # A battery supplier + An authorized battery collection facility # Recycling facility86 Maintenance Section Battery Electrolyte Level - Check Battery Electrolyte Level - Check SMCS Code: 1401-535-FLV When the engine is not run for long periods of lime of 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, If batteries are properly charged, ammeter reading should be very near zero, 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. 1. Remove the filler caps. Maintain the electrolyte level to the “FULL mark on the battery. If the addition of water is necessary, use distilled water, If distilled water is not available use clean water that is low in minerals. Do not use artificially softened water. 2. Check the condition of the electrolyte with the 1U-7298 Coolant/Battery Tester (°C) or the 1U-7297 Coolant/Battery Tester (*F. 3. Keep the batteries clean. Clean the baitery case with one of the following Cleaning solutions: © A mixture of 0.1 L (.12 qt) of baking soda and 1L(1 qt) of clean water © A mixture of 0.1L (12 qt) of ammonia and 1 L (1 at) of clean water Thoroughly rinse the batlery case with clean water. Use a fine grade of sandpaper to clean tho terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excossive removal Cf material can cause the clamps to not fit properly. Coat the clamps and the terminals with 5N-5561 Lubrication Compound, petroleum jelly or MPGM grease. Combustion Sensor - Clean/ Inspect/Replace SMCS Code: 1900: 1905 To provide a signal without interference to the engine control module, the sensor must be in good condition. The connections must be clean. ustraton 61 oRaESIT (1) Cable (2) Fiting (3) Extension (4) Sensor Note: Clean the connections and polish the connections with a clean, dry cloth. 1. Disconnect cable (1) from fitting (2). Clean the end of the cable. 2. Remove fitting (2). Clean the inside of the adapters that are attached to the fitting, 3. Remove extension (3), Clean the inside of both ends of the extension Pressure air can cause personal injury. When pressure air is used for cleaning, wear a protec- tive face shield, protective clothing, and protec- tive 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. ait. Ensure that the area around the sensor is clean and free of debris87 Maintenance Section ‘Combustion Sensor - Clean/Inspect/Replace 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. I 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, After the sensor is removed, discard gasket (8). tustration 62 Combustion sensor (5) Terminal post (6} Insulator (7) Shel (8) Gasket (@) Bectrode 6. Inspect the sensor closely for damage. Terminal post (5) must not move. If the terminal ost can be moved by hand, discard the sensor. Inspect insulator (6) for cracks. If a crack is found, discard the sensor. Inspect shell (7) for damage. Cracks can be caused by overlightening the sensor Overtightening can also loosen the shell. Discard ‘any sensor that has a shell that is cracked or loose. Inspect electrode (9) for excessive wear. A light brown or beige deposit around the electrode is produced by normal operation. White deposits or gray deposits may be caused by the following substances: © Excessive oil © Use af the wrong oil # Assubstance that is inttoduced through the fuel system or the air system A buildup of ash on the electrade reduces the officiency of the sensor. Measure the resistance between terminal post (5) and electrode (9). The sensor must pass a low voltage check for continuity between the terminal post ana the electrode (15 volts DC). The resistance must not exceed five ohms 7. Thoroughly clean the sensor. Clean the shell and the electrode that is inside of the shell. Do not use @ 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 nol use glass beads on the outside of the shell or on the upper part of the insulator. Ensure that the sensor is clean and tree 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 8, Place @ now 108-3515 Plug Gasket on the sensor, Install the sensor by hand until the sensor bottoms out. Tighten the sensor to 38 + 2 Nm (2822 Ibi) 9. Assemble the parts in reverse order of removal. Ensure that the parts and the connections are clean. Tighten fitting (2) {Illustration 61) to 35 = 2N-m (26 = 2 lb ft)88 Maintenance Section Controt Panel - Inspect Control Panel - Inspect SMCS Code: 4490-040 Inspect the condition of the panel. If a component is damaged, ensure thal the component is repaired oF that the component is replaced. Ensure that the electronic displays are operating property. Inspect the wiring for good condition. Ensure that the wiring connections are secure Record the Data and Review the Data Check the gauges and indicators frequently during normal operation. Record the data in a log. Compare the new data to the data that was previously recorded. Comparing the new dala 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. snrersea Coolant Analysis - Obtain SMCS Code: 1350-081 ‘The concentration of supplemental coolant additive (SCA) should be checked regularly with test kits. The concentration of SCA can also be checked with an $05 coolant analysis (Level I). A more detailed coolant analysis is recommended periodically. For example, considerable deposits are found in the water jacket areas on the external cooling system, but the concentrations of coolant additives were carefully maintained. The coolant water probably contained minerals which were deposited on the engine over time. ‘A-coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system. A full water analysis may be obtained from the following sources: * Local water utility company © Agricultural agent + Private laboratories Caterpillar recommends an $-0'S coolant analysis (Level $-0-S Coolant Analysis (Level Il) ‘An S-O°S coolant analysis (Level i) is @ ‘comprehensive coolant analysis which completely analyzes the coolant. An S:O'S coolant analysis (Level Il) provides the following information ‘© Complete $:0'S coolant analysis (Level + Properties of the coolant are visually inspected. ‘¢ Metal corrosion and contaminants are identified «Identification of built up impurities that can cause problems BEFORE the problems make repairs necessary, A report of the results of the SOS coolant analysis (Level Il) s provided. Maintenance recommendations are based on the result. For more information about $:0'S coolant analysis, consult your Caterpillar dealer,e@ Cooling System Coolant - 89 Maintenance Section Cooling System Coolant - Change soerrear Change SMCS Code: 1395-044 Clean the cooling system betore the recommended maintenance interval ifthe following conditions exist. '* The engine overheats frequently, ‘* Foaming is observed The oil has entered the cooling system and the coolant is contaminated NOTICE Use of commercially available cooling system clean- ers may cause damage to cooling system compo- ents. Use only cooling system cleaners that are ap- proved for Caterpillar engines. Drain the Cooling System 1. Stop the engine and allow the engine to cool Ensure that the engine will not start when the Cooling system is drained 2. Loosen the cooling system filer cap slowly in order to relieve any pressure. Remove the cooling system filler cap, Imustation 63 028745 Location of cooling system drain valves or dain plugs on the water pumps (1) Jacket water pump (2) Aftarcooler and ot cooler pump Iustration 64 Location of drain plugs for the jackat water system 8. Open the cooling system drain valves (if equipped). Remove the cooling system drain plugs. Allow the coolant to drain. NOTICE Dispose of used engine coolant properly or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The ful distillation procedure is the only method acceptable by Caterpilar to reciaim the used coolant For information regarding the disposal and the cycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Service Technology Group: Outside Minois: 1-800-542-TOOL Inside tilinois: 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 systern drain valves (it equipped). Clean the cooling system drain plugs and install the cooling system drain plugs. NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 3, Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Adc .5 L (7 pint) of cleaner per 15 L (4 US gal) of the cooling system capacity. Install the cooling system filer cap.80 Maintenance Section Cooling System Coolant - Change 4. Start the engine. Operate the engine for 2 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 filer cap. Open the cooling system Grain valves (if equipped). Remove the cooling system drain plugs. Allow the water to drain, NOTICE Improper or incomplete rinsing of the cooling system ‘can result in damage to copper and other metal ‘components, To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until ali signs of the cleaning agent are gone. 6. Flush the cooling system with clean water Until the water that drains is clean. Close the cooling system drain valves (if equipped). Clean the cooling system drain plugs and install the cooling system drain plugs. Cleaning a Cooling System that has Heavy Deposits or Plugging Note: For the following procedure to be effective, there must be an active flow through the cooling system components. 1. Flush the cooling system with clean water in order to remove any debris. 2. Close the cooling system drain valves (it 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 10 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 filer cap, Open the cooling system drain valves (if equipped). Remove the cooling system drain plugs. Allow the water to drain NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal ‘components. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone. 6. Flush the cooling system with clean water until the water that drains is clean. Close the cooling system drain valves (if equipped). Clean the cooling system drain plugs and install the cooling system drain plugs. Fill the Cooling System ; NOTICE Fill the cooling system no faster than 19 L (5 US gal) peer minute in order to avoid air locks, Note: For information about the proper coolant fo use, see this Operation and Maintenance Manual, "Coolant Recommendations” (Maintenance Section). For the capacity of the cooling system, see the Operation and Maintenance Manual, “Refill Capacities’ (Maintenance Section). 1. Fil the cooling system with coolant/antifreeze. Do ‘not install the cooling system filler cap. 2. Siart the engine. Operate the engine in order to purge the air from the cavities of the engine block. Allow the caolant to warm and allow the coolant level to stabilize. Stop the engine. 3. Chock the coolant level, Maintain the coolant to the proper level on the sight gauge (if equipped). If a sight gauge is not equipped, maintain the coolant to the level that is specified by the OEM of the cooling system. 4, Clean the cooling system filler cap. inspect the gaskets of the cooling system filler cap. If the gaskets of the cooling system filer cap are damaged, discard the old cooling system filer cap and install a new cooling system filler cap. It the gaskets of the cooling system filer cap are not Gamaged, use a 98-8140 Pressurizing Pump in order to pressure test the cooling system filler cap, The correct pressure is stamped on the tace of the cooling system filer cap. If the cooling system filler cap does not retain the correct Pressure, install a new cooling system filer cap. 6. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.ot Maintenance Section, Cooling System Coolant Level - Check @ 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. Engines That Are Equipped With a Sight Gauge ooTs008 tustration 65 (1) Filer cap (2) Sight gauge I the engine is equipped with a sight gauge, observe the position of the coolant in the sight gauge. Al normal operating temperature, the proper Coolant level is in the upper half of the sight gauge If the coolant level is low, add the proper coolant mixture Engines That Are Not Equipped With a Sight Gauge Check the coolant lovel when the engine is stopped and cool. Check the coolant level only after the engine has been stopped and the cooling system filler cap is Coo! enough to touch with your bare hand. Remove the cooling system filler cap slowly in order to relieve any pressure. Maintain the coolant to the level that is specified by the OEM of the cooling system, Add Coolant Note: For the proper coolant mixture to use, see this Operation and Maintenance Manual, "Coolant Recommendations” (Maintenance Section) 1, Stop the engine. Allow the engine to cool 2. Remove the cooling system filler cap slowly in order to relieve any pressure. Pour the proper coolant mixture into the fiker pipe. tustravon 66 Gaskets 3. Clean the cooling system iler cap. Inspect the gaskets of the cooling system filler cap. if the gaskels 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92 Maintenance Section Cooling System Level Switch - Inspect wosrerar 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, Hi the coolant level is low, coolant must be added to the expansion tank or the heat exchanger “er Musteation 67 (2) Swit 2} Lines 028805 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 ail oF a flexible wire can be used to clean the lines. 4. Install switch (1), 5. Pour the coolant into the cooling system. Verity 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, sos08015 Cooling System Supplemental Coolant Ad SMCS Code: 1352; 1395-081 Cooling system coolant additive contains alkal To help prevent personal injury, avoid contact with the skin and eyes. Do not drink co system coolant additive. Note: Test the concentration of the SCA or obtain an $-0'S coolant analysis (Level |). 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 BT -5296 Coolant Conditioner Test Kit or the 40-9301 Coolant Conditioner Test Kit. Follow the instructions that are on the label of the test 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. Follow the instructions, thal are in this Operation and Maintenance Manual "Water/Supplemental Coolant Additive (SCA)" topic (Maintenance Section). S-0-S Coolant Analysis (Level 1) Level | is a basic analysis of the coolant. The following items are tested: SCA concentration, lycol concentration, pH, and conductivity. The results are reported, and recommendations are made according to the results. Consult your Caterpillar dealer for information on the benetits of managing your equipment with an SOS analysis.Add the SCA, If Necessary 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. 1. Remove the cooling system filler cap slowly. Note: Always dispose of fluids a regulations cording 10 local 2. It necessary, drain some coolant in arder to allow space for the addition of the SCA NOTICE Excessive supplemental coolant additive concentra tion can form deposits on the higher temperature sur- faces of the cooling system, reducing the engine's heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. Excessive supplemental coolant additive concentra- tion could also result in blockage of the heat ex- changer, overheating, andlor accelerated wear of the water pump seal Do not exceed the recommended amount of supple- mental coolant additive concentration. 3. Add the proper amount of SCA. The concentration af the SCA depends on the type of coolant that is used. a, For cooling systems that use conventional coolant/antifreeze, see this Operation and Maintenance Manual, “Conventional Coolant) Antifreeze Cooling System Maintenance" topic (Maintenance Section). bb. For cooling systems that use only @ mixture of water and SCA, see this Operation and Maintenance Manual, “Water/Supplemental Coolant Additive (SCA)" topic (Maintenance Section), 4, Clean the cooling system filler cap. Install the cooling system filler cap. 93 Maintenance Section Crankcase Blowby - Measure/Record Crankcase Blowby - Measure/ Record SMCS Code: 1317 Note: The typical crankcase blowby on a new engine Is approximately 0.02 m'/bkW h (50 ff/ohp A). 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. Alter a new engine is used for a short time, the crankcase blowby can decrease as the piston rings are seated. The crankease blowby will gradually increase as the follwing components show wear: « piston rings. # cylinder liners Note: A problem with the piston rings causes the «il to deteriorate rapidly. Information regarding the condition of the piston rings can be obiained 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 @ 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.94 Maintenance Section Crankshaft Vibration Damper - Inspect 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 biowby has become excessive. Use the following tools to measure the blowby: © 81-2700 Blowby/Air Flow Indicator # 10-8860 Large Engine Blowby Pickup Group Refer to these Special Instructions that are provided with the tools: © Special Instruction, SEHS8712, “Using the 81-2700 Blowby/Airflow Indicator Group" # Special Instruction, SEHS8984, “Using the 10-8860 Large Engine Blowby Pickup Group’ 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 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 filed 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 10 other engine components. A deteriorating damper can cause excessive gear train noise at variable points in the speed range. ‘A damper that is hot may be the result of excessive friction. This could be due to misalignment, Use an infrared thermometer to monitor the temperature of the damper during operation. If the temperature reaches 100 *C (212 °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 flu. The fluid in the damper is silicone. Silicone has the following characteristics: transparent, viscous, smooth, and difficult to temove Irom surfaces, Ifthe fluid leak is oil, inspect the crankshatt seals for leaks. Ifa leak is observed, replace all of the seals. Inspect the damper and repair or replace the damper for any of the following reasons. © The damper is dented, cracked, or leaking # The paint on the damper is discolored from heat, ‘# The engine has had a failure because of a broken crankshat ‘* 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 cil Removal and Installation Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement,95 Maintenance Section Cylinder Pressure - Measure/Record Cylinder Pressure - Measure/ Record SMCS Code: 7450-082 Measure the cylinder pressure of new engines. Record the dala. 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 af 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. Cylinder pressure can be measured during inspection of the spark plugs. Use the following, uidelines for checking the cylinder pressure: ‘¢ Remove ali of the spark plugs '* Minimize the cranking time. This will enable a maximum consistent cranking speed for the check. Aiso, the starting air or battery power will be conserved. A toss of cylinder pressure or a change of pressure in one or more cylinders may indicate the following conditions, These conditions may indicate @ 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 Ii 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, use Special Instruction, GMGO0694, “Analyzing Cylinder Condition By Measuring Air Flow". Aiso, use the 146-2739 Cylinder Pressure Adapter. Mlustration 68 is a graph of typical cylinder pressures for engines with diffe mpression ratios, 854. (240) 1585. (230) rae 1309 (190) ° naz 96: Ma 4 vos4 (150 tustraion 68 es (¥) Oytnder pressure in KPa (pst (00) Compression ratio. (1) Normal range for cyindor prossuce Record the pressure for each cylinder. Use this Operation and Maintenance Manual, “Valve Data Sheet” (Reference Materials Section}96 Maintenance Section Cylinders - inspect iooersee Cylinders - Inspect ‘SMCS Code: 1223 Use a borescope to inspect the cylinders. The inspection will provide information about the internal condition of the engine. A borescope with a lens that can be rotated is recommended. This type of borescope provides a ar 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. To perform this procedure, insert the borescope through the openings for the combustion sensors. Use the borescope to look for the following conditions: * Valve wear Deposits on the vaive 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 vaive face. Inspect, the valve seat and the valve face for excessive deposits. if excessive deposits are found, replace the valve and the valve seat For information on replacing the components, see the Service Manual. Consult your Caterpillar dealer for assistance. Driven Equipment - Check SMCS Code: 3279-535 Every 5000 Service Hours Engines That Are Not Attached To the Base with a Dowel I some engines are too rigidly mounted, excessive stress may affect the internal support of the cylinder block, This could cause the following problems: « Distortion of the bores of the main bearing « Distortion of the alignment of the bore Severe damage to the engine could result. The service fife of the engine could be severely reduced For engines that are not attached fo the base with a dowel, check the alignment alter every 5000 service hours. Every 10,000 Service Hours Engines That Are Attached To the Base with a Dowel Some engines must be more rigidly mounted. Due to thermal expansion, a cold engine will expand alter the engine achieves operating temperature. Some engines are attached to the base with a dowel in the rear mounting support. This installation forces the thermal growth forward. The driven equipment is also attached with a dowel in order to maintain alignment with the engine. For this type of installation, check the alignment alter every 10,000 service hours. Check the Alignment The alignment between the engine and the driven equipment must be maintained properly. Improper alignment will cause damage to the engine, the coupling, and the driven equipment. Check the alignment according to the instructions thal are provided by the following manufacturers: © Caterpillar # OEM of the coupling # OEM of the driven equipmentDriven Equipment - Inspect/ Replace/Lubricate SMCS Code: 3279-040 Perform any maintenance thal is recommended by the OEM of the driven equipment. Refer to the literature of the OEM of the driven equipment for the following service instructions, ‘¢ Inspection of the driven equipment # Replacement of the driven equipment or components, «Lubricating grease and lubricating oil requirements for the driven equipment Inspect the Flexible Rubber Coupling (If Equipped) Inspect the flexible rubber coupling for the following conditions, * Fraying * Cracking '* Deterioration Wear ¥ any of these conditions are evident, replace the flexible rubber coupling, if necessary. Refer to the Reusability Guidelines that are provided by the OEM of the flexible rubber coupling. Refer to the instructions of the OEM of the flexible rubber ‘coupling for the replacement procedure. 7 Maintenance Section Driven Equipment - Inspect Replace/Lubricate Engine Air Cleaner Element - Replace SMCS Code: 1051-510 NOTICE Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet. NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine, Clean the air cleaner elements or replace the @ cleaner elements when the following conditions occur '* Caterpillar recommends an inspection of the air Cleaner elements belore the air restriction reaches 2.5 kPa (10 inches of H.0}. A loss of engine erlormance may occur when the air restriction exceeds this limit, # Clean or replace the air cleaner elements before the air restriction exceeds 3.75 kPa (15 inches of H.O). Servicing the Air Cleaner Elements Note: If the air cleaner is not manutactured by Caterpillar, follow the instructions that are provided by the OEM of the air cleaner. Ii 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 deaier has the proper ait cleaner elements for your application. Consult your Caterpillar dealer for the correct air cleaner element. ‘* Check the precleaner (if equipped) daily for accumulation of dist and debris. Remove any dirt and debris, as needed Replace the dirty paper air cleaner elements with clean air cleaner elements. Before installation, thoroughly inspect the air cleaner elements for tears andjor holes in the filler 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.98 Maintenance Section Engine Air Cleaner Element - Replace 1. Remove the air cleaner cover. Remove the air cleaner eloment 2. Cover the turbachargs to keep dirt out ir inlet with tape in order 3. Clean the inside of the air cleaner cover and body with a clean, dry cloth 4. Remove the tape for the turbocharger air inlet. Install an air cleaner element that is new or cleaned 5. Install the air cleaner cover. Crankcase Air Cleaner Engines that are equipped with positive crankcase ventilation have an air cleaner for crankcase ventilation. Clean the air cleaner element or replace the air cleaner element when the following conditions occur # The yellow diaphragm enters the red zone. '* The red piston locks in a visible position The air restriction reaches 0.25 kPa (1 inch of Hu Mustration 69 one (1) Service inaicator (2) Cover 1. Remove cover (2) 2. Remove the used element and dispose of the element, 3. Clean the inside of cover (2) and clean the inside of the body. 4, Install a new element, install cover (2). 5. Reset service indicator (1), if necessary. Inspecting Air Cleaner Elements stration 70 Inspect the clean, dry air cleaner element. Use @ 60 watt blue light in a dark room or in a similar facilty. Place the blue light in the element. Rotate the element. Inspect the element for tears and/or holes. Inspect the element for light that may show through the filter material. Itt is necessary in order to confirm the result, compare the element to a new element that has the same part number. ‘Do not use an element that has any tears andjor holes in the filter material, Do not use an element with damaged pleats, gaskets or seals. Discard damaged elements, Storing Air Cleaner Elements If an element that passes inspection will not be used, the element can be stored for future use. ustraton 79 ‘0261694 Do not use paint, @ waterproof cover, or plastic as a protective covering for storage. Restricted air flow may result, To protect against dirt and damage, wrap the elements in Volalite Corrosion Inhibited (VCi) paper. Place the element into a box for storage. For Identification, mark the outside of the box.99 Maintenance Section Engine Air Cleaner Service Indicator - Inspect e Store the box in a dry location sora Engine Air Cleaner Service Indicator - Inspect Some engines are equipped with positive crankcase. ventilation. The air cleaner for crankcase ventilation is mounted on the crankshaft inspection cover This ait cleaner filters air that 1s drawn into the crankcase. The air dilutes the harmful fumes that may accumulate in the crankcase. The air and the fumes are drawn away from the crankcase, ustation 72 oma (1) Service incator Observe service indicator (1). Clean the air cleaner element or replace the air cleaner element when one of the faliowing conditions occur ‘The yellow diaphragm enters the red zone. ‘¢ The red piston locks in the visible position. '¢ The air restriction reaches .25 kPa (1 inch of H.O). For instructions on replacing the air cleaner ‘element, see this Operation and Maintenance Manual, “Engine Air Cleaner Element - Replace” topic (Maintenance Section). 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400 Maintenance Section Engine Crankcase Breather - Clean '¢ Check the movement of the yellow core when the engine is accelerated to the engine rated rpm. ‘The yellow core should latch approximately at the greatest vacuum that is attained It 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. Engine Crankcase Breather - Clean SMCS Code: 1317-070 If the crankcase breather is not maintained on a teguiar basis, the crankcase breather will become plugged. A piugged crankcase breather will cause excessive crankcase pressure thal can shut down the engine. Leakage of the crankshaft seal can occur. Perform this maintenance when the engine is stopped, liustration 73 POSTTS Porous titer A porous filler is part of a fitting that is used for mounting of the service indicator. Inspect the fier for cleanliness. Clean the filter, if necessary, Use compressed air or @ clean, nonflammable solvent. The service indicator may need fo 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 Nem (18 Ib in} IMystration 74 sons (1) Breather assomtly (2) Tee (@} Hose came (4) Oxing seat (6) Retaning clamp 1. Loosen retaining clamps (5). Loosen hose clamps (3). Remove breather assemblies (1) and Oxting seats (4) Wash the breather elements in clean nonflammable solvent. Inspect tee (2) for cracks that can be caused by vibration. Replace the old lee with a new tee if cracking is foun. 3. Install new O-ring seals (4) 4. Allow the breather elements to dry before installation. Instail the breather assemblies in the original position. Coat the rubber parts with clean engine oil or petroleum jelly in order to make installation easier. Install the retaining clamps and the hose clamps. See the Service Manual, “Specifications” module for the proper torque.e Engine Mounts - Check 101 Maintenance Section Engine Mounts - Check SMCS Code: 1152-535 Check the torque of the bolts for the mounting plates. For the proper torque, see Gas Engines Application and installation Guide, LEKQ7252, ‘G3600 Mounting, Alignment” Engine vibration can be caused by the following conditions: ‘@ Improper mounting of the engine Deterioration of the isolators Settling of the isolators will result in misalignment between the engine and the driven equigment, 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, see the literature that is provide by the OEM of the isolators. Also see the following publications: Gas Engines Application and Installation Guide, LEKQ7252, "G3600 Mounting, Alignment” # Special Instruction, SEHS9162, “Spring Isolator Group Installation and Adjustment Procedure” Consult your Caterpillar dealer for assistance. Engine Oil - Change SMCS Code: 1348 Oil Change Interval Considerations for the oll change interval include the type of fuel and the engine application, The establishment of an $-0'S oll analysis program will enable an evaluation of the used oil. The evaluation can be used fo delermine if this oil change interval ig suitable for your specific engine. Engines That Use Bio-Gas ‘The oll change interval is determined by the results of oil analysis. Change tho lubrication oil when oil analysis determines that the oil has reached the condemning limit 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 cil 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 boon operated at normal ‘operaling temperature, STOP the engine Note: Drain the oil into a suitable container. Dispose of fluids according to local regulations.102 Maintenance Section Engine Oil - Change tg OOTSO7RG ustraton 75. (1) Drain valve 2. Open drain valve (1) in order to drain used oil Aiter the oil has drained, close drain valve (1). 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 at) 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. Mustation 76 nar (2) Screen assembly 1a. 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 nontiammable solvent. Allow the screen assembly to dry belore installation ¢. Install the screen assembly. Install a new gasket. Install the cover. 4. Change the engine oil ters. See this Operation and Maintenance Manual, "Engine Oil Fiter - Change” topic (Maintenance Section). NOTICE Only use oils that are recommended by Caterpil- lar. For the proper oil to use, refer to this Operation and Maintenance Manual, "Engine Oil” topic (Mainte- nance Section). 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 enable the crankshatt to dip into the oil. This will reduce the power that is developed and also force air bubbles into the il. These bubbles (foam) can cause the following problems: reduction of the oil's ability to lubricate, eduction of oil pressure, inadequate cooling of the pistons, oil blowing out of the crankcase breathers, and excessive oll consumption. Excessive oil consumption will enable deposits to form on the pistons and in the combustion chamber. Deposits in the combustion chamber lead to the following problems: guttering of the valves, packing of carbon under the piston rings, and wear of the cylinder liner. Note: For the amount of oil o use, see this Operation and Maintenance Manual, “Refill Capacities” (Maintenance Section). 5. Remove the oil filer cap. Fill the crankcase through the oil filer tube only. Clean the oi! 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. Slop the engine and allow the oil to drain back into the sump for 2 minimum of ten minutes,103 Maintenance Section Engine Oil Filter - Change 8. Remove the oll love! gauge and check the oil level. Maintain the oil tevel to the "FULL" mack on tho "ENGINE STOPPED" side of the oil level gauge. Engine Oil Filter - Change SMCS Code: 1308 Replace the engine oil filters when the following conditions are met: # Every oll change # The engine oil iter differential pressure reaches 100 kPa (15 psi) Service tools are available to aid in the service of oil fitters. 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 7 MOU Hot oil and components can cause personal in- jury. Do not allow hot oil or components to contact skit Perform the following procedure after the ail has been drained Note: Use this procedure if the engine oil fiters do not have a control valve. ara stration 7 (1) Pressure gauge @) Drain (@) Cover {8} Control valve 1. Connect a hose from each drain valve (2) to a Suitable container in order to catch the Oil104 Maintenance Section Engine Oil Filter - Change 2. Open both drain valves (2). Allow the oil to drain. Note: Some oil will eemain in the housing atter the oil has been drained. This oil will pour out of the housing when cover (3) is removed. Prepare to catch the oll in a suitable container. Clean up any spilled oil with rags. DO NOT use absorbent Particles to clean up the oi 7 OG Personal injury can result from parts and/or cov- ers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosene 3. Be alert to the spring force. The cover has a spring force up to 240 N (64 Ib). Gradually loosen But do not remove the last two bolls or nuts that are located at opposite ends of covers (3) Bofore removing the last two bolis or nuts, pry the covers loose oF tap the covers with a rubber mallet in order to relieve any spring pressure, F888 Wusvation 76 (5) Wie rack (6) Oving seat 7) Element 4, Elements (7) are mounted on wire racks (5) inside the housing. Use a pan fo 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 specif cations. 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 cil filers rec- ‘ommended by Caterpillar 5. Ensure that the new oil filter elements are in good condition. Place the elements on wire rack: (6). Install the wire rack and the elements 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 seais. 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 cantrol valve (if equipped) to the “FILL” position for each housing, After both of the housings are full of oll, 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 yO Filter contains hot pressurized fluid when engine is running. Follow instructions on contro! valve to avoid personal injury. If rapid air movement exists to blow fluid, Stop the engine to avoi It itis necessary to replace the oil filters during engine operation, perform the following procedure.105 Maintenance Section Engine Oil Filter - Change ttustation 79| (1) Pressure gauge 2) Orain (G) Cover (8) Control vane 1. Connect a hose from drain valve (2) to a suitable container in order to caich the ol 2. Rotate control valve (4) to the “LOWER SERVICE" position, 8. Open drain vaive (2) and drain the fower 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 PU Uy Personal injury can result from parts and/or cov- ers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 4, Alter zoro pressure has been reached, remove cover (3). Be alert to the spring force. The cover has a spring force up to 240 N ($4 Ib). Gradually loosen but do not remove the last two bolts or ‘huts that are located at opposite ends of cover (3). Before removing the last two bolts or nuts, ry the cover loose or tap the cover with a rubber mallet in order to relieve any spring pressure. stration @0 oy (5) Wie cack (6) O-nng seal (7) Element 5. Elements (7} are mounted on wire rack (5) inside the housing, Use a pan to caich the oil that drips when wire rack (8) is removed. Remove wire rack (5). Remove used elements (7). Clean up any oil that is spilled NOTICE Caterpillar oll fters are. built to Caterpillar specifi- cations. Use of an oil filer not recommended by Caterpillar could result in severe engine damage to the engine bearings, crankshatt, etc. as a result of the larger waste particles from unfitered cil entering the engine lubricating system. Only use oil fters rec- ‘ommended by Caterpillar 6. Ensute thal the new oil filler elements are in good condition, Place the elements on wire rack (). Install the wire rack and the elements. 7. Ensure that the surfaces for O-ring seal (6) are lean. 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 Orting seai 8. Install cover (3). Ensure that the spring is se properly between eloment (8) and cover (3). Close drain vaive (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 ail filter housing is full of oil 10. Alter 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 cl fier106 Maintenance Section Engine Oil Level - Check 11. Alter the oil filters have been serviced and alter the pressure of the lower oil fier and the upper oil filter is equal, rotate control vaive (4) to the "RUN" position. Inspect the Used Oil Filter Elements Cut the used oil fillor element open with a utility knife, Remove the metal wrap. Cut the filter element ‘ree 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 oF 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 con 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. Perts that may be affected include the following components: main bearings, rod bearings, turbocharger bearings, and cylinder heads. Aluminum debris may indicate problems with the bearings of the front gears. If aluminum debris is found, inspect the crankshaft vibration damper and the bearings of the front idler gear. Due to normal wear and friction, itis not uncommon to find small amounts of debris in the oil fiter 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, Engine Oil Level - Check SMCS Code: 1318; 1326-535 The most accurate check of the oil fevel is performed when the engine is stopped. Perform this maintenance on a surface that is as level as possible, Iustation 61 oer 48 (1) 0¥ level gauge (2) 01 fitor stration 62 00636568 (3) ENGINE STOPPED WITH OIL COLD” sido (@) “ENGINE AT LOW {OLE WITH WARM OIL” side (8) "ADD" mark (6) "FULL" mark Note: For engines with powered crankcase ventilation, remove the oil filer cap. Allow the crankcase pressure 10 stabilize belore checking the engine oil level. 1. Ensure thal oil level gauge (1) is seated, 2. If the engine is stopped, remove oil level gauge (1). Observe the oil level on “ENGINE STOPPED WITH OIL COLD’ side (3).107 Maintenance Section Engine Oil Level Gauge - Calibrate . If the engine is operating, reduce the engine speed to low idle, Remove oil level gauge (1) and observe the oil level on "ENGINE AT LOW IDLE WITH WARM OIL" side (4) The oil level should be between "ADD" mark (8) and "FULL" mark (6), 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 enable the crankshatt to dip into the oil. This will reduce the power that is developed and also force air bubbles into the oil. These bubbles (foam) can cause the following problems: reduction of the oil's ability to lubricate, eduction of oil pressure, inadequate cooling of the pistons, oil blowing out of the crankcase breathers, and excessive oil consumption, Excessive oil consumption will enable deposits to form on the pistons and in the combustion chamber. Deposits in the combustion chamber lead to the following problems: guttering of the valves, packing of carbon under the piston rings, and wear of the cylinder liner. If the oil level is above the “FULL" mark on the oil level gauge, drain some of the oil immediately, 2. Ii necessary, remove oil filer cap (2) and add oil. For the correct oil 10 use, see this Operation, and Maintenance Manual, “Engine Oil” topic {Maintenance Section). Do not Mil the crankcase above “FULL” mark (6). Clean the oil filler cap. install the ail filer cap. 3. Record the amount of oil that is added. For the next oil sample and analysis, include the total amount of oil that has been added since the Previous sample. This will help to provide the most accurate oil analysis. Engine Oil Level Gauge - Calibrate SMCS Code: 1326-524; 1326 If the oil level gauge is not marked, the oll level gauge requires calibration. Consult your Caterpillar dealer for the procedure te calibrate the oil level gauge. Calibrating the Oil Level Gauge for Full Load Operation The oil level gauge can be marked in order to be checked while the engine is operating at full load. This will eliminate the need to reduce the engine speed to low idle in order to check the oil level 1. Ensure that the oil level is full nkei 2. Operate the engine at full load. Ensure that the engine operation is normal and stabio 8, Ensure that the oil level gauge is seated. Remove the oil level gauge. Observe the oil level on the oi! level gauge. 4, Engrave a mark for the oil level on the oil level gauge. Label the mark "FULL LOAD". Install the oii level gauge.108 Maintenance Section Engine Oil Sample - Obtain SMCS Code: 1000; 7542.554-0C, SM Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Obtain the Sample and the Analysis In adeition to @ good preventive maintenance program, Caterpilar recommends using S-0°S oil analysis at regular scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine. To ensure that the sample is representative of the oil in the crankcase. obtain a warm, well mixed oil sample. Obtain the S-0-S Sample Use one of the following methods in order to obtain an S:0°8 sample ‘* Use the oil sampling vaive (it equipped). ¢ Use a 10-5758 Vacuum Pump or use an equivalent pump that is inserted into the sump. Caterpillar recommends using a sampling valve in order to obtain oil samples. The quality and the consistency of the samples is better when the ‘sampling valve is used. The location of the sampling valve must allow oil that is flowing under pressure to be obtained during normal engine operation. If the engine is not equipped with a sampling valve, the use of a 1U-5758 Vacuum Pump is preferred. To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean. For more information, see Special Publication, PEHP6001, "How To Take A Good Oil Sample” Consult your Caterpillar dealer for complete information and assistance in establishing an SOS program for your engine. ‘osases Engine Oil Temperature Regulator - Replace SMCS Code: 1330-510 ‘The oil temperature regulators divert the engine oil to the oil cooler in order to maintain engine oil temperature. For instructions on replacing the oil temperature regulators, see the Service Manual, “Disassembly and Assembly” module.