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SEBU5560-01
C.l.TERPILLAR~ November 1983

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G342C Natural Gas Engine

71B1250-UP
it IMPORTANT SAFETY NOTICE

Most accidents involving engine operation are caused by failure

to observe basic safety rules or precautions. An accident can
often be avoided by recognizing potentially hazardous situations
before an accident occurs.

Improper operation is dangerous and could result in injury or

death.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

WARNINGS BEFORE OPERATING THIS ENGINE.

Basic safety precautions are outlined in the "Safety" Section of

this Guide and in the description of operations where hazards
exist. Warning decals have also been put on the engine to
provide instructions and to identify specific hazards which, if
not heeded, could cause bodily injury or death to you or other
persons. These warnings in the Guide and on the engine
decals are identified by the symbol&

Operations that may result only in engine damage are

identified by CAUTION decals on the engine and in the Guide.

Caterpillar cannot anticipate every possible circumstance that

might involve a potential hazard. The warnings in this Guide and
on the engine are therefore not all inclusive. If an operation is
not performed as specifically recommended by Caterpillar, you
must satisfy yourself that it is safe for you and others. You
should also ensure that the engine will not be damaged or made
unsafe by the method of operation you choose.

A WARNING .

The proper and safe lubrication and maintenance procedures for this
engine, recommended by Caterpillar, are outlined in the "Lubrication &
Maintenance" Section of this Guide.

Improper performance of lubrication or maintenance procedures is dan-

gerous and could result in injury or death. Read and understand the
"Lubrication & Maintenance" Section before performing any lubrication
or maintenance.
 TABLE OF CONTENTS

Operation Section Lubrication and Maintenance Section

Safety Precautions . Fuel. Lubricant and Coolant Specifications 11

Initial Adjustments 2 Lubrication and Maintenance Chart .. 13

Starting 4 Recommended Lubricant Viscosities 17

Stopping 6 Refill Capacities 17

Attachments 6 Engine Specifications 17

Determining Cause of Shutdown 9 Engine Lubrication System 18

Woodward UG8 Governor 9 Air Induction and Exhaust System 20

Altitude Operation 10 Engine Valves 23

Fuel System 25

Cooling System 28

Starting System 32

Electrical System 34

Power Coupling System 40

Miscellaneous Maintenance 41
 FOREWORD

This guide contains operation instructions and lubrication
and maintenance information.
The operation section is a reference for the new operator
and a refresher for the experienced one. Read - study -
and keep it handy.
Illustrations guide the operator through the correct pro-
cedures of checking, starting, operating and stopping the
engine.
The maintenance section is a guide to equipment care.
The illustrated, step-by-step instructions are grouped by
servicing intervals. Topics without specific intervals are
listed under "When Required." Topics in the "Lubrication
and Maintenance Chart" are referenced to detailed instruc-
tions that follow.
Use the service hour meter to determine servicing inter-
vals. Calendar intervals shown (daily, weekly, monthly,
etc.) may be used instead of service hour meter intervals if
they provide more convenient servicing schedules and ap-
proximate the indicated servce meter reading. Recom-
mended service should always be performed at the interval
that occurs first.
Under extremely severe, dusty or wet operating condi-
tion, more frequent lubrication than is specified in the "Lu-
brication and Maintenance Chart" may be necessary.
Perform service on topics at multiples of the original
requirement. For example, at Every 500 Service Hours or 3
Months, also service those topics listed under Every 250
Service Hours or Monthly, Every 125 Service Hours or 2
Weeks, Every 50 Service Hours or Weekly, and Every 10
Service Hours or Daily.
Continuing improvement and advancement of product
design may have caused changes to your engine which
may not be covered in this publication.
Whenever a question arises regarding your engine or this
publication, please consult your Caterpillar dealer for the
latest available information.
ENGINE IDENTIFICATION
Caterpillar engines are identified with SERIAL NUMBERS
and ARRANGEMENT NUMBERS. In some cases MODIFI-
CATION NUMBERS are also used. These numbers are
shown on the serial nuber plate mounted on the engine.
Caterpillar dealers need all of these numbers to deter-
mine which components were included on the engine when
it was assembled at the factory. This permits accurate
identifcation of replacement part numbers.
ORDERING PARTS
Quality Caterpillar replacement parts are available from
Caterpillar dealers throughout the world. Their parts stocks
are up to date and include all parts normally reqUired to
protect your investment in Caterpillar engines. When order-
ing parts, your order should specify the quantity, part
number, part name and serial number, arrangement number
and modification number of the engine for which the parts
are needed. If in doubt about the part number, please
provide your dealer with a complete description of the
needed item.

Some photographs in this publication may show details

or attachments that may be different from your engine.
Also, guards and covers may have been removed for illus-
trative purposes.
 GAS ENGINE OPERATION
GENERAL
Proper engine operation and maintenance are essential
to long engine life and maximum performance. The
essentials for proper operation and normal periodic
maintenance are outlined in this guide. However, your
Caterpillar dealer is available for troubleshooting and/or
SAFETY PRECAUTIONS
Safety is basically common sense. There are standard
safety rules but each situation has its own peculiarities
which cannot always be covered by rules. Therefore,
your experience and common sense will be your best
gu ides to safety. Lack of attention to safety can resu It
in: accidents, personal injury, reduction in efficiency
and worst of all- loss of life. Watch for safety hazards.
Correct deficiencies promptly.
Use the following safety precautions as a general guide
to safe operation.
1. Never adjust or repair a machine while in oper-
ation.
2. Remove all loose tools and electrical cords from
the engine before starting.
3. Keep the engine room and floor area clean.
4. Store oily rags in containers.
5. Never store flammable liquids near the engine.
6. Do not smoke around batteries. Hydrogen gas
generated by a charging battery is explosive. Keep
batteries in a well ventilated area.
INSTALL GUARDS ON ALL EXPOSED ROTATING COMPONENTS
repairs when required.
Before starting the engine, familiarize yourself with
these procedures and apply the principles to your partic-
ular installation.
7. Observe NO SMOKING signs.
8. Do not wear loose clothing around machinery.
9. Be sure the engine room is properly ventilated.
10. Always disconnect and tape the ground battery
lead before working on the electrical system.
11. All electrical equipment must be grounded ac-
cording to local building codes.
12. Be sure an automatic start-stop system is inopera-
tive when the engine is being worked on. 0 is-
connect the starter from the start switch.
13. Use the emergency stop button for emergency
only. (This procedure shorts out the magneto,
thus leaving unburned gas in the manifold.)
14. An overly rich fuel mixture can cause combustion
in the exhaust system.
15. All gas lines and valves must meet local codes.
16. Check piping periodically for gas leaks.
Remember, safety is everyone's business.
 PERIODS OF LIMITED USE
Prolonged operation at low idle or reduced load may
cause oil consumption and carboning in the combustion
chamber and result in poor performance and a loss of
power. Every four hours, load the engine to clear carbon
from the combustion chamber.
If the engine is to be stored or left standing for a long
period of time, the lUbricating oil may drain away from the
cylinder walls and piston rings. This lack of lubricant per-
mits rings to rust, and causes unnecessary wear by metal-
to-metal contact between the pistons and rings when the
INITIAL ADJUSTMENTS
Before making initial adjustments, check the engine
and installation as you would during normal operation.
See page 4.
CARBURETOR ADJUSTMENT
CARBURETOR ADJUSTMENTS
1. Idle Adjustment Screw 2. Power Mixture Screw
1. Set the power mixture screw (2) midway between
ilL" and IIR".
2. Turn the idle adjustment screw (1) clockwise all
the way in, then out four turns.
3. Set low idle speed on a cold engine. With the
engine running, turn the low idle screw (1) to
obtain recommended low idle speed (see the En-
gine Information Plate).
Change the gas pressure delivered by the line pressure
regulator to compensate for any change in heat content
of the fuel. See your Caterpillar dealer for pressure
settings.
LINKAGE ADJUSTMENT
1. Disconnect linkage (1).
2. Turn screw (2) counterclockwise until the throt-
tle plate will close without touching the screw.
3. Turn screw (2) until it touches stop (3) with the
throttle plate closed.
2
engine is started. The lack of lubricant may not cause any
noticeable change in engine operation after it has been
started, but it does contribute to shorter engine life.
If an engine is not going to be used for several weeks,
renew the oil film by running the engine once a week until
it is thoroughly warm. This will circulate the oil and will
prevent rust from forming. Lubricate all points mentioned
in the lubrication chart.
If an engine is going to be put in winter storage, see your
Caterpillar dealer for storage instructions.
LINKAGE ADJUSTMENTS
1. Governor Linkage 2. Throttle Stop Screw 3. Stop
4. With the governor lever in the OFF position and
the throttle plate closed, adjust the linkages and
reconnect them. (If additional linkage ad-
justment is necessary, see your Caterpillar
dealer.)
5. On Vee engines adjust linkage so that both throt-
tle plates open simu ltaneously.
GAS LINE PRESSURE
Gas line pressure must be regulated for use in engines.
Naturally aspirated engines, using a line pressure regula-
tor, require line pressure of 3 PSI to 20 PSI. A turbo-
charged engine must have greater working pressure avail-
able-12 PSI to 20 PSI. Twenty PSI is the maximum line
pressure which is easily reduced to a working pressure. If
gas pressure exceeds 20 PSI, a second regulator will have
to be used.
LINE PRESSURE REGULATOR
The line pressure regulator requires adjustment when
the engine is installed, when the regulator is reworked,
or when the heat content of the fuel is changed. A water
manometer is used to set the regulator output gas
pressure.
1. Remove plugs (1) and (2) from the carburetor.

CARBURETOR
1. Air Pressure Manomet... Plug 2. Gas inlet Plug
3. Power Mixture Screw
2. Connect a water manometer between the two
pressure taps.
LINE PRESSURE REGULATOR
4. Regulator Adjustment Plug
NOTE
A valve is used between the manometer
and the carburetor to prevent water from
being drawn into the engine during start
up. Close the valve during cranking and
start up, then open the valve when en-
gine is running.
3. 0 pen the main gas valve.
4. Adjust the gas pressure to support a 5'h inch (14
cm) column of water, or to correct differential if
fuel BTU is known.
5 The regulator adjustment is made by removing
plug (4) and turning the slotted cap clockwise to
increase output pressure and counterclockwise to
decrease pressure.
3
6. Repeat this procedure for each carburetor.
7. After these initial adjustments the engine can
be started.
ADJUSTING LINE PRESSURE REGUALTOR WITH
KNOWN BTU FUEL
1. With known BTU fuel, refer to a differential and
BTU curve. See Form FE036044, or see your
Caterpillar Dealer for pressure setting.
2. Use the curve to find proper differential setting
which gives the correct air fuel ratio.
3. Follow procedure under line pressure regulator
until adjusted gas pressure will support the pro·
per differential with engine at idle condition.
ADJUSTING LINE PRESSURE REGULATOR WITH
UNKNOWN BTU FUELS
1. Follow procedure under line pressure regulator
for setting which will allow starting of engine.
2. Install accurate tachometer on engine.
3. Remove line regulator plug (4) and install adjust·
ing tool.
NOTE
On turbocharged engines a special tool is
necessary to prevent boost pressure from
escaping when regulator cap is removed.
4. Start engine and put under constant fixed load.
Load should be as near full load as possible with
engine running steady.
5. Physically lock carburetor throttle plate in posi-
tion while engine is operating. (On Vee Engines
lock both throttle plates.)
6. Disconnect governor linkage.
7. Adjust regulator slotted cap to get maximum en-
gine RPM. Maximum engine RPM can be found
best by starting with a lean mixture and slowly
increasing to reach maximum RPM.
8. Reduce the maximum obtainable RPM by 3%.
This is done by leaning mixture - turn slotted
cap counterclockwise in regulator. This will give
proper air fuel ratio.
NOTE
On Vee Engines each side has to be ad-
justed separately.
9. Reconnect governor linkage and unlock throttle
plate.
10. Remove special tool from regulator or install cap.
11. If differential is desired, a manometer may be
installed at carburetor point 1 and 2 and read.
ADJUSTING POWER MIXTURE SCREW- opposite bank. This reduces the amount of unbalanced
1. Power mixture screw (3) should be adjusted with load possible and keeps one bank from overworking. The
engine operating at rated load and RPM only. maximum amount of unbalance without a loss of power
is .3 inches (0,76 em) of mercury. Unbalance is deter-
2. Increase richness until engine reaches its ma- mined in the following manner.
ximum RPM.
3. Turn power mixture screw to lean until engine
loses RPM.
4. Turn power mixture screw to rich until engine
regains highest RPM.
NOTE
Power mixture screw is only effective at
rated load and RPM. With 905 BTU LHV
fuel mixture, screw should be set 2%
notches trom lean.

BALANCE LINE

Turbocharged engines have a balance line from the

carburetor to the line pressure regulator. The balance
line transmits manifold air pressure to the upper side of
the regulator diaphragm. This force, added to the spring
force, ensures that gas pressure to the carburetor will
always be greater than inlet air pressure regardless of
load conditions. A turbocharged engine will not develop
full power without a balance line.
THROTTLE SYNCHRONIZATION - VEE ENGINES
Be sure both linkages have been adjusted.
Two turbochargers are used on Vee engines. The air
induction system is cross blown, that is, the turbo-
charger turbine wheel is driven by the exhaust from one
bank and the compressor wheel supplies air to the
MANOMETER CONNECTION LOCATION
With the engine stopped:
1. Remove the plug from each manifold and con-
nect the manometer.
2. Close the valve on the manometer and start the
engine. Open the valve.
3. Run the engine at 2/3 rated speed and adjust the
throttle linkage until the difference in the two
columns is within .3 inches (0,76 em) of mercury.
DO NOT change gas pressure to balance the
output.
4. Repeat Step 3 with engine at 2/3 load and at
rated speed.

STARTING
Perform required periodic maintenance before starting tion. It only takes a few minutes to correct minor dis-
the engine. Make a "walk-around" check of the installa- crepancies. This can prevent major repairs at a later date.

PRE-START CHECKS

1. Check the air cleaner service indicator. If the red 2. Correct any leaks, loose bolts or covers. The fan
piston is locked in the raised position, service the and radiator must be clear of restrictions.
air cleaner.

4
 DIPSTICK

4. The crankcase oil level must be above the ADD

mark.

AIR CLEANER SERVICE INDICATOR 5. 0 isconnect any battery chargers that are not pro·
tected against the starter current drain.
3. Check the coolant level. The rad iator must be fu II 6. All guards must be in place. If guards are inade-
to the bottom of the filler neck. quate or in need of repair, notify your supervisor.

STARTING PROCEDURE

ELECTRIC START
1. Open the raw water valve-if so equ ipped.
-
2. Open the gas valve.
3. Disengage the clutch or open the circuit breaker.
Do not start an engine under load.
4. Move the controls to half engine speed position.
5. Reset any safety devices.
Safety Gauges-Push reset button on the mag-
netic switch and hold the oil pressure reset PUSH TO SET OIL PRESSURE SWITCH TO OFF POSITION
button in.
Electrical-turn oil pressure switch OFF. 6. Start the engine.
7. If the engine fails to start after 30 seconds of
/'
cranking, stop. Allow the starter to cool for two
minutes. Turn the gas valve OFF and crank the
engine for 10 to 15 seconds to purge unburned
gas from the exhaust system.
8. Turn the gas valve ON and repeat cranking
procedure.
CAUTION
Do not engage the starter when the
flywheel is moving.

Clearances and tolerances are designed for operating

RESET OIL PRESSURE SWITCH conditions-including operating temperature. When the

5
engine is started it takes several minutes to establish the The lubricator must be filled with oil. See the Lubri-
lubricating oil film and allow the moving parts to heat cation and Maintenance Procedures.
up and expand. Loading a cold engine will cause short-
HYDRAULIC START
ened service life, Le., broken rings, seized pistons, etc.
This warm up period allows time for another "walk- Perform all electric starting preliminary checks.
around" check for leaks, etc. Check the hydraulic accumulator pressure-it must be
If oil pressure fails to register, stop the engine and 3000 PSI.
determine the cause. On the units with an oil pressure
switch, the reset knob will move from ON to RUN auto-
matically when oil pressure builds up. If the knob fails
to move, stop the engine and determ ine the cause.
AIR START
Perform all electric starting preliminary checks.

Check the air supply. The air starter must have 100
PSI air pressure available. The standard receiver stores
10.5 cubic ft. (.3 cubic m ) of air at 250 PSI. Pressure is
reduced at the air starter motor.
Open bleed valve (on the bottom of the receiver)
weekly, to drain any condensation and oil carryover.

STOPPING
1. Remove the load from the engine.
2. Allow the engine to run at about half speed for
five minutes. This reduces internal temperatures
and prevents the loss of coolant by "afterboil".
3. Reduce speed to low idle for about 30 seconds.
4. DO NOT race the engine before shut off. This
causes the turbocharger to "coast" without
lubrication.
5. Turn gas valve off to stop the engine. Do not use
emergency stop button except in emergencies.

ATTACHMENTS
GOVERNOR CONTROLS
Various types of governor controls can be installed on
engines according to the application. The most common
control is direct mechanical. The control may be
mounted either on the engine or on a remote control
panel. Engine mounted controls normally consist of a
positive locking handle connected directly to the gover-
nor shaft. Cables and vernier controls mount on the
engine or on a control panel.
Shutdown controls are used only to stop the engine.
Mechanical or electrical controls are commonly used.
These devices stop the gas flow. Shutdown controls
allow the engine to be restarted after shutdown without
readjusting the speed controls. Shutdown controls are
usually found on Automatic Start-Stop installations.

GAUGES
Gauges provide a "look" inside the engine. Be sure
they are in good working order. You can determine what
is "normal" operating range by observing the gauges over
a period of time. The cause of any sudden or significant
change in the readings should be determined and cor-
rected.

OIL PRESSURE WATER TEMPERATURE

6
OIL PRESSURE - Oil pressure is normally greatest
when starting a cold engine. As the oil warms up it will
produce less pressure. Oil pressure is greater at operating
speeds than at low idle. Fluctuating readings can mean
air in the oil or a sticking pressure relief valve. Stop the
engine immediately if a sudden loss of oil pressure
occurs.
WATER TEMPERATURE - The operating temperature
is determined by the water temperature regulator. High
coolant temperatures mean the cooling system is not dis-
sipating enough engine heat. Pressurized cooling system
gauges are marked with ranges rather than temperatures.
If the gauge indicates in the red range, the cooling sys-
tem should be inspected.
The minimum operating temperature should not be
below the opening temperature of the water temperature
regulator.
AUTOMATIC START-STOP
An automatic start-stop system ensures that power is
supplied to a load when the normal power source is
interrupted. The cranking panel is the heart of the sys-
tem and consists of the failure warning system and relays
to start and stop the engine. When a power failure occurs
the system senses the failure and starts the engine to
transfer the load to standby. When power is restored, it
senses and transfers the load from standby and stops the
engine. The major use of automatic start-stop systems is
standby electric sets and this discussion is limited to that
application.
If a power failure occurs, a circuit breaker opens and a
set of contacts in the transfer switch closes, completing
the circuit to the starter motor. When the engine starts,
the starter circu it opens, protecting the starter from
overspeed damage.
Since a standby engine is usually unmanned, it is
usually protected from mechanical malfunction by a
series of electrical safety devices: high water tempera-
ture, low oil pressure and engine overspeed. If a fault
occurs it energizes one of the shut-off controls and
grounds the magneto to stop the engine.
CAUTION
DO NOT use any emergency shut-off
control for normal shut down. The emer-
gency shut-off controls are for emer-
gencies only.
If the unit has a standard cranking panel, the battery
and starter are protected from prolonged cranking by a
cranking cycle timer. A timer providing five ten-second
cranking cycles can be used. Both units have fault lights
which light if the cranking cycle is completed and the
engine does not start.
7
In cold weather the temperature gauge may fluctuate
in or near the cold range. This indicates the engine is
being overcooled. In these instances the use of radiator
louvers is suggested.
AMMETER
AMMETER - The ammeter should register in the charg-
ing range when the engine is running above low idle. If
the gauge registers a discharge when the engine speed is
increased, determine the cause.
Automatic start-stop units may have a time delay
relay to prevent the standby circuit breaker from closing
until the engine has had a few seconds warm up time. A
shutdown time delay provides up to two minutes to cool
off after the load has been transferred back to normal
power source.
A time delay relay in the transfer circuit can be ad-
justed from 1 to 30 minutes. This delays the transfer
from standby to normal power until the normal source
has been restored and remained stable for the preset
period.
Unattended units may have an exerciser. At a preset
time the engine automatically starts and runs, under load
if possible, and shuts itself off. This helps to ensure the
unit will start and perform as required when necessary.
A shutdown timer may also be used with an auto-
matic start-stop system. This provides a two minute cool
off period after the load has been removed from the
engine. This allows the heat of full load operation to be
dissipated gradually.
Many safety circuits have fault lights to aid the oper-
ator in locating the cause of the malfunction. These
lights are lighted by the safety circuit that is energized
by a mechanical fault i.e., high water temperature, low
oil pressure, etc.
SAFETY GAUGES
Safety shut-offs protect the engine from damage if
conditions exceed normal operating limits. The safety
circuits sense oil pressure and water temperature. The
sending units are a part of the gauges in the instrument
panels. If a fault occurs, the water temperature or oil
pressure indicator will make contact with a terminal and
completes the shutdown circuit. A magnetic switch is
energized and grounds the magneto to stop the engine.
Before restarting the engine, push the magnetic switch
reset button, located on the instrument panel. The oil
pressure switch reset button, located on the oil pressure
gauge, must be held in during starting.
SAFETY GAUGES
A manual stop button located on the instrument
panel should be used only in an emergency. The manual
stop button grounds the magneto to stop the engine.
WARNING
Unburned gas left in the manifold can
ignite when the engine is restarted.
Before restarting any gas engine which was stopped by
grounding the magneto, crank the engine with the gas
valve turned off and the magneto grounded for 10-15
seconds. This will clear the unburned gas from the ex-
haust system.
GAS SHUT-OFF VALVE
A gas shut-off valve is available. On an electrical signal
from either the safety circuit or a remote mounted
switch, the valve closes, stopping the gas flow to the
engine. This valve must be reset manually.
OVERSPEED SWITCH
A contactor actuated by a flyweight governor pro-
vides overspeed protection for the engine. The overspeed
switch is mounted on the tachometer drive. If the engine
overspeeds, the governor closes the contacts, energizing
RESET OVERSPEED SWITCH
the magnetic switch. The switch grounds the magneto to
stop the engine. When an overspeed occurs, the switch
must be reset before the engine can be started.
8
SAFETY SHUT-OFF
A safety shut-off system which is not part of the
gauges is available. The system stops the engine if the oil
pressure or water temperature exceed safe operating
limits. The overspeed switch can be used with this
system.
High water temperature causes an internal element to
expand and operate a microswitch. The microswitch
closes and grounds the magneto, stopping the engine.
The magneto is grounded by contacts in the oil pressure
switch if oil pressure falls below safe operating limits. A
magnetic switch, used with the safety gauges, is not
required with this safety shut-off due to higher capacity
contactors.
NOTE
Oil pressure shut·off is designed to pro-
tect engine from sudden oil lossage or
pressure, not against low oil level. Like-
wise, the temperature shut-off protects
against an increasing water temperature
but offers no protection against sudden
water lossage or when temperature ele-
ment is not in the water. A low coolant
level will not actuate the switch.
After an emergency shutdown, the oil pressure and/or
overspeed switch must be reset.
The oil pressure switch must always be reset before
starting the engine. To reset the switch, push the button
to the OFF position. As oil pressure increases the button
wi II automatically pOSition itself to the RUN position.
SAFETY SHUT-OFF TESTING
Safety shut-offs function only when an abnormal con-
dition exists. Because the shut-offs operate only in time
of a mechanical emergency, it is impossible to tell if they
are in good working order through normal operation.
Since it is important they are in working order, have the
shut-offs checked periodically by your Caterpillar dealer.
See the Lubrication and Maintenance Chart for service
intervals.
ALARM SWITCH
Alarm switches are available to notify the operator
that a fault condition exists. If oil pressure drops to a
dangerous level or water temperature reaches a high level
an alarm is activated. Depending on the system, a light is
turned on, or a bell or horn is sounded calling the oper-
ator's attention to the problem.
CAUTION
The water temperature element must be
in contact with the coolant to operate. A
low coolant level will not actuate the
switch.
 DETERMINING CAUSE OF SHUTDOWN
Anytime an engine is shut down by its safety circuit,
the cause must be determined. In some cases the cause
will be obvious but often an investigation will have to be
made. On installations with fault lights the fault is in-
dicated. Under no circumstances should the engine be
put back into service without determining and correcting
the cause of shutdown.
HIGH WATER TEMPERATURE
Look for the obvious first.
1. Determ ine if there is water on the floor from
spilled or leaking coolant.
2. Check the water temperature gauge for accuracy.
WARNING
DO NOT remove the radiator cap of an
overheated unit. The coolant is under
pressure and relieving this pressure will
cause the coolant to flash into steam.
Serious bums and engine damage can
result from the escaping coolant. Pressure
in a radiator may be reduced by pouring
warm water on the top tank to condense
the steam.
CAUTION
NEVER add cold water to an overheated
engine.
3. Check air flow through the radiator and water
flow through the heat exchanger.
4. Check air temperature to radiator. Few radiators
can adequately cool a fu lIy loaded engine with
WOODWARD UG8 GOVERNOR
1. Speed Droop Knob 4. Synchronizer Indicator
2. Synchronizer Knob 5. Load Indicator Pointer
3. load Limit Knob
9
1250 F (52 0 C) ambient air.
5. Check for recirculating air currents.
6. Check fan belts for proper tension.
7. See that engine room vents and louvers are open.
a. Check water flow.
9. Check water hoses for leaks. Check for collapsed
hoses. Hoses have been known to peel off inter-
nally and restrict water flow.
10. Determine if flow valves are open.
11. Check water pump drive belts.
12. Check raw water flow to heat exchanger.
13. If the engine is overloaded, overheating can
result.
14. Check engine timing.
Overheating can cause seals and gaskets to relax. If
severe or prolonged overheating has occurred, have the
engine checked by properly trained personnel.
LOW OIL PRESSURE
Look for the obvious first.
1. Check the dipstick.
2. Check floor for oil from leaks.
3. To determine if low oil pressure was the cause of
the shutdown, crank the engine with the fuel off.
If unusual noises come from the engine, discon-
tinue cranking. If oil pressure fails to build up,
and no external leaks are found, the problem is
probably internal.
CONTROLS
SPEED DROOP KNOB - Controls the speed change
from no load to full load.
SYNCHRONIZER KNOB - Throttle. Controls engine
speed.
LOAD LIMIT KNOB - Controls the horsepower out-
put of the engine to the nameplate rating.
SYNCHRONIZER INDICATOR - Indicates how
many turns of the synchronizer knob have been made.
LOAD INDICATOR POINTER - Indicates relative
load.
STARTING
Make all prelim inary starting checks.
1. Turn the load limit knob until the indicator is
 between "5" and "]".
2. Turn the synchronizer knob clockwise until the
indicator is at "8".
3. Start the engine and ru n it at 900 RPM for 5
minutes. To adjust speed turn the synchronizer
knob.
4. Turn the load limit knob to "10" to carry the
load.
5. Turn the synchronizer knob clockwise until the
engine runs at full governed speed.
6. Speed droop is dictated by the application.
A. Single unit operation. When constant speed or
frequency is required, set the speed droop
knob to "0".
B. Parallel operation. When several units are
operated in parallel and constant speed or
frequency is required, the first unit on the
line may be set at "0" droop and additional
units set from "30" to "70". If constant
speed is not required, set the speed droop
from "30" to "70" on all units.
7. Apply the load and readjust the synchronizer
knob to obtain the desired division. The load in-
dicator pointer behind the load limit knob indi-
cates the relative load.
When engines are paralleled, individual engine output
is controlled by the synchronizer knob. Turn the knob
clockwise to assume more of the load.
STOPPING THE ENGINE
1. Remove the load and move the synchronizer
knob counterclockwise to reduce the speed to
900 RPM. Allow the engine to cool for 5
minutes.
2. Stop the engine by turning the load limit knob to
"0".

ALTITUDE OPERATION
Turbocharger speed is determined by engine high idle
speed, turbocharger nozzle, exhaust bypass valve regula-
tor assembly, and the altitude at which the engine is
operating. The altitude limits are stamped on the engine
information plate. The regulator assembly is sealed and
any changes to the regulator assembly should be made
only by your Caterpillar dealer.
The engine can be operated safely at lower altitudes
than specified on the engine information plate, but will
not produce rated horsepower.
Always consult your Caterpillar dealer whenever
changes in operating altitudes are anticipated which
differ from the nameplate limits.
EXHAUST BYPASS VALVE

Moon NO. CF CYl. 80" STROKE

ENGINE snlAL NO
NO LOAD ENGINE R.P.M.
ruLL LOAD ENGINE R.P.M
RACK SETTING
H.P. SETTING AT SEA LEVEL
INJECTION TIMING
LIFTER SETTING AT T.e.
BILL OF MAT'l OR ESO NO

WARNING _ TURBOCHARGfD ENGINES OM.Y_

ENGlNE HAS BEEN CORRECTlY SET TO OPERATE AT ALTI_
TUDE LIMIT SHOWN

I I IFT. OR BB.OW
GOVERNOR AND TUR80CHARGER ARE SEAlED. 00
NOT CHANGE RACK SiTTING. TURBINE NOZZlE OR ENG-
INE SPEED WITHOUT PROPER INSTRUCTIONS. THE RACK
SETTING MUST BE CHANGED BY YOUR CATERPillAR
DEALER BEFORE OPERATING AT A HIGHER ALTITUDE AS
SERIOUS DAMAGE OR INAIRY MAY RESULT DUE TO
TURBOCHARGER OVERSPEEOlNG
REFER TO OPERATION AND MAINTENANCE INSTRUC-
TIONS FOR HIGH AlTITUDE OPERATION

ENGINE INFORMATION PLATE

10
 FUEL, LUBRICANT AND COOLANT SPECIFICATIONS

FUEL SPECIFICATIONS

DRY NATURAL GAS

Dry natural gas is a mixture of Methane, Ethane and not
more than 5 percent Propane and a fractional percentage
of Butane. It can also be referred to as commercial pipe line
natural gas.
The reference to "dry" refers to the absence of liquid
petroleum products such as liuid Butane or liquid Propane.
The BTU content of dry natural gas can vary. Caterpillar
gas engines are factory adjusted with a dry natural gas
having a low heat value (LHV) of 905 BTU/feet'
(33. 72kJ 11).
NGO
1. The coolant outlet temperature should be maintained
between 88°C and 93°C (190°F and 200°F). Tem-
perature rise across the engine should be no more
than 9°C (15°F), and a 6°C (10°F) rise is desirable.
Water and sulfur oxides are formed during combus-
tion and will condense on cylinger walls at low tem-
perature. The higher jacket temperature will minimize
the amount of condensation.
Engines equipped with inlet control cooling systems
will maintain outlet temperatures in the 88°C to 93 °C
(190°F to 200°F) range. Engines with outlet control
cooling systems may require additional external con-
trols to maintain 88 °C to 93 ° C (190 ° F to 200 ° F)
outlet temperatures.

Oil recommendation is determined by the gas and the
intake air conditions.
Units operating on processed natural gas should use oils
formulated with additive systems containing between zero
and 0.5% maximum slufated ash and meet the CB (Supp 1)
clasification. The oils are composed of ashless dispersants
and either organa-metallic (provided they do not contain
barium, calcium or magnesium) or completely ashless oxi-
dation inhibitors. Your oil supplier knows which oils meet
these requirements.
2. The temperature of the oil in the sump should be
maintained high enough to prevent water from con-
densing in the oil. Normally maintaining the jacket
water outlet temperature at a minimum of 88°C
(190°F) will accomplish this.
3. Establish an oil analysis program to assure oil change
periods are not extended byond safe limits and that
other problems are not overlooked. Caterpillar deal-
ers are capable of establishing and conducting such
programs.

Sour gas generally refers to fuels containing sulfur com- 4. A CD grade oil with less than 1% sulfated ash can be
pounds, primarily hydrogen sulfide. (Gases containing no used instead of oils normally ued in natural gas en-
sulfur compounds are referred to as "sweet gas".) Severe gines. CD oil has a higher TBN (which indicates its
damage to engines can occur if this contaminant is ignored. ability to neutralize acids formed from products of
Water vapor and sulfur oxides formed during combustion combustion of sulfur compounds) than normal gas
can combine to form sulfuric acid compounds. Internal com- engine oil.
ponents, particularly valve guides, piston rings, and cylin-
5. Where it is possible to start the engine on sweet gas,
der liners will be subjected to corrosive wear shortening
the engine should be brought up to operating tem-
engine service life.
perature on sweet gas, then switched to sour gas.
If analysis of the fuel shows the concentration of hydro- The procedure should be reversed when shutting the
gen sulfide to be greater thanO. 1% by volume, the fuel engine down.
should be treated (scrubbed) to lower the H2S level below
Consult your Caterpillar dealer if other conditions exist.
0.1 %. When using fuels with 0.1 % H2S or less, the following
preventive steps should be taken:
LUBRICANT SPECIFICATIONS

MPG

Use Multipurpose-type Grease. Multipurpose-type

grease which contains 3% to 5% molybdenum disulfide is
preferred. NLGI No.2 Grade is suitable for most tempera-
tures. Us NLGI No. 1 or No. 0 Grade for extremely low
temperatures.

11
COOLANT SPECIFICATIONS

Use a mixture of approved fill water, antifreeze and
cooling system conditioner.
"Know Your Cooling System," Form SEBD0518, can
provide more detailed specificatios.
FILL WATER
COOLANT CONDITIONER (LIQUID)
Use Caterpillar liquid cooling system conditioner or
equivalent. Follow the instructions on the container.
On a new or reconditioned engine add 1 pint (0.5 liter) of
Caterpillar cooling system conditioner for each 4 U.S. gal-
lons (15 liters) so that the cooling system will have a 3% to
6% concentration of conditioner.

Acceptable Water
50% Antifreeze Without COOLANT CONDITIONER ELEMENT
Water Content 50% Water Antifreeze
Contact your Caterpillar dealer for the correct coolant
100 ppm 50 ppm
Chlorides conditioner element.
or less or less
100 ppm 50 ppm
Sulfates
or less or less
Hardness as 200 ppm 100 ppm
CaCo, or less or less
500 ppm 250 ppm
Dissolved Solids
or less or less
pH 6.5 or higher 6.5 or higher
ppm = parts per million

Always add conditioner to water. Never use plain water

only.

ANTIFREEZE

Use ethylene glycol-type antifreeze. Use the correct

amount to provide freeze protection to the lowest expected
operating environment.

12
 LUBRICATION AND MAINTENANCE CHART

The LUBRICATION AND MAINTENANCE CHART lists all serviceable items which are either standard equipment
or attachments commonly ordered on your model of engine.

Items needing periodic maintenance are grouped according to frequency of service. Items needing service AS
REQUI RED are grouped by Systems, and follow the periodic interval items.

Use the service meter to determine servicing intervals. The service meter readings are based on engine speed, not
clock hours. Calendar intervals shown (daily, weekly, 2 weeks, etc.) may be used instead of service meter intervals if it
is necessary to coordinate servicing schedules. Perform previous interval items at multiples of the original requirement.
For example, at 100 service hours or 2 weeks, also perform those items listed under "Every 50 Service Hours or
Weekly" and "Every 10 Service Hours or Daily".

Items which do not pertain to your engine may be lined out to customize your chart.

13
Lubrication and Maintenance Chart

Item Service Lube. Page

Frequently During Operation
Crankcase Lube Oil Pressure Check oil pressure gauge reading. 18
Operating Water Temperature Check water temperature gauge reading. 28
Battery Charge Rate Check ammeter reading. 35
Every 10 Service Hours or Daily
Crankcase Lube Oil Level Check oil level - fill as required. NGO 18
Air Cleaner-Single Stage or Two Stage Check service indicator - service. 20
Woodward UG8 Governor Check oil level. NGO 25
Cooling System Check coolant level. 28
Enclosed Clutch and/or Front Power Take-off Lubricate shift collar and shaft. MPG 40
Every 50 Service Hours or Weekly
Two Stage Air Cleaner Empty dust collector cup. 21
Raw Water System Inspect zinc rods. 30
Batteries Check electroly1e. 35
Every 125 Service Hours or 2 Weeks
Enclosed Clutch and/or Front Power Take-off Lubricate shift lever bearings. MPG 40
Lubricate pilot bearing. Lubricate main
shaft bearing.
Every 250 Service Hours or Monthly-Turbocharged-Aftercooled Engine
Air Cleaner Element (See Note C) Install replacement filter element. 20
Radiator Fan Belt Check belt wear and adjustment. 29
Radiator Fan Lubricate fan bearings. MPG 30
Oil Filter (See Note A) Change filter element. 19
Every 300 Service Hours or 6 Weeks-Naturally Aspirated Engine
Oil Filter (See Note A) Change filter element. 19
Every 500 Service Hours or 3 Months-Turbocharged-Aftercooled Engine
Crankcase Lube System (See Note B) Change oil. NGO 18
Every 600 Service Hours or 3 Months-Naturally Aspirated Engine
Crankcase Lube System (See Note B) Change oil. NGO 18
Crankcase Breather Clean breather. 18
Carburetor Linkage Lubricate fitting. MPG 27

14
Lubrication and Maintenance Chart

Item I Service I Lube. I Page

Every 1000 Service Hours or 6 Months
Tachometer Drive Lubricate tachometer drive bearing. MPG 41
Safety Shut-off Controls Check operation at least every 6 months. 41
Spark Plugs Clean and gap. 17
Woodward UG8 Governor Change governor oil supply. Lubricate
synchronizing motor. NGO 25
Every 2000 Service Hours or 1 Year
Intake and Exhaust Valves Check valve adjustment. 17
Valve Rotators Check rotation of valves. 24
Exhaust By-pass Valve Breathers Clean elements. 24
Air Cleaner Install new filter element. 20
Hydraulic Starting System Install new filter element. 33
As Required-Air Induction and Exhaust System
Single Stage Air Cleaner Install replacement filter element. 20
Two Stage Air Cleaner Install replacement filter element. 21
Used Air Cleaner Filter Elements Cleaning procedures. 22
Air Cleaner Precleaner Service precleaner. 23
Intake and Exhaust Valves Adjust valve lash. 24
As Required-Fuel System
Woodward UG8 Governor Bleeding the governor. 25
As Required-Cooling System
Engine Jacket Water System Drain - flush - fill. 28
Fan Belts Adjust belt tension. 30
Raw Water Heat Exchanger-Aftercooler Water Install new zinc rods. 31
As Required-Starting System
Air Starting Fill motor oiler jar. Adjust oiler feed. Empty
collector jar. NGO 32

15
Lubrication and Maintenance Chart

Item I Service \ Lube. IPage

As Required-Electrical System
Batteries Installation - Maintenance. 34
Generator Charting Rate Ammeter reading. 35
Mechanical Magneto Timing magneto - Checking timing. 3?
Solid State Magneto Timing magneto - Checking timing. 3?
As Required-Power Coupling System
Clutch Adjustment Check - adjust. 40

(A) Oil filters should be changed whenever the filter indicator button raises halfway up regardless of the hours.

(B) Sour gas generally refers to fuels containing sullur compounds, primarily hydrogen sullide. (Gases containing no sulfur compounds are
referred to as "sweet gas. ") Severe damage to engines can occur if this contaminant is ignored. Water vapor and sulfur oxides formed during
combustion can combine to form sulfuric acid compounds. Internal components, parbcularly valve guides. piston rings, and cylinder liners,
will be subjected to corrosive wear, shortening engine service life.
If analysis of the fuel shows the concentration of hydrogen sulfide to be greater than the 0.1% by volume, the fuel should be treated
(scrubbed) to lower the H,g level below 0.1%. When using the fuels with 0.1% H,g or less, the following preventive steps should be taken:
1. The coolant oultet temperature should be maintained befween 88'e and 93'e (190'F and 200'F). Temperature rise across the
engine should be no more than goC (15 tl F), and a 6°C (10°F) rise is desirable. Water and sutfur oxides are formed during combustion and
will condense on cylinder walls at low temperature. The higher jacket temperature will minimize the amount of condensation. (Engines
equipped with inlet control cooling systems will maintain outlet temperatures in the 88°C to 93°C (190°F to 200°F) range. Engines with outlet
control cooling systems may require additional external controls to maintain 88°C to 93°e (190°F to 200°F) outlet temperatures.)
2. The temperature of the oil in the sump should be maintained high enough to prevent water from condensing in the oil. (Normally
maintaining the jacket water outlet temperature at a minimum of 190°F will accomplish this.)
3. Establish an oil analysis program to assure oil change periods are not extended beyond safe limits and that other problems are not
overlooked. Caterpillar delaers are capable of establishing and conducting such programs.
4. A CD grade oil with less than 1% sulfated ash can be used instead of oils normally used in natural gas engines. CD oil has a higher
TBN (Which indicates its ability to neutralize acids formed from products of combustion of sulfur compounds) than normal gas engine oil.
5. Where it is possibte to start the engine on sweet gas, the engine should be brought up to operating temperature on sweet gas, then
switched to sour gas. The procedure should be reversed when shutting engine down.

(C) Service intervals will be shortened under dusty conditions. If after servicing the air cleaner, the exhaust smoke and/or loss of power
continues, discard the element and install a new element. Install a new element at least once a year.

16
 RECOMMENDED VISCOSITIES AT VARIOUS STARTING TEMPERATURES

ABOVE 320F 32°F TO 10°F 10°F TO ·lOoF BELOW -lOOF

COMPONENT (ABOVE OOC) (O°C TO ·120 C) (·12o C TO ·23 0 C) (BELOW -23°C)

Air starting motor oiler jar SAE10W SAE lOW SAE lOW SAE lOW

Gas engine crankcase SAE 30 SAE lOW(l) SAE10W SAE lOW(2)

Governor, Woodward UG8

and synchronizing motor SAE 30 SAE lOW(l) SAE lOW SAE lOW

(1 )SAE lOW oil may be used even if daytime ambient temperatures rise to looF (210Cl.
(2) It may be necessary to warm the oil so the engine can be cranked and the oil will circulate freely.

REFILL CAPACITIES (Approximate)

U.S. Gals. Imp. Gal. Liters

Gas engine lubrication system: 9 8 34

Cooling system (engine only): 17 14 63

Cooling system (with radiator): 26 22 99

IGNITION SPECIFICATIONS

Spark plugs:

Gap: .013 inch 0,33 mm

Torque: 18lb·ft 2,5 mkg

Magneto points:

Gap: .017 inch 0,43 mm

VALVE LASH
(ENGINE COLD)

Exhaust Valves .030 inch (0,76 mm)

Inlet Valves .018 inch (0,46 mm)

17
 LUBRICATION AND MAINTENANCE PROCEDURES
ENGINE LUBRICATION SYSTEM
GAS ENGINE LUBE OIL

CHECKING OIL PRESSURE GAUGE READING 3. Remove the oil cooler drain plug.
After starting and during operation, frequently observe
the oil pressure gauge. If the gauge indicator registers below
"NORMAL", or if the indicator fluctuates, check the oil
level and take corrective measures.

CHECKING OIL LEVEL

Check the oil level with the engine idling. Oil level must
be between the ADD and FULL marks on the oil level
gauge. Add oil as required. See Lubrication and Mainte-
nance Chart for proper oil.

OIL COOLER DRAIN PLUG

4. Remove the crankcase oil plug.

CHECKING CRANKCASE OIL LEVEL

DRAINING CRANKCASE LUBE OIL REMOVING CRANKCASE DRAIN PLUG

With engine stopped and oil warm:

1. Wipe dirt from each oil filter housing.
2. Remove the oil filter housing drain plug(s). CLEANING BREATHER (S)
1. Remove the breather cover and breather element.

REMOVING OIL FILTER DRAIN PLUG REMOVING COVER AND ELEMENT

18
 2. loosen the hose clamp and remove the fumes disposal
tube.

LOOSENING HOSE CLAMP

3. Remove the breather assembly. REMOVING FILTER ELEMENT

4. Wipe both filter housings.

REMOVING BREATHER ASSEMBLY

4. Wash the breather and elements in clean diesel fuel or

kerosene.
5. Install the breather, breather element and cover.
WIPING FILTER HOUSING
INSTALLING NEWOll FilTER ELEMENTS
5. Install new filter elements and covers.
1. Drain the oil filter housing.
6. Install drain plugs which were removed.
2. Remove both covers.
7. Fill the crankcase to the FUll mark on the oil level
gauge.

REMOVING FILTER COVER

3. Remove both filter elements.

19
 AIR INDUCTION AND EXHAUST SYSTEM
AIR CLEANER SERVICE INDICATOR
CHECKING AIR CLEANER SERVICE INDICATOR
Before starting, check the window of the indicator. If the
red piston is locked in the raised position, service the air
cleaner as outlined.
NOTE
Have spare elements on hand to install while
cleaning used elements.
CAUTION
Service the air cleaner with the engine
STOPPED. PISTON LOCKED IN RAISED POSITION

SINGLE STAGE AIR CLEANER

SERVICING SINGLE STAGE AIR CLEANER 4. Inspect the replacement element for damage and dirt.
1. Remove the air cleaner cover and element.
5. Remove the covering from the air inlet opening.

6. Install the element.

REMOVING COVER AND FILTER ELEMENT

2. Cover the air inlet opening to prevent dirt from en-
tering the engine.
3. Clean the inside of the air cleaner cover and the air
cleaner body.
INSTALLING AIR CLEANER ELEMENT
7. Install the air cleaner cover.
8. Reset the service indicator piston by pushing the reset
button. (See the instructions for air cleaner element
cleaning).

CLEANING INSIDE OF AIR CLEANER

1. Air Inlet Cover RESETTING AIR INDICATOR PISTON

20
 TWO STAGE AIR CLEANER

EMPTYING DUST COLLECTOR CUP 3. Remove the lower body. Clean the tubes from both
1. Loosen the clamping bolt on the lower body. ends.

2. Remove and empty the dust collector cup. 4. Inspect and install the upper body seal. Install a new
seal if it is damaged.
3. Inspect and install. the seal; install a new seal if neces-
sary. INSTALLING REPLACEMENT FILTER ELEMENT
1. Remove the cover.

REMOVING DUST CUP

1. Seal
REMOVING COVER AND INNER COVER
4. Inspect the tubes in the lower body. If dirty, clean 2. Remove the inner cover and filter element. In cold
the tubes with a round bottle brush. weather, a stuck inner cover may be removed by
5. Install the dust collector cup. warming the air cleaner cover to 70-75 0 F (21-24°C).

CLEANING THE LOWER BODY

1. Remove the dust collector cup.
2. Loosen the clamping bolt on the upper body.

REMOVE ELEMENT

3. Clean all parts of the air cleaner.

4. Inspect the replacement element for damage and
cleanliness.
5. Install the element, inner cover, and wing nut. Tight-
en the wing nut to prevent dust from bypassing the
fi Iter element.
6. Install the cover.
If, after servicing the air cleaner, the exhaust smoke and/
or loss of power continues; or the service indicator locks in
REMOVING LOWER BODY the raised position, discard that element and install a new
1. Seal element. Install a new element at least once a year.

21
 CLEANING USED AIR CLEANER ELEMENTS
CLEANING WITH PRESSURE AIR
1. Use clean, dry air-l00 PSI maximum. Hold the
nozzle at least one inch from the element and at a
slight angle. (A direct blast can rip the pleating.)
CLEANING ELEMENT WITH AIR
2. 0 irect the air stream along the complete length of
each pleat on the CLEANEST side of the element.
(This will loosen the dirt from the dirtier side.)
3. Blow the loosened dirt from the DI RTY side.
4. 0 irect the air from the CLEAN side through to the
DIRTY side to remove dirt blown into the pleating.
CLEANING WITH WATER
1. Use clean water at no more than 40 PSI. Do not use a
nozzle.
2. Direct the water stream along the complete length of
each pleat on the CLEAN side of the element.
CLEANING ELEMENT WITH WATER
3. Direct water along the complete length of each pleat
on the 0 IRTY side of the element.
4. Rinse the CLEAN side of the element.
5. Allow the cleaned element to dry thoroughly.
22
CLEANING WITH DETERGENT
1. Wash both sides of the element in a solution of warm
water and non-sudsing household detergent.
2. Rinse the CLEANEST side of the element with clean
water (40 PSI maximum) along the complete length
of each pleat.
WASHING ELEMENT WITH DETERGENT
3. Rinse the opposite side of the element along the com-
plete length of each pleat.
4. Rinse the first side again to remove all loosened dirt.
5. Allow the cleaned element to dry thoroughly.
STORING CLEANED ELEMENTS
1. Hold the dried element in front of a lighted electric
bulb. Carefully inspect the element for tiny, pin·
points of light. Any light showing indicates a pleat has
ruptured and will tear with further use. Discard the
element.
INSPECTING ELEMENT
2. Wrap usable elements in heavy paper.
3. Store the wrapped element in a dry, clean place.
 PRECLEANER
SERVICING
When the precleaner body is 3/4 full, remove and empty the precleaner. Wash the precleaner in water.

ENGINE VALVES
VALVE LASH

PREPARING TO CHECK ADJUSTMENT CHECKING ADJUSTMENT:

1. Stop the engine. Allow it to cool at least 20 minutes. 1. Observe the rocker arms for cylinder No.1. Deter-
2. Remove the flywheel housing timing cover(s). mine if the piston is on compression or exhaust
stroke.
Compression stroke: Both intake and exhaust valves
are closed.
Exhaust stroke: I ntake valve is closed, exhaust valve is
opened.
2. With NO 1 CYLINDER ON COMPRESSION
STROKE, check the lash of the following valves: Ad-
just if necessary.
REMOVING TIMING COVER IS!
NO.1 CYLINDER ON COMPRESSION STROKE
(COUNTERCLOCKWISE ROTATION!
3. Wipe dirt from the base of the valve covers. Viewed from Flywheel

4. Remove the valve covers. VALVE LASH (Inches)

5. Move the compression release lever to the START VALVES CYLINDERS 6342
position. Exhaust 1-3-5 .030
Inlet 1-2-4 .018
.030 Inch =0,76 mm.
.018 Inch = 0,46 mm.

3. Bar the flywheel counterclockwise one revolution.

Align the "TDC 1-6" timing mark with the timing
pointer on the flywheel housing.
4. With NO. 1 CYLINDER ON EXHAUST STROKE,
check the lash of the following valves; adjust if nec-
essary.

NO.1 CYLINDER ON EXHAUST STROKE

(COUNTERCLOCKWISE ROTATION!
COMPRESSION RELEASE LEVER Viewed from Flywheel
VALVE LASH (Inches)
6. Bar the flywheel counterclockwise. Align the "TDC VALVES CYLINDERS G342
1-6" timing mark with the timing pointer on the
Exhaust 2-4-6 .030
flywheel housing.
Inlet 3-5-6 .018
NUMBERING OF CYLINDERS .030 inch = 0,76 mm.

•018 inch = 0,46 mm.

F
CYLINDERS R
0
N
CDCDCDCD®® R
E
A
R
VALVES I·E I-E I·E I-E I·E I-E
T

23
 ADJUSTING VALVE LASH

1. Loosen the locknut on the adjusting screw.

ADJUSTING VALVE LASH

LOOSENING LOCKNUT 3. Hold the adjusting screw and tighten the locknut.
2. Hold the locknut and turn the adjusting screw to ob-
tain the proper lash. 4. Recheck the lash.

VALVE ROTATORS

CHECKING ROTATION
After checking all valve c1earances,and before installing
the valve covers:
1. Start the engine.
2. Move the governor control to low idle position.
3. Watch the serrations on each valve retainer. Each
valve retainer should turn slightly each time the valve
closes.

If it is suspected a valve is not rotating, contact your

Caterpillar dealer. Repairs must be made to prevent
burning the valve.
CHECK VALVES FOR ROTATION
If all valves rotate, proceed as follows:
4. Stop the engine.
5. Inspect and install valve cover gaskets. Install new gas-
kets if necessary.
6. Install the valve covers.
7. Install the flywheel housing timing cover.

EXHAUST BYPASS VALVE BREATHERS

Remove both exhaust bypass valve breathers and wash
them in clean kerosene.
REMOVING BREATHER ELEMENT

24
 FUEL SYSTEM
CHECKING GOVERNOR OIL LEVEL
1. Check the governor oil level sight gauge.
2. Maintain the oil level between the ADD and FULL
marks. Add oil as required. See Lubrication and Main·
tenance Chart for proper oil.
CHECKING OIL LEVEL
CHANGING GOVERNOR OIL
1. Move the governor control lever to the shut-off posi-
tion.
2. Shut off the fuel tank fuel supply valve.
3. 0 isconnect the ground cable from the battery.
WARNING
Be sure the engine cannot be started while
wort< is being done. This is very important
when the engine is equipped with an Auto-
matic Start-8top System.
4. Disconnect the governor linkage from the governor.
5. Disconnect the governor synchronizing motor wires.
DISCONNECT SYNCHRONIZING MOTOR
25
6. Remove the governor from the engine.
7. Remove the governor cover.
REMOVING GOVERNOR COVER
8. Turn the governor upside down and drain the oil.
9. Flush the governor with clean diesel fuel or kero-
sene.
10. Install the governor on the engine.
11. Fill the governor, with clean oil, to the FU LL mark
on the sight gauge. See Lubrication and Maintenance
Chart for proper oil.
12. Connect the governor linkage.
WARNING
Before starting the engine, check to be sure
the governor linkage has been connected to
the governor.
13. Connect the ground cable to the battery.
BLEEDING GOVERNOR
1. Start the engine and allow the engine to reach nor-
mal operating temperature.
2. Loosen the nut on the side of the governor which
holds the compensation adjusting pointer.
3. Manually move the pointer to the extreme upper
position and tighten the nut. This will allow the gov-
ernor to be purged of air.
SETTING POINTER AT UPPER POSITION
 4. Remove the plug from the base of the governor. If the engine speed stabilizes, and the needle valve is only
1/2 to 3/4 turn open, the governor is properly adjusted.
5. Using a wide blade screwdriver, engage the wide shal-
Install the base plug.
low screwdriver slot and turn the needle valve 3 or
more turns counterclockwise. If more than a 3/4 turn is required to stop the engine
from surging, proceed with the following steps.
12. Raise the pointer two divisions on the pointer scale.
13. Engage the wide shallow slot and turn the needle
valve counterclockwise 3 or more turns.
14. Allow the engine to surge approximately 30 seconds.
15. Gradually turn the needle valve clockwise until surg-
ing just stops.
16. Note the portion of a turn required to close the
need Ie valve.
17. Open the valve exactly to the same position surging
stopped.
18. Manually move the governor linkage to disturb the
engine speed. The engine speed should stabilize with
OPENING NEEDLE VALVE the needle valve opened 1/2 to 3/4 turn.
19. A valve opened less than 1/2 of a turn produces a
6. Allow the engine to surge for approximately 30 slow response to load changes. A valve opened more
seconds. than 3/4 of a turn produces excessive speed response
to load change. If the engine does not stabilize be-
7. Loosen the nut and move the compensation adjust-
tween 1/2 to 3/4 turn open, raise the pointer two
ing pointer to the extreme downward position.
divisions and repeat steps 12 through 19.
Tighten the nut.
20. When the engine speed stabilizes, install the base
8. Slowly turn the needle valve (wide shallow slot)
plug.
clockwise until the surging stops.
LUBRICATING THE GOVERNOR SYNCHRONIZING
9. It should now take less than one turn from this
MOTOR
point to close the valve completely.
Fill the cup on top of the motor with clean oil. See
10. Open the valve to the same position where the surg-
Lubrication and Maintenance Chart for proper oil.
ing had stopped.
11. Manually move the governor linkage to disturb the
engine speed.

MANUALLV CHANGING ENGINE SPEED LUBRICATING ELECTRIC MOTOR

26
CARBURETOR LINKAGE GOVERNOR CONTROL AIR ACTUATOR
The governor shaft requires two strokes, 1 fitting. If the actuator air supply is not oil conditioned, inspect
the rear leather cup seal. This seal must be kept well lubri-
cated. If the leather appears dry, apply grease as required.

FITTING FOR CARBURETOR LINKAGE

27
 COOLING SYSTEM
ENGINE JACKET WATER

CHECKING COOLANT LEVEL 3. Whenever the reading changes, investigate the cause
With the engine stopped: and have necessary repairs made.

1. Slowly turn the filler cap to the first stop and release
pressure.
WARNING
Be careful. If the engine is warm-steam may
spray outward under high pressure.
2. Push the cap down; turn until the cap is released.
3. Maintain level to base of fill pipe. The coolant re-
quires expansion space as it is heated.
DRAINING RADIATOR OR EXPANSION TANK
Whenever it is necessary to drain the cooling system for
repairs:
1. Shut the engine off.
2. SlOWly turn the pressure cap to the first stop and
release pressure.
WARNING
Be careful. If the engine is warm-steam may
spray outward under high pressure.
3. Push the cap down and turn until the cap is released.
4. Open the drain valve on the radiator, if so equipped.

PROPER COOLANT LEVEL

4. Make-up coolant should be one of the following, in
the order of preference:
a. Permanent anti-freeze and water solution.
b. Drinkable water and rust inhibitor solution.
c. Drinkable water.
d. Any available water.
COOLANT DRAIN
(a) Must be used if engine is to be shut down in below
freezing weather without draining the coolant. (bl Can only DRAINING COMPLETE COOLING SYSTEM
be used when the coolant temperature is above freezing, or 1. Remove the engine block drain cover; rear left side.
if the coolant will be immediately drained after shut down 2. Remove the water pump drain plug.
during below freezing temperatures.
(c) or (d) Should only be used as a "temporary fix". As
soon as possible, return the system to either (a) or (b).
CHECKING WATER TEMPERATURE GAUGE READING
The water temperature gauge should normally register in
the NORMAL range when operating. However, with some
systems, as long as the coolant does not boil the cooling
system is functioning properly.
1. If the water temperature gauge continually registers
near-or in the "HOT" range-without boiling, have
the system checked to determine if the cooling sys-
tem is functioning properly.
2. Frequently check the water temperature gauge while COOLANT DRAINS
operating. Be sure to note any deviation from the
normal read ing. 3. Remove the oil cooler bonnet drain plug.

28
 2. Start the engine and operate at operating tempera·
tures for 1/2 to 1 hour.
3. Stop the engine and drain the cooling system.
4. Flush the system with clean water until the draining
water is clear.
5. Install all drain plugs.
6. F ill with a solution consisting of 'h pound of sodium
carbonate crystals (Na2C03, 10 H20) with every 10
gallons of water (mix 0,06 kg with every 10 liters of
water).

COOLANT DRAIN
7. Start and run the engine for 10 minutes.

4. Remove the water shield drain plugs if equipped
with a water cooled manifold.
5. Remove aftercooler drain plugs if so equipped.
6. Allow the coolant to drain.
FILLING COOLING SYSTEM
7. Install all drain covers and plugs.
8. Close the radiator drain valve.
FLUSHING COOLING SYSTEM
To clean the cooling system, any good commercial radia·
tor cleaning solution can be used. Follow the instructions
included with the cleaner.
8. Stop the engine and drain the cooling system.
9. Flush the cooling system with clean water.
10. Install all drain plugs.
1. Add either rust inhibitor or permanent type anti·
freeze. Do not add both.
2. Fill to correct level with water which is free as pos-
sible from scale forming minerals.
3. Open the raw water valve.

The cooling system can be cleaned using oxalic acid and
sodium carbonate as follows:
1. F ill the cooling system with a solution consisting of
two pounds of oxalic acid or sodium bisulphate
(NaHS04) with every 10 gallons of water (mix 0,24
kg with every 10 liters of water).
4. Start and run engine for 10 minutes.
5. Remove the radiator cap and check the coolant level.
6. Add coolant, if needed, until coolant is to the bottom
of the filler tube.
7. Install the radiator or expansion tank cap.

FAN BELTS AND DRIVE

1. Check belt wear.

2. Apply a 25 pound (10 kg) force, perpendicular to the
belt, midway between the driver and driven pulley
and measure the belt deflection.
3. Proper belt deflection is 9/16 to 13/16" (14 to 20
mm). Adjust the belt tension as required.
4. If one belt in a set requires replacement, always in-
stall a new matched set of belts-never replace just
the worn belt. I f only the worn belt is replaced, the
new belt will be carrying all of the load-as it will
not be stretched as much as the older belts-and all
of the belts will fail in rapid succession. MEASURING BELT DEFLECTION

29
ADJUSTING FAN BELTS LUBRICATING FAN DRIVE
1. Loosen the four nuts holding the fan plate to the Lubricate the fan drive bearing with grease; 1 or 2
engine block. strokes, 1 fitting.
2. Loosen locknut. Turn the adjusting screw until belt
is adjusted properly.
3. Tighten the four nuts and locknut.
4. Check the belt adjustment.

ADJUSTING FAN BELT TENSION FAN DRIVE BEARING

RAW WATER

Salt water has a highly corrosive reaction with metal by a

chemical action called "electrolysis". To prevent this
chemical action taking place, with parts used in the raw
water system, zinc plugs are placed in the raw water piping.
Zinc is a relatively soft metal which reacts quite readily
with the salt water. Thus, by the deterioration of the zinc,
the raw water system parts are protected from corrosion.
The zinc rods must be inspected regularly and be re-
placed as they become deteriorated. The zinc rod plugs are
painted red for easy identification.

INSPECTING ZINC RODS

1. Move the governor control lever to the shut-off
position.
2. Remove and inspect all of the zinc plugs. They are
painted red for easy identification. Depending upon
the engine, their location may be in the oil cooler
heat exchanger bonnet, raw water heat exchanger
bonnet, aftercooler Iines, raw water pump, or in the
raw water lines.
3. Tap the zinc rods lightly with a hammer. ZINC PLUGS

30
 4. Inspect the rods. If a rod has deteriorated, or flakes
apart when tapped, install a new zinc rod.

INSPECTING ZINC ROD

INSTALLING NEW ZINC ROD
INSTALLING NEW ZINC ROD
1. Unscrew or drill the existing rod from the plug base.
2. Install a new rod in the plug base. 3. Install the plug.

31
 STARTING SYSTEM
AIR STARTING
The motor oiler lubricates the vanes of the starting
motor with a fine oil mist as the motor is operating.
The collector jar collects both the oil after it has lubri-
cated the starting motor vanes, and the moisture condensa-
tion from the compressed air. Empty the collector jar
whenever the jar becomes half full.
REMOVING OIL COLLECTOR JAR
When the oiler jar becomes half empty, remove the oil
filler plug and fill the jar with clean oil. Refer to Lubrica-
tion and Maintenance Chart for proper oil.
ADDING OIL TO MOTOR OILER
32
CAUTION
Never allow the jar to become empty. The
starting motor will be damaged by lack of
proper lubrication.
ADJUSTING THE AIR STARTING MOTOR
OILER FEED
If necessary, adjust the oiler to release approximately
four drops of oil per minute into the starting motor air
stream.
1. Move the compression release lever to the START
position, and move the governor control lever to the
SHUT-OFF position.
2. Pull up on the air start control lever and crank the
engine.
3. Count the drops of oil released per minute into the
air stream.
a. Turn the valve needle (the uppermost knob on
the oiler) counterclockwise to increase the num-
ber of drops.
b. Turn the valve needle clockwise to decrease the
number of drops.
ADJUSTING MOTOR OILER
 HYDRAULIC STARTING

RELEASING HYDRAULIC PRESSURE 4. Clean all parts in diesel fuel.

CAUTION 5. Check the cap and housing for damaged threads.
Before disconnecting any part of the hy- 6. Install a new O-ring in the cover.
draulic starting circuit, release all hydraulic 7. Install the plate, spring, new filter element and
pressure. cover.
1. Move the governor control to turn off the fuel.
2. If the engine is equ ipped with a compression release
lever, move the lever to the START position.
3. Engage the hydraulic start control valve.
Hold the control valve in the engaged position until the
engine stops. Disengage and engage the control lever several
times. The hydraulic gauge must indicate "0 psi" before
removing any part.
INSTALLING OIL FILTER ELEMENT
1. Remove the filter cover slowly. Pressure oil may be
present.
2. Remove the filter element.
3. Remove the plate and spring.
I
HYDRAULIC STARTER OIL FILTER

33
 ELECTRICAL SYSTEM
BATTERY INSTALLATION
PREPARING DRY CHARGE BATTERIES
One day before installing a new dry charge battery, add
the electrolyte solution to each cell.
1. F ill each cell to the bottom of the vent with electro-
lyte solution.
CAUTION
If the battery is initially filled with water by
mistake, the battery is ruined and must be
replaced.
2. Allow the battery to sit for several minutes to per-
mit the battery plates to absorb the electrolyte.
3. Add make-up electrolyte solution until the level
stabilizes. Once the level stabilizes, never add any-
th ing but water.
4. Install the vent caps.
5. Remove the tape covering the vent hole in each cap.
6. Slowly charge the battery on a battery charger until
the specific gravity of the solution is at least 1.240
at a temperature of 800 F (27 o C).
NOTE
If the electrolyte solution temperature nears
1250 F (53 0 C) reduce the charging rate.
Temperature in excess of 125°F (530 C) will
ruin the battery.
PREPARING WET CHARGE BATTERIES
The electrolyte solution was added by the manufacturer.
Make-up solution must be water; never add electrolyte or
acid to a wet charge battery. I f necessary, slowly charge the
battery before using.
USING A BATTERY CHARGER
A desirable charging rate can be calculated by multiply-
ing the amp-hour rating of the battery by .07 (7%).
BATTERY MAINTENANCE
TESTING THE ELECTROLYTE SOLUTION
The general condition of a battery can be determined by
measuring the specific gravity of the electrolyte solution
and adjusting the reading to 800 F (27 0 C). If the electrolyte
level is too low to allow taking a hydrometer reading, add
make-up water to the correct level and then charge the
battery 2 to 4 hours before taking a reading.
1. Insert the hydrometer into a cell. Fill the hydro-
meter barrel while holding it vertically. The float
must not drag on the wall of the barrel.
34
Shut off the battery charger before disconnecting the
booster charger clamps from the battery terminals. While
the battery is charging, hydrogen gas is being given off
through each vent cap. When hydrogen gas is mixed with
air, the mixture is highly explosive and will explode in the
presence of a spark or small flame.
WARNING
Never smoke near the area where batteries
are being charged.
INSTALLING BATTERY
1. Be sure the tray is free of objects which may punc-
ture the battery case when the hold down straps are
tightened.
2. Be sure terminal posts and cable clamps are clean.
3. Place the battery in the tray. Tighten the hold
downs evenly until the battery is snug. Do not over-
tighten.
4. Connect the "hot" terminal first.
5. Connect the ground terminal last.
CAUTION
Always connect the "hot" terminal first.
When the "hot" terminal is connected first, no arcing can
occur if the wrench accidentally contacts both the terminal
and the frame or tray. The part that is contacted will take
the same polarity as the battery term inal.
By connecting the ground terminal first, the frame or
tray is connected to ground. Then, if the wrench acciden-
tally contacts the frame while connecting the "hot" termi-
nal, a circuit is completed through the wrench. A hot spark
will occur which could burn the person holding the wrench,
or possibly explode the battery if an excess of hydrogen gas
is present at anyone of the vent holes.
After connecting both cables, apply a thin coating of
grease over the cable clamps, terminals and hold down fas-
teners.
2. Read the hydrometer:
1.250 or above - fully charged battery cell
1.250-1.225 - full to half charged battery cell
1.225-1.150 - half to low charged battery cell
Below 1.150 - dead cell
1.000 - water
3. Test each cell in the same manner.
 1. Maintain the electrolyte level to the base of each
vent well.
2. The make-up water must be one of the following (in
order of preference):
a. Distilled water.
b. Odorless, tasteless drinking water.
c. Iron free water.
d. Any available water.
WARNING
Never add acid or electrolyte.
READING THE AMMETER
MEASURING SPECIFIC GRAVITY 1. After starting the engine, the ammeter indicator
should register to the right of zero, but should never
4. If there is more than .050 (50 gravity points) varia- be "pegged".
tion between the highest and lowest reading, the bat-
tery should be replaced. 2. After the engine has been running, the indicator
should be just to the right of zero.
5. Adjust the readings to 80°F (27°C).
If the indicator either "pegs" to the right, or remains to
a. For every 10Fo (5.5Co) the electrolyte tempera-
the left of zero with an increase of engine speed, have the
ture is above 80°F (27 0 Cl. add .004 (4 gravity
electrical charging system checked.
points) to the specific gravity reading.
The alternator charging rate maintains the battery's elec-
Example: Electrolyte temperature = lOOoF; 38°C
trolyte specific gravity reading, and the battery's perform-
Corrected temperature = 80°F; 27°C
ance. An undercharge rate cannot maintain a desired 1.250
Difference: = 20°F; 11°C
specific gravity reading. An overcharge rate will boil the
Increments: 10; 5.5
water from the electrolyte solution. A proper charging rate
20 + 10 = 2 ; 11 + 5.5 = 2
should require no more than one ounce (30 cc) of water per
2 x 4 gravity points = 8 gravity points
cell per week to maintain a fully charged battery.
Add 8 gravity points to your hydrometer reading to ob-
tain the adjusted reading at lOOoF. If the uncorrected CLEANING BATTERY
hydrometer is 1.240 the corrected reading would be: 1.240 1. Mix a weak solution of baking soda and water.
+ 8, or 1.248 Apply the solution with a bristle brush.
b. For every 10Fo (5.5COj the electrolyte tempera-
ture is below 80°F (27°C), subtract .004 (4
gravity points) from the specific gravity reading.
Example: Electrolyte Temperature = 10°F; -13 0 C
Corrected temperature = 800 F; 27 0 C
Difference = 700 F; 400 C
Increments: 10; 5.5
70+ 10=7;40+5.5=7
7 x 4 gravity points = 28 gravity points
If the uncorrected hydrometer reading is 1.210 the cor-
rected reading would be 1.210- 28= 1.182
The corrected reading is of most importance during cold
weather when the hydrometer reading is always corrected
to a lower specific gravity reading. A low reading signifies
the battery has less available power to crank the engine and CLEANING BATTERY TERMINALS
that booster batteries may be required.
2. Thoroughly rinse the battery and battery tray with
CHECKING ELECTROLYTE LEVEL clean water.
Check the electrolyte level of each cell and the general 3. Apply grease to the battery cable clamps and termi-
cond ition of the battery. nals and to all threads.

35
 COLD WEATHER BATTERY MAINTENANCE

The following instructions aid in obtaining maximum

performance in cold weather:
1. After adding make-up water, charge the battery.
The added water will dilute the electrolyte_ This will
lower the specific gravity of the solution, raise the
freezing point of the solution and lower the charge
of the battery.

SERIES CONNECTED BOOSTER BATTERIES

CONNECTED IN PARALLEL

2. Using a pair of jumper cables, connect the red

CHARGING A BATTERY
2_ Keep the batteries fully charged either by operating
the charging system or by using a battery charger_
3. Keep the electrolyte warm when the battery is not
in use_ The heat from an electric light bulb usually is
sufficient.
CAUTION
Do not lay cloth or any flammable material
in contact with a lighted bulb. Charring, or
fire, can result.
REMOVING JUMPER CABLES
4. Use starting aids as instructed when starting.
As soon as the engine starts:
5. Use booster batteries as required. Connect as in-
structed below.
CONNECTING FIVE 6 VOLT BOOSTER
BATTERIES TO OBTAIN 30 VOLT STARTING
1. Using four jumper cables, connect five fully charged
6 volt batteries in series: Connect the positive ter-
minal of one battery to the negative terminal of a
second battery.
jumper cable to the "hot" terminal of the booster
batteries.
3. Connect the black jumper cable to the ground termi-
nal of the booster batteries.
CAUTION
Keep the red and black cable terminals from
touching each other.
4. Connect the other end of the red jumper cable to
the "hot" term inal of the engine batteries.
5. Connect the other end of the black jumper cable to
the ground terminal of the engine batteries.
6. Start the engine using starting aids as instructed.
1. Disconnect the black jumper cable from the engine
battery ground term inal.
2. Disconnect the red jumper cable from the engine
battery "hot" terminal.
3. Disconnect the black jumper cable from the booster
batteries.
4. Disconnect the red jumper cable from the booster
batteries.
5. Disconnect the booster batteries. Charge them to
full capacity with a battery charger.

CHARGING ALTERNATOR
CHECKING ALTERNATOR BELTS 2. Apply a 25 pound (11,34 kg) force, perpendicular to
1. Check belt wear. the belt, midway between the driver and driven pul-
leys. Measure the belt deflection.

36

MEASURING BELT DEFLECTION
3. Proper belt deflection is 9/16 to 13/16" (14 to 20
mm). Adjust the belt tension as required.
4. If one belt in a set requires replacement, always in-
stall a new matched set of belts-never replace just
the worn belt. If only the worn belt is replaced, the
new belt will be carrying all of the load-as it will
not be stretched as much as the older belts-and all
of the belts will fail in rapid succession.
MECHANICAL AND SOLID STATE MAGNETOS
ROTATION
Both the magneto rotor and the engine flyWheel rotate
counterclockwise when viewed from the rear.
FIRING ORDER
Firing order is 1-5-3-6-2-4
POLARITY OF IGNITION TRANSFORMERS
Mechanical Magneto
The mechanical magneto supplies a low voltage alter-
nating current which is stepped up by individual transform-
ers at each cylinder. Since the output alternates, the trans-
formers must be properly wired to provide proper spark
plug firing.
Connect the mechanical magneto lead wires to cylinders
1-2·3 to the NEGATIVE transformer terminals.
Connect the mechanical magneto lead wires to cylinders
4-5·6 to the POSITIVE transformer terminals.
37
ADJUSTING ALTERNATOR BELTS
1. Remove the belt guard.
2. Loosen the alternator mounting bolts.
3. Push the alternator outward until the belt is proper-
ly adjusted.
4. Tighten the mounting bolts.
5. Check the belt adjustment.
6. Install the belt guard.
ADJUSTING BELT TENSION
Solid State Ignition
The solid state magneto uses pulse activated solid state
electronic components which eliminate breaker contacts,
brushes and other mechanical contacts. A silicon controlled
rectifier functions as a switch to release constant polarity-
stored energy to each transformer. Alternating transformer
connections are not required.
The solid state ignition system requires no periodic main-
tenance. There are no contact points to adjust. Units are
serviced only as an assembly. If repairs are needed, call your
Caterpillar dealer.
MAGNETO INSTALLATION
The magneto must be statically timed with No.1 piston
on compression stroke; and with regard to the type of fuel
burned and the compression ratio of the engine. The com-
pression ratio is stamped on a plate which is mounted on
the flywheel housing.
 1. Remove the timing cover from the flywheel housing.
Remove the valve covers.
2. Turn the flywheel counterclockwise until No. 1
piston is coming up on compression stroke.
The compression stroke for No. 1 piston begins
when the exhaust valve for No. 6 piston begins to
open.
Cy Iinders are numbered consecutively from front of
en gi ne to rear.
3. Continue turning the flywheel until the specified
timing mark appears under the flywheel timing
pointer.
See the MAGNETO TIMING CHART for the correct
timing number.
6. Turn the magneto coupling drive until the timing
mark on the rotor is centered in the timing hole of
the hou sing.
7. The magneto coupling drive lugs should be aligned
with the magneto drive shaft.
If they do not align, pull out, index and install the
magneto drive shaft from the magneto drive housing.
Do not tum the magneto coupling drive lugs; this
will change the rotor timing.
8. Install the magneto to the magneto drive housing.
Install the magneto so that the housing timing hole
is up. Tighten the mounting screws finger tight.
9. Install the magneto timing plug and valve covers.
10. Check the magneto timing with a timing light.

MAGNETO TIMING CHART

MECHANICAL
Engine MAGNETO SOLID STATE MAGNETO
Compression Engine Fuel
Ratio Arrangement Static Static Running
Timing Timing Timing·

10:1 T.A. (goo water) Natural Gas 17.5° BTC 2.50 ATC 17.50 BTC
10:1 N.A. Natural Gas 250 BTC 50 BTC 250 BTC
10:1 NA. Propane 12.50 BTC 7.5 0 ATC 12.50 BTC
7:1 TA. (1300 water) Natural Gas 300BTC 100 BTC 300 BTC
7:1 N.A. Natural Gas 300 BTC 100 BTC 300 BTC
7:1 NA. Wet Natural 200 BTC ooBTC 200 BTC
Gas & Butane

See your Caterpillar dealer for additional fuel·timing information.

Use propane in only non~ug applications.
'Running timing is obtained at full load speed.

4. Check both rocker arms for No. 1 piston. Both

rocker arms must be free to move.
CAUTION
Both rocker arms must be loose. If either
rocker arm is tight. continue turning the
flywheel until No. 1 piston is on compres-
sion stroke.
Improper timing can cause raw gas to ignite
in the exhaust manifold or stack when start-
ing the engine.
5. Remove the timing plug from the magneto housing.
CHECKING MAGNETO TIMING
To check magneto timing, the magneto must be installed
on the engine.
1. Remove the timing cover from the flywheel housing
if it has not already been removed in preceding step
1.
2. Connect a timing light in series with No.1 cylinder
spark plug wire.
3. Start the engine. Gradually increase engine speed to
full load RPM.
4. Check the flywheel timing mark with the timing
light. Compare the reading with the MAGNETO
TIMING CHART value.
A mechanical magneto should maintain static setting
when running.

38
 POWER COUPLING SYSTEM
ENCLOSED CLUTCHES AND/OR
FRONT POWER TAKE-OFF

CHECKING CLUTCH ADJUSTMENT LUBRICATING FLYWHEEL CLUTCHES AND FRONT

While engaging the clutch to pick up the load, check the POWER TAKE-OFF CLUTCHES
clutch adjustment. The clutch should engage with a hard
push and distinct snap. If engagement is "soft", adjust the Lubricate the clutch bearings with grease, 1 or 2 strokes
clutch. each fitting.

ADJUSTING CLUTCH 1. Lubricate the shift lever bearings; 1 fitting on each

side of the clutch housing.
1. Stop the engine and remove the clutch inspection
cover.

LUBRICATING SHIFT LEVER BEARINGS

CLUTCH INSPECTION COVER
2. Lubricate pilot bearing; 1 fitting at the end of shaft.
2. Turn the clutch until the lock pin, engaged in the If this fitting is not accessible, remove the plug lo-
locking ring, is visible. cated on the circumference of the shaft near the rear
of the housing, and install a fitting.
3. Disengage the lock pin and rotate the locking ring
clockwise until the lock pin engages the next notch.

PULLING LOCKING PIN PILOT,SHIFT COLLAR ANO SHAFT BEARINGS

4. Test the clutch adjustment. If still too "soft", rotate 3. Lubricate shift-collar and shaft; 1 fitting at top-left
the ring to the next notch. If the adjustment is too of center.
tight-turn the ring back one notch. 4. Lubricate the shaft bearing; 1 fitting on top-rear of
5. Install the cover. housing.

40
 MISCELLANEOUS MAINTENANCE

LUBRICATING TACHOMETER DRIVE

Lubricate the tachometer drive bearing with grease; 1 or
2 strokes, 1 fitting.

SAFETY SHUT-OFF CONTROLS

The shut-off controls must be checked to insure proper
functioning if and when needed. To prevent damage to
your engine while making the required tests, only author-
ized personnel should perform the checks. Contact your
Caterpillar dealer.

TACHOMETER LUBRICATION FITTING

41