SEBU7201-01 G3516B.pdf

SEBU7201-01October 2001

Operation andMaintenanceManualG3516B EnginesCEY1-Up (Engine)7EZ1-Up (Engine)

i01097883

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure toobserve basic safety rules or precautions. An accident can often be avoided by recognizing potentiallyhazardous situations before an accident occurs. A person must be alert to potential hazards. Thisperson 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 andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazardwarnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written orpictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Thewarnings 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 theproduct will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information beforeyou start any job. Caterpillar dealers have the most current information available. For a list of the mostcurrent publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

3Table of Contents

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Signs and Labels ......................................... 6

General Hazard Information ................................... 9

Burn Prevention .................................................... 11

Fire Prevention and Explosion Prevention ............ 12

Crushing Prevention and Cutting Prevention ........ 13

Mounting and Dismounting ................................... 14

Ignition Systems ................................................... 14

Before Starting Engine .......................................... 14

Engine Starting ..................................................... 14

Engine Stopping ................................................... 15

Electrical System .................................................. 15

Product Information Section

Model Views and Specifications ........................... 16

Product Identification Information ........................ 20

Operation Section

Engine Lifting and Storage ................................... 22

Engine Features and Controls .............................. 23

Engine Starting ..................................................... 32

Engine Operation .................................................. 37

Engine Stopping ................................................... 38

Maintenance Section

Torque Specifications ............................................ 40

Lubricant Specifications ........................................ 43

Fuel Specifications ................................................ 46

Cooling System Specifications ............................. 48

Refill Capacities .................................................... 56

Maintenance Interval Schedule ............................ 57

Reference Information Section

Customer Service ............................................... 109

Reference Materials ............................................ 111

Index Section

Index ................................................................... 116

4Foreword

Foreword

Literature Information

This manual contains safety, operation instructions,lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.

English is the primary language for all Caterpillarpublications. The English used facilitates translationand consistency in electronic media delivery.

Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Caterpillar dealer for the latestavailable information.

Safety

This safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenanceand repair on this product.

Operation

Operating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.

The operation section is a reference for operators.Photographs and illustrations guide the operatorthrough procedures of inspecting, starting,operating and stopping the engine. This sectionalso includes a discussion of electronic diagnosticinformation.

Maintenance

The maintenance section is a guide to enginecare. The illustrated, step-by-step instructions aregrouped by service hours and/or calendar timemaintenance intervals. Items in the maintenanceschedule are referenced to detailed instructionsthat follow.

Use service hours to determine intervals. Calendarintervals shown (daily, annually, etc) may be usedinstead of service meter intervals if they providemore convenient schedules and approximate theindicated service meter reading.

Recommended service should always beperformed at the service hour interval. The actualoperating environment of the engine also governsthe maintenance schedule. Therefore, underextremely severe, dusty, wet or freezing coldoperating conditions, more frequent lubrication andmaintenance than is specified in the maintenanceschedule may be necessary.

The maintenance schedule items are organizedfor a preventive maintenance managementprogram. If the preventive maintenance programis followed, a periodic tune-up is not required.The implementation of a preventive maintenancemanagement program should minimize operatingcosts through cost avoidances resulting fromreductions in unscheduled downtime and failures.

Maintenance Intervals

Perform maintenance on items at multiplesof the original requirement. Each level and/orindividual items in each level should be shiftedahead or back depending upon your specificmaintenance practices, operation and application.We recommend that the maintenance schedulesbe reproduced and displayed near the engine asa convenient reminder. We also recommend that amaintenance record be maintained as part of theengine’s permanent record.

See the section in the Operation and MaintenanceManual, “Maintenance Records” for informationregarding documents that are generally acceptedas proof of maintenance or repair. Your authorizedCaterpillar dealer can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.

California Proposition 65 Warning

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

5Foreword

Overhaul

Major engine overhaul details are not covered in theOperation and Maintenance Manual except for theinterval and the maintenance items in that interval.Major repairs are best left to trained personnel oran authorized Caterpillar dealer. Your Caterpillardealer offers a variety of options regarding overhaulprograms. If you experience a major engine failure,there are also numerous after failure overhauloptions available from your Caterpillar dealer.Consult with your dealer for information regardingthese options.

6Safety SectionSafety Signs and Labels

Safety Section

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Safety Signs and LabelsSMCS Code: 1000; 7405

There may be several specific safety signs on yourengine. The exact location and a description of thesigns are reviewed in this section. Please becomefamiliar with all of the signs.

Ensure that all of the signs are legible. Clean thesigns or replace the signs if the words cannot beread or if the illustrations are not visible. Use acloth, water, and soap for cleaning the signs. Do notuse solvents, gasoline, or other harsh chemicals.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the signs. The signs thatare loosened could drop off of the engine.

Replace any sign that is damaged or missing. Ifa sign is attached to a part of the engine that isreplaced, install a new sign on the replacementpart. Your Caterpillar dealer can provide new signs.

Do not operate or work on this engine unless youhave read and understand the instructions andwarnings in the Operation and Maintenance Man-ual. Failure to follow the instructions or heed thewarnings could result in injury or death. Contactany Caterpillar dealer for replacement manuals.Proper care is your responsibility.

The safety signs that may be attached on theengine are illustrated and described below.

Crankcase Covers

g00305845Illustration 1

The warning label for the crankcase covers islocated on the crankcase covers.

g00123185

Flash fire may result in personal injury, ifcrankcase covers are removed within fifteenminutes after emergency shut down. Do notrestart engine until cause for shutdown has beencorrected.

7Safety Section

Safety Signs and Labels

Electrical Distribution (Generator)


The warning label for electrical distribution(generator) is located on the covers of thegenerator.

g00296980

Do not connect generator to a utility electrical dis-tribution system unless it is isolated from the sys-tem. Electrical feedback into the distribution sys-tem can occur and could cause personal injury ordeath.

Open and secure main distribution system switch,or if the connection is permanent, install a dou-ble throw transfer switch to prevent electrical feed-back. Some generators are specifically approvedby a utility to run in parallel with the distributionsystem and isolation may not be required. Alwayscheck with your utility as to the applicable circum-stances.

Electrical Shock


The warning label for electrical shock is located onthe valve covers.

g00305892

Ignition systems can cause electrical shocks. Avoidcontacting the ignition system components and thewiring.

Do not operate or work on the engine unless theinstruction and warnings in the Operation andMaintenance Manual are understood. Failure tofollow the instructions or failure to heed the warningscould result in injury or death. Proper care is yourresponsibility.

8Safety SectionSafety Signs and Labels

Engine Lifting


The warning label for engine lifting is located onthe valve covers.

g00306083

Improper lift rigging can allow unit to tumble caus-ing injury and damage.

If improper equipment is used to lift the engine,injury and damage can occur. Use cables that areproperly rated for the weight. Use a spreader barand attach the cables according to the informationon the warning label.

Oil Filter


The warning label for the oil filter is located on thecover of the oil filter.

g00306243

Filter contains hot pressurized fluid when engineis running. Follow instructions on control valve toavoid injury if rapid air movement exists to blowfluid. Stop engine to avoid fire.

9Safety Section

General Hazard Information

Prelube Pump


The warning label for the prelube pump is locatedon the prelube pump.

g00306385

Motor must be grounded in accordance with na-tional electrical code and local codes, by trainedpersonnel to prevent serious electrical shocks.

Lifting provisions are intended for lifting the motoronly.

Motor has an automatic reset thermal protector. Ifmotor overheats, thermal protector will open mo-tor circuit.

After motor cools sufficiently, thermal protectorwill reset without warning and restart motor.

To service motor, disconnect power source frommotor and any accessory devices and allow motorto come to a complete standstill.

i01359759

General Hazard InformationSMCS Code: 1000; 7405


Attach a “Do Not Operate” warning tag or a similarwarning tag to the start switch or to the controlsbefore the engine is serviced or before the engineis repaired. These warning tags (Special Instruction,SEHS7332) are available from your Caterpillardealer. Attach the warning tags to the engineand to each operator control station. When it isappropriate, disconnect the starting controls.

Do not allow unauthorized personnel on the engine,or around the engine when the engine is beingserviced.

Engine exhaust contains products of combustionwhich may be harmful to your health. Alwaysstart the engine and operate the engine in a wellventilated area. If the engine is in an enclosed area,vent the engine exhaust to the outside.

Cautiously remove the following parts. To helpprevent spraying or splashing of pressurized fluids,hold a rag over the part that is being removed.

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed.Gradually loosen, but do not remove the last twobolts or nuts that are located at opposite ends ofthe cover plate or the device. Before removing thelast two bolts or nuts, pry the cover loose in orderto relieve any spring pressure or other pressure.

10Safety SectionGeneral Hazard Information


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

• When work is performed around an engine thatis operating, wear protective devices for ears inorder to help prevent damage to hearing.

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

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

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

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, performthe maintenance under the following conditions:

• The engine is stopped. Ensure that the enginecannot be started.

• Disconnect the batteries when maintenanceis performed or when the electrical system isserviced. Disconnect the battery ground leads.Tape the leads in order to help prevent sparks.

• Do not attempt any repairs that are notunderstood. Use the proper tools. Replaceany equipment that is damaged or repair theequipment.

California Proposition 65 Warning

Some engine exhaust constituents are known to theState of California to cause cancer, birth defects,and other reproductive harm.

Pressure Air and Water

Pressurized air and/or water can cause debrisand/or hot water to be blown out. This could resultin personal injury.

When pressure air and/or pressure water is usedfor cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must bebelow 275 kPa (40 psi).

Fluid Penetration


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leakcan cause severe injury. If fluid is injected into yourskin, you must get treatment immediately. Seektreatment from a doctor that is familiar with this typeof injury.

Containing Fluid Spillage

Care must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theengine. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component containing fluids.

Refer to Special Publication, NENG2500, “Tools andShop Products Guide” for the following items:

• Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

11Safety Section

Burn Prevention

Obey all local regulations for the disposal of liquids.

Asbestos Information


Caterpillar equipment and replacement parts thatare shipped from Caterpillar are asbestos free.Caterpillar recommends the use of only genuineCaterpillar replacement parts. Use the followingguidelines when you handle any replacement partsthat contain asbestos or when you handle asbestosdebris.

Use caution. Avoid inhaling dust that might begenerated when you handle components thatcontain asbestos fibers. Inhaling this dust canbe hazardous to your health. The componentsthat may contain asbestos fibers are brake pads,brake bands, lining material, clutch plates, andsome gaskets. The asbestos that is used in thesecomponents is usually bound in a resin or sealed insome way. Normal handling is not hazardous unlessairborne dust that contains asbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestosmaterials.

• A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.

• Use exhaust ventilation on permanent machiningjobs.

• Wear an approved respirator if there is no otherway to control the dust.

• Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposalof asbestos.

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

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

i01480768

Burn PreventionSMCS Code: 1000; 7405

Do not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.

Coolant

When the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

12Safety SectionFire Prevention and Explosion Prevention

Any contact with hot coolant or with steamcan cause severe burns. Allow cooling systemcomponents to cool before the cooling system isdrained.

Check the coolant level after the engine hasstopped and the engine has been allowed to cool.

Ensure that the filler cap is cool before removingthe filler cap. The filler cap must be cool enoughto touch with a bare hand. Remove the filler capslowly in order to relieve pressure.

Cooling system conditioner contains alkali. Alkalican cause personal injury. Do not allow alkali tocontact the skin, the eyes, or the mouth.

Oils

Hot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.

Batteries

Electrolyte is an acid. Electrolyte can causepersonal injury. Do not allow electrolyte to contactthe skin or the eyes. Always wear protective glassesfor servicing batteries. Wash hands after touchingthe batteries and connectors. Use of gloves isrecommended.

i01372262

Fire Prevention and ExplosionPreventionSMCS Code: 1000; 7405


All fuels, most lubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency shutdown.

Determine whether the engine will be operated inan environment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.

If the application involves the presence ofcombustible gases, consult your Caterpillar dealerfor additional information about suitable protectiondevices.

Remove all flammable materials such as fuel, oil,and debris from the engine. Do not allow anyflammable materials to accumulate on the engine.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in case of a line,a hose, or a seal failure. Exhaust shields must beinstalled correctly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines that contain flammablefluid. Clean any such lines thoroughly with anonflammable solvent prior to welding or flamecutting.

Wiring must be kept in good condition. All electricalwires must be properly routed and securelyattached. Check all electrical wires daily. Repair anywires that are loose or frayed before you operatethe engine. Clean all electrical connections andtighten all electrical connections.

Eliminate all wiring that is unattached orunnecessary. Do not use any wires or cables thatare smaller than the recommended gauge. Do notbypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and properlymaintained battery cables will help to prevent arcingor sparking.

13Safety Section

Crushing Prevention and Cutting Prevention

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.

Oil filters and fuel filters must be properly installed.The filter housings must be tightened to the propertorque.


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may causean explosion.

The batteries must be kept clean. The covers (ifequipped) must be kept on the cells. Use therecommended cables, connections, and batterybox covers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Caterpillar dealer forrepair or for replacement parts.

Check lines, tubes and hoses carefully. Do notuse your bare hand to check for leaks. Use aboard or cardboard to check for leaks. Tighten allconnections to the recommended torque.

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

i01359666

Crushing Prevention andCutting PreventionSMCS Code: 1000; 7405

Support the component properly when workbeneath the component is performed.

Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.

Stay clear of all rotating parts and of all movingparts. Leave the guards in place until maintenanceis performed. After the maintenance is performed,reinstall the guards.

Keep objects away from moving fan blades. Thefan blades will throw objects or cut objects.

When objects are struck, wear protective glasses inorder to avoid injury to the eyes.

14Safety SectionMounting and Dismounting

Chips or other debris may fly off objects whenobjects are struck. Before objects are struck, ensurethat no one will be injured by flying debris.

i01372247

Mounting and DismountingSMCS Code: 1000; 7405

Inspect the steps, the handholds, and the workarea before mounting the engine. Keep these itemsclean and keep these items in good repair.

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

Face the engine in order to mount the engine ordismount the engine. Maintain a three-point contactwith the steps and handholds. Use two feet and onehand or use one foot and two hands. Do not useany controls as handholds.

Do not stand on components which cannot supportyour weight. Use an adequate ladder or use a workplatform. Secure the climbing equipment so that theequipment will not move.

Do not carry tools or supplies when you mount theengine or when you dismount the engine. Use ahand line to raise and lower tools or supplies.

i00702251

Ignition SystemsSMCS Code: 1550

Ignition systems can cause electrical shocks. Avoidcontacting the ignition system components andwiring.

Do not attempt to remove the valve covers when theengine is operating. The transformers are groundedto the valve covers. Personal injury or death mayresult and the ignition system will be damaged if thevalve covers are removed during engine operation.The engine will not operate without the valve covers.

i00659904

Before Starting EngineSMCS 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 thearea is free of personnel.

Ensure that the engine is equipped with a lightingsystem that is suitable for the conditions. Ensurethat all lights work properly.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuitsare provided in order to help prevent personalinjury. The circuits are also provided in order to helpprevent engine damage.

On the initial start-up of a new engine or an enginethat has been serviced, be prepared to stop theengine if an overspeed condition occurs. This maybe accomplished by shutting off the fuel supply tothe engine, or shutting off the ignition system.

See the Service Manual for repairs and foradjustments.

i00572000

Engine StartingSMCS Code: 1000

If a warning tag is attached to the engine startswitch or to the controls, DO NOT start the engineor move the controls. Consult with the person thatattached the warning tag before the engine isstarted.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine from the operator’s compartment orfrom the engine start switch.

Always start the engine according to the procedurethat is described in the Operation and MaintenanceManual, “Engine Starting” topic in the OperationSection. Knowing the correct procedure will help toprevent major damage to the engine components.Knowing the procedure will also help to preventpersonal injury.

15Safety Section

Engine Stopping

To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingproperly, check the water temperature gaugeand the oil temperature gauge during the heateroperation.

Engine exhaust contains products of combustionwhich can be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is started in an enclosed area,vent the engine exhaust to the outside.

i00659907

Engine StoppingSMCS Code: 1000

To avoid overheating of the engine and acceleratedwear of the engine components, stop the engineaccording to the instructions in this Operation andMaintenance Manual, “Engine Stopping” topic(Operation Section).

Use the Emergency Stop Button (if equipped)ONLY in an emergency situation. Do not use theEmergency Stop Button for normal engine stopping.After an emergency stop, DO NOT start the engineuntil the problem that caused the emergency stophas been corrected.

On the initial start-up of a new engine or an enginethat has been serviced, make provisions to stopthe engine if an overspeed occurs. This may beaccomplished by shutting off the fuel supply to theengine, or shutting off the ignition system.

i00887114

Electrical SystemSMCS Code: 1000; 1400

Never disconnect any charging unit circuit or batterycircuit cable from the battery when the charging unitis operating. A spark can cause the combustiblegases that are produced by some batteries to ignite.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is operated. Repair all frayedelectrical wires before the engine is started.

Grounding Practices

Proper grounding is necessary for optimum engineperformance and reliability. Improper grounding willresult in uncontrolled electrical circuit paths and inunreliable electrical circuit paths.

Uncontrolled electrical circuit paths can resultin damage to main bearings, to crankshaftjournal surfaces, and to aluminum components.Uncontrolled electrical circuit paths can also causeelectrical activity that may degrade the engineelectronics and communications.

For the starting motor, do not attach the batterynegative terminal to the engine block.

Use a ground strap to ground the case of all controlpanels to the engine block.

Ground the engine block with a ground strap thatis furnished by the customer. Connect this groundstrap to the ground plane.

Use a separate ground strap to ground the batterynegative terminal for the control system to theground plane.

Rubber couplings may connect the steel piping ofthe cooling system and the radiator. This causesthe piping and the radiator to be electricallyisolated. Ensure that the piping and the radiator iscontinuously grounded to the engine. Use groundstraps that bypass the rubber couplings.

Ensure that all grounds are secure and free ofcorrosion.

16Product Information SectionModel Views and Specifications

Product InformationSection

Model Views andSpecifications

i01494576

Model View IllustrationsSMCS Code: 1000

The illustrations show various typical features ofG3500B Engines. The illustrations do not show all ofthe options that are available. An arrangement forcogeneration is shown.


(1) Air cleaner(2) Gas inlet(3) Engine oil filter(4) Oil filler

(5) Oil level gauge(6) Hydraulic oil filter(7) Hydraulic system’s oil tank(8) Electric water pump

17Product Information Section

Model Views and Specifications


(9) Air/water separator(10) Air purge valve

(11) Junction box(12) Crankcase breathers

i01451665

Product DescriptionSMCS Code: 1000

The G3500B Engines were developed in order toprovide electronically controlled gas engines. Theengines have the ability to burn a wide variety ofgaseous fuels.

Fuel System (Air/Fuel RatioControl)

The fuel system includes these components:

• Engine control module (ECM)

• Electrohydraulic actuator

• Fuel metering valve

• Inlet manifold pressure sensor

• Inlet manifold temperature sensor

• Oxygen sensor

The fuel metering valve controls the flow of fuel tothe engine. The ECM determines the requirement forthe mixture of air and fuel. The ECM sends a signalto the fuel metering valve. The fuel metering valvecontrols the volume of the gas flow to the engine.

An oxygen sensor measures the oxygen contentin the exhaust gas. The inlet manifold pressureand temperature are monitored. This information isprovided to the ECM. The ECM uses this informationto adjust the flow of fuel in order to meet emissionsrequirements. This is a continuous process duringengine operation.

18Product Information SectionModel Views and Specifications

The fuel flows through the fuel metering valve intothe mixer. The mixture of air and fuel flows throughthe turbocharger compressor. The air/fuel mixtureis cooled in the aftercooler. The mixture enters thecylinders through a throttle valve.

The ECM sends an electronic throttle signal to theelectrohydraulic actuator. The throttle is hydraulicallycontrolled by the electrohydraulic actuator.

Ignition System

The engine is equipped with an electronic ignitionsystem. The system provides dependable firingand low maintenance. The system provides precisecontrol of the spark and the ignition timing for eachcylinder.

The system also provides diagnostic capability thatenhances troubleshooting. The primary ignitionwiring is routed internally through the engine.

The engines are equipped with protection fromdetonation. A detonation sensor is located betweenevery two cylinders. The ignition timing is retardedfor a cylinder when excessive detonation is sensedin that cylinder. If the maximum retarded positionis attained and detonation continues to occur, theECM shuts down the engine.

The engines are equipped with flame arrestors. Theflame arrestors are located at the entrance of eachinlet port. If the engine backfires, the flame arrestorsprevent the fire from entering the air/fuel mixture.

Lubrication System

The engine lubrication oil is circulated by agear-driven pump. The oil is cooled and filtered.A bypass valve provides unrestricted flow oflubrication oil to the engine parts if the oil filterelements become plugged.

Cooling System

The standard cooling system has a gear-drivencentrifugal pump. For applications that combineheating and power, the pump for circulating thejacket water is supplied by the customer. Thecooling system has temperature regulators thatregulate the temperature of the coolant. Thetemperature depends on the application.

The turbocharged engine has a Separate CircuitAftercooler (SCAC). The SCAC is required to operateat one of the following two inlet temperatures. Thetemperature depends on the engine rating and theapplication.

• 32 �C (90 �F)

• 54 �C (130 �F)

If the inlet temperature to the SCAC exceeds thesetemperatures, consult your Caterpillar dealer.

In an engine with jacket water system that operatesat a temperature greater then 99 �C (210 �F), the oilcooler is not in the jacket water circuit. The circuit forthe oil cooler and the circuit for the aftercooler maybe combined or separate circuits. In the combinedsystem, a pump circulates water through both theaftercooler and oil cooler cores. The combinedsystem uses a thermostatic control to regulate theoil temperature. This prevents overcooling.

Jacket water for high temperature cooling can besupplied at temperatures up to 127 �C (260 �F).The customer must supply a pump for circulatingthe jacket water.

Engine Service Life

Engine efficiency and maximum utilization of engineperformance depend on adherence to properoperation and maintenance recommendations. Thisincludes the use of recommended lubricants, fuels,and coolants.

For the engine maintenance that is required,refer to this Operation and Maintenance Manual,“Maintenance Interval Schedule” (MaintenanceSection).


Model Views and Specifications

i01451734

SpecificationsSMCS Code: 1000

Table 1

Engine Specifications

Item G3516B Engine

Cylinders and arrangement 60 degree V-16

Bore 170 mm (6.7 inch)

Stroke 190 mm (7.5 inch)

Total displacement 69 L (4210 cu in)

Compression ratio 11.7:1

Aspiration TA with SCAC (1)

Rotation (flywheel end) Counterclockwise

Inlet valve lash 0.51 mm (.020 inch)

Exhaust valve lash 1.27 mm (.050 inch)

(1) Turbocharged Aftercooled with Separate Circuit Aftercooling


G3516B Engine design

(A) Inlet valves(B) Exhaust valves(C) Flywheel

Table 2

Crankshaft Positions For Valve Lash SettingStandard Counterclockwise Rotation

EngineStroke For The Number1 Piston At Top Center

Position (1)Inlet Valves Exhaust Valves

Compression Stroke 1-2-5-7-8-12-13-14 1-2-3-4-5-6-8-9

Exhaust Stroke 3-4-6-9-10-11-15-16 7-10-11-12-13-14-15-16G3516B

Firing Order 1-2-5-6-3-4-9-10-15-16-11-12-13-14-7-8

(1) For the complete procedure, refer to the Service Manual, “Systems Operations Testing and Adjusting”.

20Product Information SectionProduct Identification Information

Product IdentificationInformation

i01617523

Plate Locations and FilmLocationsSMCS Code: 1000

Engine Identification

Caterpillar engines are identified with serialnumbers, with performance specification numbers,and with arrangement numbers. In some of thecases, modification numbers are used. Thesenumbers are shown on the Serial Number Plateand the Information Plate that are mounted on theengine.

Caterpillar dealers need these numbers in order todetermine the components that were included withthe engine. This permits accurate identification ofreplacement part numbers.

Serial Number Plate


(1) Location of the Serial Number Plate

The Serial Number Plate is on the left side of thecylinder block near the rear of the engine.


Typical Serial Number Plate

The following information is stamped on the SerialNumber Plate: engine serial number, model, andarrangement number.

Information Plate


(1) Location of the Information Plate

The Information Plate is on the left side top surfaceof the cylinder block in front of the front cylinderhead.


Typical Information Plate


Product Identification Information

The following information is stamped on theInformation Plate: compression ratio, aftercoolertemperature, power (kilowatts and horsepower), fullload rpm, and other information.

i01452057

Reference InformationSMCS Code: 1000

Identification of the items in Table 3 may be neededin order to obtain parts and service. Some of thenumbers are on the engine Serial Number Plateand/or Information Plate. Locate the informationfor your engine. Record the information on theappropriate space in Table 3. Make a copy of thislist for a record. Retain the information for futurereference.

The top level part numbers in the Parts Manual forthe engine are listed with the engine arrangementnumber.

The packaging arrangement may also be called apricing arrangement or a customer arrangement.This is the total package with attachments andoptions that are not included in the enginearrangement.

The performance specification can be used byyour Caterpillar dealer with the Technical MarketingInformation system. Before the engine leaves thefactory, the engine performance is tested. Detailedperformance data is recorded. The performancespecification number can be used for obtaining thedata.

Table 3

Reference Numbers

Engine Model

Serial Number

Arrangement Number

Packaging Arrangement

Turbocharger

Fuel Filter Element

Lubrication Oil FilterElement

Auxiliary Oil Filter Element

Air Cleaner Element

Fan Drive Belt

Alternator Belt

Capacity of the LubricationSystem

Capacity of the CoolingSystem

Performance SpecificationNumber

Low Idle rpm

High Idle rpm

Full Load rpm

Power Rating

22Operation SectionEngine Lifting and Storage

Operation Section

Engine Lifting and Storage

i01028344

Engine LiftingSMCS Code: 1000; 1122


NOTICENever bend the eyebolts and the brackets. Only loadthe eyebolts and the brackets under tension. Remem-ber that the capacity of an eyebolt is less as the anglebetween the supporting members and the object be-comes less than 90 degrees.

When it is necessary to remove a component at anangle, only use a link bracket that is properly rated forthe weight.

Use a hoist to remove heavy components. Usean adjustable lifting beam to lift the engine. Allsupporting members (chains and cables) shouldbe parallel to each other. The chains and cablesshould be perpendicular to the top of the objectthat is being lifted.

Some removals require lifting the fixtures in order toobtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes thatare on the engine.

Lifting eyes are designed and installed for thespecific engine arrangement. Alterations to the liftingeyes and/or the engine make the lifting eyes andthe lifting fixtures obsolete. If alterations are made,ensure that proper lifting devices are provided.Consult your Caterpillar dealer for informationregarding fixtures for proper engine lifting.

i00816700

Engine StorageSMCS Code: 1000

If the engine will not be started for several weeks,the lubricating oil will drain from the cylinder wallsand from the piston rings. Rust can form on thecylinder liner surface, which will increase enginewear which can reduce engine service life.

To help prevent excessive engine wear, use thefollowing guidelines:

• Complete all of the lubrication recommendationsthat are listed in this Operation and MaintenanceManual, “Maintenance Interval Schedule”(Maintenance Section).

• If freezing temperatures are expected, check thecooling system for adequate protection againstfreezing. See this Operation and MaintenanceManual, “General Coolant Information”(Maintenance Section).

If an engine is out of operation and if use of theengine is not planned, special precautions shouldbe made. If the engine will be stored for more thanone month, a complete protection procedure isrecommended.

Your Caterpillar dealer will have instructions forpreparing the engine for extended storage periods.

For more detailed information on engine storage,see Special Instruction, SEHS9031, “StorageProcedure for Caterpillar Products”.

Generator Storage

For information on generator storage, see theliterature that is provided by the OEM of thegenerator. Consult your Caterpillar dealer forassistance.

23Operation Section

Engine Features and Controls

Engine Features andControls

i01452114

Performance ParametersSMCS Code: 1000

Air/Fuel Ratio

The correct air/fuel ratio is very important for thefollowing considerations:

• Margin of detonation

• Control of emissions

• Achieving optimum service life for the engine

If the air/fuel ratio is not appropriate for the fuel andthe operating conditions, a failure of the enginemay occur. The service life of the turbocharger, thevalves, and other components may be reduced.

Any changes to the air/fuel ratio may affectthe exhaust emissions. After adjustment, usean emissions analyzer to measure the exhaustemissions. Ensure that the engine is in compliancewith local regulations for emissions.

Fuel Supply Pressure

The engine can operate with a minimum pressure of7 kPa (1 psi). Fluctuations of the fuel pressure priorto the fuel control valve will have a negative effect onthe stability of the engine rpm. Control of emissionscan also be affected. Ensure that the engine has astable fuel pressure of ± 0.25 kPa (± 1 in H2O).

Installation Before the Fuel Control Valve

To optimize the accuracy of the flow of fuel, installa straight pipe prior to the fuel control valve. Use apipe with a minimum length of 1 m (3 ft). Do NOTinstall an elbow within 1 m (3 ft) of the fuel controlvalve.

To prevent particles from entering the engine,install a one micron fuel filter 1 m (3 ft) before thefuel control valve. The recommended filter is the4P-4717 Fuel Filter with the 4P-4720 Gas FilterElement.

Fuel Temperature

The system is designed for fuel temperatures lessthan 60 �C (140 �F). For optimum performance, themaximum recommended differential temperature forthe fuel and air is 2.8 �C (5 �F).

Temperature of the Air Supply

Changes in the temperature of the air supply affectsthe air/fuel ratio. In addition to seasonal changes,the air temperature changes overnight. Control ofthe temperature in the engine room will help tomaintain the air/fuel ratio.

To avoid hot air from a generator, use ducting.For more information, refer to Application andInstallation Guide, LEKQ7250, “Air Intake”. Consultyour Caterpillar dealer for assistance.

Setting of the Exhaust Bypass(Wastegate)

The engine has an adjustable exhaust bypass valve.

The exhaust bypass is adjusted in order to achieveoperation under a rated load with a 70 degreeangle of the throttle plate.

After the desired exhaust emissions are obtained,use ET to verify the desired percent of oxygen inthe exhaust gas. Then adjust the exhaust bypassin order to obtain full load operation at the desiredthrottle position.

Oil Consumption

The rate of oil consumption is called Brake SpecificOil Consumption (BSOC). The unit of measure isgrams per brake kilowatt hour or pounds per brakehorsepower hour. The BSOC depends on the enginemodel, the aspiration, the operating load, and theoil that is used. For information on calculating theBSOC, refer to Engine Data Sheet 96.2, LEKQ4028,“Oil Consumption Data”.

Table 4 lists the normal mid-life BSOC for G3500Engines under the following conditions:

• Load factor of 100 percent

• Maintenance is performed according tothis Operation and Maintenance Manual,“Maintenance Interval Schedule” (MaintenanceSection).

24Operation SectionEngine Features and Controls

Table 4

BSOC for G3500 Engines

Turbocharged Aftercooled Engine 0.426 g/bkw h(.0007 lb/bhp h)

i01520257

Sensors and ElectricalComponentsSMCS Code: 1900; 7400

Note: This section contains some generalinformation about the engine electronic system andsensors. For more information, refer to SystemsOperation/Testing and Adjusting.

Electronic System

The Caterpillar Electronic System is a completeelectronic control system for gas engines.The following benefits are the most significantadvantages of the electronic system:

• Air/Fuel ratio control

• Extensive system diagnostics

• Elimination of parts that are prone to mechanicalwear

• Precise control of engine operation

• Protection from detonation

• Timing control of individual cylinders


Junction box

Most of the functions of the electronic system areprovided by the engine control module. The enginecontrol module is a sealed unit. The module islocated inside a junction box.

Five primary functions are supported by the enginecontrol module:

• Governing of the engine rpm

• Control of ignition

• Control of the air/fuel ratio

• Start/stop control

• Monitoring of engine operation

Governing of the Engine RPM

The engine control module receives a signal fromthe speed/timing sensor. The engine control modulemaintains the desired engine rpm through electricalcontrol of the Hydrax actuator. The actuatorregulates the throttle plate.

The actual throttle position can be observed on amechanical indicator that is on the housing of theactuator.

Control of Ignition

Each cylinder has an ignition transformer that islocated under the valve cover. To initiate combustionin each cylinder, the engine control module sends apulse to the primary coil of the ignition transformer.The transformer increases the voltage which createsa spark across the spark plug electrode.

The transformers are grounded through the valvecover. Use caution when a valve cover is removed.

Always disconnect the ignition harness from thetransformer when a valve cover is removed.

An ignition harness connects each transformer tothe engine control module. The harness is routedinside the engine.

Control of Air and Fuel

The ECM determines the desired volume for theflow rates of the air and fuel. The determinationis based on the desired engine speed, the actualengine speed, and the calculated load. Next, theECM sends information on the desired flow of airand fuel to the fuel metering valve via a PWM signal.The ECM monitors the content of the resultingexhaust gas. The ECM fine tunes the signal tothe fuel metering valve in order to achieve thedesired exhaust oxygen. The process is repeatedcontinuously during engine operation.

25Operation Section


Start/Stop Control

The engine control module contains the logic andthe outputs for controlling the starting and stoppingof the engine. The logic for starting and stoppingcan be programmed by the customer. The enginecontrol module supplies positive “+” battery voltageto the starting motor relay and the gas shutoff valve.

The engine uses an energize-to-run system. Thegas shutoff valve must remain energized in order tosupply fuel to the engine. If power is removed fromthe gas shutoff valve, the fuel is shut off.

Monitoring Engine Operation

Sensors are used in order to monitor engineoperation. Wiring harnesses connect the sensorsto the engine control module. The module usesinformation from the sensors in order to monitor andcontrol the engine. The information is also used togenerate event codes, and diagnostic codes. Thecodes can be read with ET.

Event – An event is a result of abnormal engineoperation. If abnormal engine operation is detected,the engine control module generates an event code.The module can generate an alarm or a shutdownfor abnormal engine operation. These conditions aresome examples of events: high inlet air temperature,low oil pressure, and engine overspeed.

Diagnostic – A diagnostic code is a result of aproblem with the operating system or with themonitoring system. The engine control moduleuses sensors and internal circuitry to monitor thesystem components. If a problem develops in acomponent or a wiring harness, the control systemwill sense the problem. The control system will notifythe operator by creating a diagnostic code. Someexamples of conditions that activate diagnostics area short in a circuit for a sensor, and open circuit, ora noisy signal.

Note: For detailed information on event codes anddiagnostic codes, refer to Troubleshooting.

Sensors

Sensors provide information to the engine controlmodule. The information enables the module tocontrol the engine as efficiently as possible over awide range of operating conditions. The informationis used for monitoring engine operation.

Illustrations 23, 24, and 25 show the locations ofthe sensors.



(1) Engine coolant pump pressure switch(inlet pressure)

(2) Detonation sensor(3) Hydrax actuator’s pressure switch

(4) Inlet air temperature sensor(5) Engine coolant temperature sensor


(6) Pressure sensor for unfiltered oil(7) Pressure sensor for filtered oil(8) Engine coolant pressure sensor (outlet)(9) Oxygen sensor

(10) Manifold air pressure sensor(11) Engine oil temperature sensor(12) Oxygen buffer(13) Speed/timing sensor

The functions of the sensors are described below.

Engine coolant pump pressure switch (inlet pressure)(1) – A pressure switch is located at the outlet ofthe oil cooler.

Detonation sensors (2) – The detonation sensorsmonitor the engine for detonation in each cylinder.To eliminate detonation, the engine control moduleretards the timing of the cylinder. If excessivedetonation continues, the engine control modulewill shut down the engine.

27Operation Section


Hydrax actuator’s pressure switch (3) – The Hydraxactuator’s pressure switch monitors the oil supplypressure. Insufficient oil pressure will activate anengine shutdown.

Inlet air temperature sensor (4) – A sensor formonitoring the air inlet temperature is located inthe elbow before the number one cylinder head.Excessive inlet air temperature can activate analarm, a derating, or a shutdown.

Engine coolant temperature sensor (5) – Thetemperature sensor is located in the watertemperature regulator housing. To monitor thecoolant temperature, the element must be in contactwith the coolant. If overheating occurs due to lowcoolant level, the sensor will not function properly. Ahigh coolant temperature will activate an alarm, aderating, or a shutdown. A low coolant temperaturewill only activate an alarm. The setpoints for theactivation can be programmed with the ET. Theengine can be restarted after a shutdown dueto high engine coolant temperature. However,another shutdown will occur after one minute if thetemperature remains high.

Oil pressure sensors (6) and (7) – The engine oilpressure is measured before the oil filters andafter the oil filters. An alarm or a shutdown can beactivated by any of the following occurrences: lowfiltered oil pressure, low oil filter differential pressure,and high oil filter differential pressure.

Engine coolant pressure sensor (8) – A pressureswitch is located at the outlet for the engine jacketwater. If the outlet pressure is too low, the enginecontrol module will activate a shutdown.

Oxygen sensor (9) and oxygen buffer (12) – Theoxygen sensor and the oxygen buffer generate asignal that is proportional to the percent of oxygenin the exhaust. The signal is used for adjustingthe air/fuel ratio in order to achieve the level ofemissions that is desired.

Manifold air pressure sensor (10) – The manifoldair pressure sensor is connected to the air inletmanifold. The sensor monitors the absolute manifoldair pressure. The information is used by the enginecontrol module to determine the engine load.

Engine oil temperature sensor (11) – An oiltemperature sensor monitors the engine oiltemperature. A high oil temperature will activate analarm or a shutdown. The electronic control modulecompares the oil temperature to the engine coolanttemperature. A high difference between the twotemperatures will activate an alarm or a shutdown.

Speed/timing sensor (13) – The engine speed/timingsensor is located on the rear end of the leftcamshaft. The engine speed/timing sensor providesaccurate information to the engine control moduleabout the position of the crankshaft and the enginerpm. The engine control module uses the position ofthe crankshaft in order to determine ignition timing.



(14) Thermocouple for the temperature ofthe cylinder exhaust port

(15) Thermocouple for the temperature ofthe exhaust inlet to the turbocharger

(16) Thermocouple for the temperature ofthe exhaust outlet from the turbochargerturbine

Cylinder Exhaust Temperature (14) – Thermocouplesmeasure the exhaust temperatures from the exhaustport of each cylinder. An alarm or a shutdownis activated if the exhaust temperature from anycylinder is too high or if the exhaust temperaturefrom any cylinder deviates excessively from theaverage temperature of all of the cylinders.

Exhaust Inlet Temperature to the Turbocharger(15) – A thermocouple is mounted at the inlet forthe exhaust gas of each turbocharger turbine. Analarm or a shutdown is activated if the temperatureof the exhaust to the turbine is too high or too low.

Exhaust Outlet Temperature from the TurbochargerTurbine (16) – A thermocouple is mounted at theoutlet for the exhaust gas of each turbochargerturbine. An alarm or a shutdown is activated if thetemperature of the exhaust from either turbine istoo high or too low.

Integrated Temperature Sensing Module

The integrated temperature sensing modulemonitors thermocouples that are located at theexhaust port of each cylinder. Thermocouplesare also mounted at the inlets and outlets to theturbochargers. The temperatures are broadcastover data links for use with other modules.

The integrated temperature sensing modulecalculates the average temperature for eachbank. Event codes are generated if the followingconditions occur:

• The temperature is higher than the limit that isprogrammed.

• The temperature of a cylinder deviatessignificantly from the average temperature for allof the cylinders.

i01617561

Alarms and ShutoffsSMCS Code: 7400

This section contains some general informationabout the function of typical engine protectivedevices.

The alarms and shutoffs are set at critical operatingtemperatures, pressures, or speeds in order toprotect the engine from damage.

An alarm warns the operator when an abnormaloperating condition occurs. The shutoffs shut downthe engine if a more critical operating conditionoccurs. The shutoffs help to prevent damage tothe engine.

If an engine protective device shuts off the engine,always determine the cause of the shutoff. Alwaysmake the necessary repairs before attempting tostart the engine. Refer to Troubleshooting.

Become familiar with the following information:

• Types of the alarms and shutoffs

29Operation Section


• Locations of the alarm and shutoff controls

• Conditions which cause each control to function

• Resetting procedure that is required beforestarting the engine

Testing Alarms and Shutoffs

Alarms must function properly in order to providetimely warning to the operator. Shutoffs help toprevent damage to the engine. It is impossibleto determine if the engine protective devices arein good working order during normal operation.Malfunctions must be simulated in order to test theengine protective devices.

NOTICEDuring testing, abnormal operating conditions must besimulated.

The tests must be performed correctly in order to pre-vent possible damage to the engine.

Periodic testing of engine protective devices forproper operation is recommended maintenance.To prevent damage to the engine, only authorizedservice personnel or your Caterpillar dealer shouldperform the tests.

Prevention of Start-up

The engine will not start if any of the conditionsthat cause a shutoff are present. The followingconditions will also prevent starting of the engine:

• An input from the driven equipment preventsstarting.

• An overcrank occurs.

• The prelube pressure is low. Operation of theprelube pump exceeds the programmed periodof time.

If any of these situations occur, the followingconditions must be met before the engine can bestarted:

• The condition that prevented starting is notpresent.

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

Setpoints for Alarms and Shutoffs

Some of the setpoints for the alarms and shutoffscan be programmed with an electronic servicetool (ET). Some of the parameters cannot beprogrammed.

The setpoints are programmed at the factory. Thestatus for most of the parameters is ON. Table 5 liststhe default setpoints of the warnings and shutoffsfor G3500B Engines.

For information on programming of parameters,refer to Systems Operation/Testing and Adjusting.


Table 5

Default Setpoints of the Warnings and Shutoffs for G3500B Engine

Parameter Setpoint for Warnings Setpoint for Shutoff

Cooling System

“High Jacket Water Inlet Pressure” (1) (2) n/a 462 ± 41 kPa (67 ± 6 psi)

“Low Jacket Water Pressure Shutdown”(outlet) (1) (2)

- (5.6655 × �C jacket water temperature)− 420.46

“High Engine Coolant Temperature” (3) 109 �C (229 �F) (1) 113 �C (235 �F) (4)

“Low Engine Coolant Temperature” (1) (3) 5 �C (41 �F) n/a

Electrical System

“High System Voltage” (1) (2) 34 volts n/a

“Low System Voltage” (1) (2) 20 volts 18 volts

Exhaust System

“Cylinder #X High Exhaust Port Temp”(1) (3)

495 �C (923 �F) 650 �C (1202 �F)

“Cylinder #X Exhaust Port TempDeviating High” (1) (3)

50 �C (122 �F) 150 �C (302 �F)

“Cylinder #X Exhaust Port TempDeviating Low” (1) (3)

50 �C (122 �F) 150 �C (302 �F)

“High Turbo Turbine Inlet Temperature”(3) (4)

495 �C (923 �F) 650 �C (1202 �F)

“High Turbo Turbine Outlet Temperature”(3) (4)

495 �C (923 �F) 650 �C (1202 �F)

“Low Turbo Turbine Inlet Temperature”(3) (4)

250 �C (482 �F) 100 �C (212 �F)

“Low Turbo Turbine Outlet Temperature”(3) (4)

250 �C (482 �F) 100 �C (212 �F)

Fuel System

“Fuel Energy Content Setting High” (1) (2) The fuel correction factor is greaterthan 125% for 20 seconds.

n/a

“Fuel Energy Content Setting Low” (1) (2) The fuel correction factor is lessthan 75% for 20 seconds.

n/a

“High Fuel Temperature” (1) (3) 60 �C (140 �F) n/a

“Fuel Quality Out of Range” (1)(2) (5) n/a The actual energy content of the fuel isnot within the range that is programmed.

“Low Gas Fuel Differential Pressure” (1)

(3)5 kPa (0.7 psi) n/a

“High Gas Fuel Differential Pressure”(1) (3)

35 kPa (5 psi) n/a

Electrohydraulic Actuator System

“Low Hydrax Oil Pressure” (1) (2) n/a 700 ± 103 kPa (102 ± 15 psi)

Ignition System

“Cylinder #X Detonation” (1) (2) n/a Detonation continues after the enginecontrol module has retarded the

timing by 6 degrees.

Inlet Air System

(continued)

31Operation Section


(Table 5, contd)

Default Setpoints of the Warnings and Shutoffs for G3500B Engine

Parameter Setpoint for Warnings Setpoint for Shutoff

“High Inlet Air Temperature at HighEngine Load” (1) (3)

53 �C (127 �F) 57 �C (135 �F)

“High Inlet Air Temperature at LowEngine Load” (1) (3)

69 �C (156 �F) 73 �C (163 �F)

Load setpoint 50% 50%

Lubrication System

“High Oil Filter Differential Pressure” (1) 103 kPa (15 psi) (3) 138 kPa (20 psi) (6)

“Low Oil Filter Differential Pressure” (1) 35 kPa (5 psi) (3) 7 kPa (1 psi) (6)

“Low Engine Oil Pressure” (1) (2)

Rated speed310 kPa (45 psi) 276 kPa (40 psi)

“Low Engine Oil Pressure” (1) (2)

Idle speed138 kPa (20 psi) 103 kPa (15 psi)

“High Engine Oil Temperature” (1) 102 �C (216 �F) (3) 104 �C (219 �F) (6)

Miscellaneous

“Customer Shutdown Requested” n/a

“Driven Equipment Not Ready” n/a

The input requests a shutdown.

“Engine Overspeed Shutdown” (1) (6) n/a 118 percent of the rated rpm (1)

“High Jacket Water to Engine OilTemperature Differential” (1)

14 �C (25 �F) (3) 20 �C (36 �F) (6)

(1) The default status is ON.(2) This parameter cannot be programmed.(3) A customer password is required for reprogramming this parameter.(4) The default status is OFF.(5) The acceptable range is 300 to 2400 BTU.(6) A factory password is required for reprogramming this parameter.

32Operation SectionEngine Starting

Engine Starting

i01452757

Before Starting EngineSMCS Code: 1000; 1400; 1450

Note: Certain procedures are required before anengine is started for the first time. See SpecialInstruction, REHS0531, “Installation and InitialStart-Up Procedures for G3516B Engines”.

Perform the required daily maintenance and otherperiodic maintenance before starting the engine.This can prevent major repairs at a later date.See this Operation and Maintenance Manual,“Maintenance Interval Schedule” (MaintenanceSection).

Walk-Around Inspection

NOTICEFor any type of leak, clean up the fluid. If leaking is ob-served, find the source and correct the leak. If leakingis suspected, check the fluid levels more often thanrecommended until the leak is found or fixed, or untilthe suspicion of a leak is proved to be unwarranted.

To obtain maximum service life for your engine,complete a thorough walk-around inspection of theinstallation before you start the engine. Look foritems such as oil or coolant leaks, loose bolts andtrash buildup. Remove any trash. Make repairs, ifnecessary.

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

• Ensure that the areas around the rotating partsare clear.

Air Inlet System

• Ensure that the air inlet piping and the air filtersare in place.

• Ensure that all clamps and connections aresecure.

• Inspect the air cleaner service indicator (ifequipped). Service the air cleaner filter elementwhen the yellow diaphragm enters the red zone,or the red piston locks in the visible position.

• Inspect the rubber boots for cracks and/or leaks.

Cooling System

• Inspect the cooling system for leaks or looseconnections. Inspect the condition of all the hosesand pipes for the cooling system. Ensure that theconnections are properly clamped.

• Inspect the water pumps for evidence of leaks.

• Check the coolant level. Add coolant, if necessary.For information on the proper coolant to use, seethis Operation and Maintenance Manual, “CoolingSystem Specifications” (Maintenance Section).

Driven Equipment

• Check the oil levels of the driven equipment.Perform any maintenance that is required for thedriven equipment. Refer to the literature that isprovided by the OEM of the driven equipment.

• If the engine is equipped with a clutch, ensurethat the clutch is disengaged.

• For generator set engines, ensure that the maincircuit 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 panelfor good condition. Reset any shutoff or alarmcomponents.

Fuel System

NEVER use a flame to check for gas leaks. Use agas detector.

An open flame can ignite mixtures of air and fuel.This will cause explosion and/or fire which couldresult in severe personal injury or death.

• Check the fuel lines for leaks with a gas detector.

• Ensure that the fuel lines are properly clamped.

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

33Operation Section

Engine Starting

Lubrication System


Oil level gauge (dipstick)

(1) “ADD” mark(2) “FULL” mark

NOTICEExcessive engine oil will increase oil consumption andresult in excessive deposits in the combustion cham-ber. Do not overfill the engine with oil.

• Check the engine crankcase oil level. Maintainthe oil level between the “ADD” and “FULL”marks on the “ENGINE STOPPED WITH OILCOLD” side of the oil level gauge. For informationon the proper oil to use, see this Operation andMaintenance Manual, “Lubricant Specifications”(Maintenance Section).

• Check for leaks at the following components:crankshaft seals, crankcase, oil filters, oil galleryplugs, sensors, and valve covers.

• Inspect the tubes, tees, and clamps on thecrankcase breathers.

Starting System

Air Starting Motor

• Drain moisture and sediment from the air tankand from any other air piping.

• Check the oil level in the lubricator. Keep thelubricator at least half full. Add oil, if necessary.For temperatures above 0 �C (32 �F), use anondetergent 10W oil. For temperatures below0 �C (32 �F), use air tool oil.

• Check the air pressure for starting. The air startingmotor requires a minimum of 690 kPa (100 psi).The maximum allowable air pressure is 1030 kPa(150 psi). Open the air supply valve.

Electric Starting Motor

• Disconnect any battery chargers that are notprotected against the high current drain that iscreated when the electric starting motor engages.

Inspect the wiring, the electrical cables, and thebattery for the following conditions:


• Wires that are worn or frayed

• Corrosion

i01489240

Cold Weather StartingSMCS Code: 1000; 1250; 1450; 1453; 1456; 1900

Note: Oil pan immersion heaters are notrecommended for heating the lube oil. To ensurethe compatibility of the components, only useequipment that is recommended by Caterpillar.

A jacket water heater is available as an option forstarting in temperatures as low as 0 �C (32 �F).The jacket water heater can maintain the watertemperature at approximately 32 �C (90 �F). Theheated water will help to keep the oil in the engineblock warm enough to flow when the engine isstarted. A jacket water heater is recommended forstarting when the temperature is less than 16 �C(60 �F).

For air starting motors, a larger volume of startingair and/or a higher air pressure may be necessaryin order to start the engine at colder temperatures.

For electric starting, extra battery capacity may benecessary.

Consult your Caterpillar dealer for more informationon the starting aids that are available for coldweather starting.


i01489245

Starting the EngineSMCS Code: 1000; 1450

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

NOTICEFor initial start-up of a new or rebuilt engine, and forstart-up of an engine that has been serviced, makeprovision to shut the engine off should an overspeedoccur. This may be accomplished by shutting off thefuel supply and/or the ignition to the engine.

Note: Using the “EMERGENCY STOP” button willshut off both the fuel and the ignition.

Unburned gas in the inlet manifold and/or in theexhaust manifold can ignite when the engine isstarted. Personal injury and/or property damagecan result. Use this procedure to clear the engineand the exhaust system of unburned gas:

Before starting an engine that was stopped by ter-minating the ignition system, turn the gas supplyOFF. Crank the engine for approximately 15 sec-onds in order to clear any unburned gas from theengine and the exhaust system.

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

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

Perform the procedures that are described inthis Operation and Maintenance Manual, “BeforeStarting Engine” (Operation Section).

Automatic Starting

When the engine is in the AUTOMATIC mode, theengine can start at any moment. To avoid personalinjury, always remain clear of the the engine whenthe engine is in the AUTOMATIC mode.

If the engine control switch is in the “AUTO”position, the engine will automatically start when theremote start/stop initiate contact closes.

Parameters for the Start/StopControl

Driven Equipment

Start-up is delayed until the switch for the drivenequipment indicates that the driven equipment isready.

Purge Cycle

Note: The engine uses an energize-to-run system.The gas shutoff valve must remain energized inorder to supply fuel to the engine.

The purge cycle allows any unburned fuel to exitthrough the exhaust before the engine is allowedto fire.

The purge cycle occurs under these conditions:

• The gas shutoff valve is de-energized.

• The ignition is off.

• The engine is cranked.

The purge cycle occurs before the crank cycle. Theamount of time for the purge cycle is programmable.

Cycle Crank Time

The maximum amount of time for activation of thestarting motor and the gas shutoff valve for startingis the cycle crank time. The amount of time isprogrammable. The cycle crank time is only activefor automatic starting.

Rest Cycle

If the engine does not start within the cycle cranktime, starting is suspended for a rest cycle. Theamount of time for the rest cycle is equal to thecycle crank time. The overcrank time is only activefor automatic starting.

35Operation Section

Engine Starting

Overcrank Time

The overcrank time includes the total purge cycle,the total cycle crank time, and the total rest cycle.These functions are repeated until termination ofthe overcrank time.

If the engine does not start within the overcranktime, the engine control module generates an eventcode.

Manual Starting

1. Ensure that fuel is supplied to the engine.

2. Ensure that the driven equipment is unloaded.For generator set engines, ensure that the maincircuit breaker is open.

NOTICEDo not engage the starting motor when flywheel isturning. Do not start the engine under load.

If the engine fails to start within 30 seconds, releasethe starter switch or button and wait two minutes toallow the starting motor to cool before attempting tostart the engine again.

3. Start the engine.

The crank terminate speed is programmable.When the engine rpm exceeds the crankterminate speed, the engine control moduledisengages the starting motor.

4. Allow the engine speed to stabilize at low idlerpm. Check all of the pressure gauges. Inspectthe engine for leaks and listen for unusual noises.When all systems are normal, the rpm may beincreased.

Table 6

Rated RPM And Low Idle RPM

Rated rpm 1000 1200 1400 1500 1800

Low idle rpm 700 900 1000 1000 1200

i01489256

Starting with Jump StartCablesSMCS Code: 1000; 1401; 1402; 1900

Improper jump start cable connections can causean explosion resulting in personal injury.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jump startcable ends to contact each other or the engine.

If the installation is not equipped with a backupbattery system, it may be necessary to start theengine from an external electrical source.

NOTICEUsing a battery source with the same voltage as theelectric starting motor. Use ONLY equal voltage forjump starting. The use of higher voltage will damagethe electrical system.

Do not reverse the battery cables. The alternator canbe damaged. Attach ground cable last and removefirst.

When using an external electrical source to start theengine, turn the engine control switch to the “OFF” po-sition. Turn all electrical accessories OFF before at-taching the jump start cables.

Ensure that the main power switch is in the OFF posi-tion before attaching the jump start cables to the en-gine being started.

1. Turn the start switch to the OFF position. Turnoff all accessories.

2. Connect one positive end of the jump start cableto the positive cable terminal of the dischargedbattery. Connect the other positive end of thejump start cable to the positive cable terminalof the electrical source.

3. Connect one negative end of the jump start cableto the negative cable terminal of the electricalsource. Connect the other negative end of thejump start cable to the engine block or to thechassis ground. This procedure helps to preventpotential sparks from igniting combustible gasesthat are produced by some batteries.

4. Start the engine.


5. Immediately after the stalled engine is started,disconnect the jump start cables in reverse order.

Note: If there is a problem with the alternator or thebattery charger, the engine will not continue to runafter starting.

i01598214

After Starting EngineSMCS Code: 1000

For new installations and engines that are recentlyrebuilt, carefully monitor the engine in order todetect any unusual engine performance.

After all systems are stabilized and normal, theengine rpm can be increased from low idle rpm torated rpm.

Engines that use pipeline natural gas are capableof ramping to full load in 30 seconds or less.

It may be necessary to apply some load in order toattain normal operating temperatures.

Engaging the Driven Equipment

1. Increase the engine speed to rated rpm.

2. Ensure that the outlet temperature of the jacketwater reaches 77 �C (170 �F). Ensure that thegauges are in the normal ranges for the enginerpm.

3. Close the main circuit breaker in order to applythe load.

37Operation SectionEngine Operation

Engine Operation

i01489264

Engine OperationSMCS Code: 1000

Proper operation and maintenance are key factorsin attaining the maximum service life and economyfor the engine. Follow the instructions in thisOperation and Maintenance Manual in order tominimize operating costs and maximize the servicelife of the engine.

Observe the gauges or the Electronic Technicianservice tool (ET) frequently while the engine isoperating. Record the data from the gauges in a log.Include the parameters that are listed in Table 7.Average the data that is recorded during operationand record the average values for each day.Compare the data to the specifications for normalengine operation. Comparing the data over time willhelp to detect trends in engine performance.

Table 7

Engine Performance

Operator Date

Engine serial number Hour meter

Load RPM

Coolant temperature Oil pressure

Oil filterdifferential pressure

Air filterdifferential pressure

Inletmanifold pressure

Inletmanifold temperature

Exhausttemperature

Exhaustpressure

Investigate any significant change in the gaugereadings. Monitor the engine operation and takeaction when discrepancies are found.

Operating the Engine and theDriven Equipment

Check the gauges and the driven equipmentfrequently while the engine is operating under aload. The engine can be operated continuously atfull load.

Partial Load Operation

Extended operation at low idle or at a reduced loadwill cause increased oil consumption and carbonbuildup in the cylinders. Carbon buildup results inthe following effects:

• Narrow margin for detonation

• Power loss

• Poor performance

• Accelerated wear of components

Caterpillar Engines can be operated at very lightloads for limited times with no harmful effects. Table8 lists the limits for hours of operation at variousloads.

After the time limit for reduced load operationhas expired, operate the engine for a minimum oftwo hours at a load that is more than 70 percentof the rated load.

For example, an engine is operating at 20 percentof the rated load. The engine may be operated atthis load factor for a maximum of one-half hour. Afterthe one-half hour, operate this engine for at leasttwo hours at a load factor of more than 70 percent.

To help keep engine maintenance at a minimum,follow the guidelines that are listed in Table 8.

Table 8

Time Limits For Low Load Operation

Engine Load Time Limit

0 to 30 percent 1/2 hour

31 to 50 percent 2 hours

51 to 100 percent Continuous (1)

(1) For continuous operation, the manifold air pressure must begreater than the atmospheric pressure.

38Operation SectionEngine Stopping

Engine Stopping

i01452769

Emergency StoppingSMCS Code: 1000; 7418

NOTICEEmergency shutoff controls are for EMERGENCY useONLY. DO NOT use emergency shutoff devices orcontrols for normal stopping procedure.

Emergency Stop Button


“EMERGENCY STOP” button on the junction box

The emergency stop button is in the OUT positionfor normal engine operation. For an emergencystop, press the emergency stop button. Thisshuts off both the fuel and the ignition.

Ensure that any system that provides externalsupport to the engine is secured after the engineis stopped.

NOTICEDo not start the engine until the problem necessitatingthe emergency stop has been located and corrected.

The engine will not restart when the button islocked. To reset the button, pull the button or turnthe button clockwise. The spring-loaded button willreturn to the OUT position.

The control system must also be reset before theengine will start. Turn the engine control switch tothe “OFF/RESET” position.

The customer may also provide other means foremergency stopping. For instructions on operation,refer to the literature that is provided by the originalequipment manufacturer.

Unplanned Shutdowns

Abnormal operating conditions may cause anengine shutdown. The fuel will be shut off, but theignition may not be shut off.

An indication of the cause will be generated bythe engine control module. The event code orthe diagnostic code can be obtained with anelectronic service tool (ET). For more informationon event codes and diagnostic codes, refer toTroubleshooting.

39Operation Section

Engine Stopping

i01489266

Manual Stop ProcedureSMCS Code: 1000; 7418

NOTICEStopping the engine immediately after the engine hasbeen operating under a load can result in overheatingand accelerated wear of the engine components.

Allow the engine to gradually cool before stopping theengine.

There may be several different methods of stoppingthe engine. Be sure that the engine stoppingprocedure is understood. Follow the instructionsthat are provided by the OEM of the control panel.

Note: Remove the load at a rate that will avoiddetonation.

1. Reduce the load to zero.

2. Open the main circuit breaker.

Note: Extended idling can cause excessive oilconsumption and related problems. Refer toOperation and Maintenance Manual, “EngineOperation” (Operation Section).

3. Reduce the engine rpm to low idle.

Note: If the cooldown feature is not utilized, operatethe engine at low idle rpm for a cooldown periodbefore stopping the engine. If the engine has beenoperated at a high load, operate the engine at lowidle until the engine systems stabilize. For example,wait until the speed of the turbochargers is reduced.

4. Stop the engine according to the instructions thatare provided by the OEM of the control panel.

If the cooldown feature is utilized, the engine willoperate for a programmed period of time beforethe engine stops. This allows the turbochargersto slow down. After the cooldown, the enginewill shut off.

The engine will coast to a stop. Ensure that anysystem that provides external support to the engineis secured after the engine is stopped.

i00662051

After Stopping EngineSMCS Code: 1000

• Check the engine crankcase oil level. Maintainthe oil level between the “ADD” and “FULL”marks on the “ENGINE STOPPED” side of the oillevel gauge.

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

• Note the service hour meter reading. Perform themaintenance that is scheduled in this Operationand Maintenance Manual, “Maintenance IntervalSchedule” (Maintenance Section).

NOTICEOnly use antifreeze/coolant mixtures recommended inthe Coolant Specifications of this manual. Failure to doso can cause engine damage.

• Allow the engine to cool. Check the coolant level.

• If freezing temperatures are expected, checkthe coolant for protection against freezing. Thecooling system must be protected against freezingto the lowest expected outside temperature. Addthe proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on alldriven equipment. Refer to the instructions thatare provided by the OEM of the driven equipment.

40Maintenance SectionTorque Specifications

Maintenance Section

Torque Specifications

i01252954

General Torque InformationSMCS Code: 1000; 7553

Mismatched or incorrect fasteners can result indamage or malfunction, or personal injury.

Take care to avoid mixing metric dimensioned fas-teners and inch dimensioned fasteners.

Exceptions to these torques are given in the ServiceManual, if necessary.

Prior to installation of any hardware, ensure thatcomponents are in near new condition. Bolts andthreads must not be worn or damaged. Threadsmust not have burrs or nicks. Hardware must befree of rust and corrosion. Clean the hardware witha noncorrosive cleaner. Do not lubricate the fastenerthreads except for the rust preventive. The rustpreventive should be applied by the supplier of thatcomponent for purposes of shipping and storage.Other applications for lubricating components mayalso be specified in the Service Manual.

i00621350

Standard Torque for MetricFastenersSMCS Code: 1000; 7553

Table 9

Metric Nuts and Bolts

Thread SizeMetric Standard Torque

M6 12 ± 3 N·m (9 ± 2 lb ft)

M8 28 ± 7 N·m (21 ± 5 lb ft)

M10 55 ± 10 N·m (41 ± 7 lb ft)

M12 100 ± 20 N·m (75 ± 15 lb ft)

M14 160 ± 30 N·m (120 ± 22 lb ft)

M16 240 ± 40 N·m (175 ± 30 lb ft)

M20 460 ± 60 N·m (340 ± 44 lb ft)

M24 800 ± 100 N·m (590 ± 75 lb ft)

M30 1600 ± 200 N·m (1180 ± 150 lb ft)

M36 2700 ± 300 N·m (2000 ± 220 lb ft)

Table 10

Metric Taperlock Studs

Thread SizeMetric Standard Torque

M6 8 ± 3 N·m (6 ± 2 lb ft)

M8 17 ± 5 N·m (13 ± 4 lb ft)

M10 35 ± 5 N·m (26 ± 4 lb ft)

M12 65 ± 10 N·m (48 ± 7 lb ft)

M16 110 ± 20 N·m (80 ± 15 lb ft)

M20 170 ± 30 N·m (125 ± 22 lb ft)

M24 400 ± 60 N·m (300 ± 44 lb ft)

M30 750 ± 80 N·m (550 ± 60 lb ft)

M36 1200 ± 150 N·m (880 ± 110 lb ft)


i00621349

Standard Torque for InchFastenersSMCS Code: 1000; 7553

Table 11

Inch Nuts and Bolts

Thread SizeInch Standard Torque

1/4 12 ± 3 N·m (9 ± 2 lb ft)

5/16 25 ± 6 N·m (18 ± 4 lb ft)

3/8 47 ± 9 N·m (35 ± 7 lb ft)

7/16 70 ± 15 N·m (50 ± 11 lb ft)

1/2 105 ± 20 N·m (75 ± 15 lb ft)

9/16 160 ± 30 N·m (120 ± 22 lb ft)

5/8 215 ± 40 N·m (160 ± 30 lb ft)

3/4 370 ± 50 N·m (275 ± 37 lb ft)

7/8 620 ± 80 N·m (460 ± 60 lb ft)

1 900 ± 100 N·m (660 ± 75 lb ft)

1 1/8 1300 ± 150 N·m (960 ± 110 lb ft)

1 1/4 1800 ± 200 N·m (1320 ± 150 lb ft)

1 3/8 2400 ± 300 N·m (1780 ± 220 lb ft)

1 1/2 3100 ± 350 N·m (2280 ± 260 lb ft)

Table 12

Inch Taperlock Studs

Thread SizeInch Standard Torque

1/4 8 ± 3 N·m (6 ± 2 lb ft)

5/16 17 ± 5 N·m (13 ± 4 lb ft)

3/8 35 ± 5 N·m (26 ± 4 lb ft)

7/16 45 ± 10 N·m (33 ± 7 lb ft)

1/2 65 ± 10 N·m (48 ± 7 lb ft)

5/8 110 ± 20 N·m (80 ± 15 lb ft)

3/4 170 ± 30 N·m (125 ± 22 lb ft)

7/8 260 ± 40 N·m (190 ± 30 lb ft)

1 400 ± 60 N·m (300 ± 44 lb ft)

1 1/8 525 ± 60 N·m (390 ± 44 lb ft)

1 1/4 750 ± 80 N·m (550 ± 60 lb ft)

1 3/8 950 ± 125 N·m (700 ± 90 lb ft)

1 1/2 1200 ± 150 N·m (880 ± 110 lb ft)

i01206505

Standard Torque for WormDrive Band Hose ClampsSMCS Code: 1000; 7553; 7554


Table 13

Width of Clamp Initial Installation TorqueOn New Hose

7.9 mm (0.31 inch) 0.9 ± 0.2 N·m (8 ± 2 lb in)

13.5 mm (0.53 inch) 4.5 ± 0.5 N·m (40 ± 4 lb in)

15.9 mm (0.63 inch) 7.5 ± 0.5 N·m (65 ± 4 lb in)

Width of Clamp Reassembly or RetighteningTorque

7.9 mm (0.31 inch) 0.7 ± 0.2 N·m (6 ± 2 lb in)

13.5 mm (0.53 inch) 3.0 ± 0.5 N·m (27 ± 4 lb in)

15.9 mm (0.63 inch) 4.5 ± 0.5 N·m (40 ± 4 lb in)

i01394891

Standard Torque for ConstantTorque Hose ClampsSMCS Code: 1000; 7553; 7554

Use a constant torque hose clamp in place of anystandard hose clamp. Ensure that the constanttorque hose clamp is the same size as the standardhose clamp. Due to extreme temperature changes,the hose will heat set. Heat setting can cause hoseclamps to loosen. Loose hose clamps can resultin leaks. There have been reports of componentfailures that have been caused by hose clamps thathave loosened. The constant torque hose clamp willhelp prevent these failures.



Use a torque wrench for proper installation of theconstant torque hose clamps. The constant torquehose clamp is installed correctly under the followingconditions:

• Screw tip (1) extends 6.35 mm (0.25 inch) (X)beyond the housing.

• The belleville washers are collapsed nearlyflat after screw (2) is tightened to a torque of11 ± 1 N·m (98 ± 9 lb in).

43Maintenance Section

Lubricant Specifications


i01489301

Lubricant InformationSMCS Code: 1000; 1300; 7581

Engine oil performs several functions:

• Keeping the engine clean

• Preventing rust and corrosion

• Acting as a coolant

• Reducing friction and wear

Engines that use gaseous fuel require oils that areformulated with additives that are specific to theseengines.

No industry standards define the performancespecifications of oils for engines that use gaseousfuels. Field tests must be used in order to determineoils that are acceptable. To aid in oil selection,guidelines are provided in this Operation andMaintenance Manual.

i01489518

Engine OilSMCS Code: 1300; 1348; 7581

Caterpillar Oils have been developed and tested inorder to provide the full performance and servicelife that has been designed and built into CaterpillarEngines. These oils are offered by Caterpillardealers. Consult your Caterpillar dealer for moreinformation on these oils.

Due to significant variations in the quality and inthe performance of commercially available oils,Caterpillar makes the following recommendation:

• Caterpillar Natural Gas Engine Oil (NGEO)

Caterpillar NGEO has been tested throughoutthe world in demanding environments. CaterpillarNGEO has been tested in engines that use all typesof gaseous fuel. The formulation of the oil has beenproven to be superior to many brands of oil thatare locally available.

For maximum service life of the engine and theengine oil, use Caterpillar NGEO with low sulfurgaseous fuels that contain less than 0.43 mg H2S/MJ(.45 µg H2S/Btu).

Caterpillar NGEO may also be used with high sulfurnatural gas and with bio-gas. Bio-gas is formed inlandfills and sewage digesters. The use of thesefuels may require a shorter oil change interval.

Caterpillar NGEO is formulated and blended withspecial additives in order to provide protectionagainst oxidation and nitration. Caterpillar NGEOalso has thermal stability.

Caterpillar NGEO also provides the followingbenefits:

• Reduction of the formation of carbon and sludge

• Resistance to foaming

• Protection against corrosion

• Protection of valves and valve seats

• Improved cleanliness of pistons

• Protection against scoring of the pistons andscuffing of the pistons

• Protection against cylinder liner wear

For the properties of Caterpillar NGEO,refer to Operation and Maintenance Manual,SEBU6400, “Caterpillar Gas Engine LubricantRecommendations”.

Commercial Oils

Industry standards do not exist for engines thatoperate on gaseous fuels. The performance oflubrication oil for gas engines is determined bya field test. Successful field operation has beenachieved with oils that meet the guidelines that areexplained in Operation and Maintenance Manual,SEBU6400, “Caterpillar Gas Engine LubricantRecommendations”.

NOTICEFailure to follow these oil recommendations can causeshortened engine service life due to deposits and/orexcessive wear.

NOTICECaterpillar recommends the use of oils that are formu-lated specifically for heavy duty spark ignited gaseousfueled engines. Oils that are formulated for gasolineengines only or for diesel engines only should not beused.

44Maintenance SectionLubricant Specifications

Field Evaluation of Oil

Caterpillar recommends oils for gas engines whichhave met the requirements of the Field EvaluationTest. Refer to Operation and Maintenance Manual,SEBU6400, “Field Evaluation of Commercial Oil” fordetails on the field evaluation test.

Lubricant ViscosityRecommendations

The proper SAE viscosity grade of oil is determinedby the minimum ambient temperature duringcold engine start-up, and the maximum ambienttemperature during engine operation. To determinethe oil viscosity that is required for starting a coldsoaked engine, refer to the minimum temperature inTable 14. To select the oil viscosity for operation atthe highest anticipated ambient temperature, referto the maximum temperature in Table 14. Use thehighest oil viscosity that is available in order to meetthe required temperature during start-up.

Table 14

Engine Oil Viscosity

Ambient TemperatureCaterpillarNGEO

Grade ofViscosity

Minimum Maximum

SAE 30 0 �C (32 �F) 40 �C (104 �F)

SAE 40 5 �C (41 �F) 50 �C (122 �F)

Note: Caterpillar NGEO is available in these gradesonly. Multigrade oils are NOT recommended foruse in Caterpillar Gas Engines. If other grades ofviscosity are selected, ensure that the oil meetsthe requirements for Caterpillar Gas Engines.Refer to Operation and Maintenance Manual,SEBU6400, “Caterpillar Gas Engine LubricantRecommendations”. Consult the supplier of theoil.

i01113615

Hydraulic OilSMCS Code: 1264; 1348; 4250; 4300; 5050; 5095;

6300; 7007; 7568; 7581

Note: Multigrade oil is NOT recommended for usein the Hydrax actuator.

For the Hydrax actuator, use the same single gradeoil that is used in the engine.

i01489947

S·O·S Oil AnalysisSMCS Code: 1348; 7542-008

Caterpillar recommends the S·O·S oil analysisprogram in order to monitor the condition of theoil and the maintenance requirements of theengine. The S·O·S program is part of the preventivemaintenance program.

The S·O·S oil analysis includes these tests:

• The Wear Rate Analysis monitors wear bydetecting, identifying and assessing the amountand the type of wear metal that is in the oil. Theincrease in the rate of engine wear metal in theoil is as important as the quantity of engine wearmetal in the oil. For this reason, regular samplingat specified intervals is necessary in order toestablish wear rates. Intermittent sampling doesnot allow wear rate trend lines to be established.Engine wear metals in the oil sample arecompared to established Caterpillar norms inorder to determine acceptability. Potential failurescan be identified when the wear rate and/or thecontaminants exceed the established trend.

• Tests are conducted in order to detectcontamination of the oil by water and/or glycol.

• The Oil Condition Analysis determines the lossof the oil’s lubricating properties. An infraredanalysis is used to compare the properties ofnew oil to the properties of the used oil sample.This analysis allows technicians to determine theamount of deterioration of the oil during use.

The test results of the oil samples will then be usedas a basis for determining the oil change intervalfor the engine. The results of the S·O·S oil analysismay enable the engine to operate longer betweenoil changes without the risk of damage.

Obtain each oil sample when the oil is warm andwell mixed in order to ensure that the sample isrepresentative of the oil in the engine crankcase.

Oil analysis is essential in order to determinesatisfactory performance of the oil.

Refer to Special Publication, PEDP7036, “S·O·SFluid Analysis” for more information.

Consult your Caterpillar dealer for completeinformation and assistance about the program.



Condemning Limits of the Oil

Oil analysis is the only method of determining ifan oil is protecting the engine. The oil analysisis compared to limits that have been establishedthrough experience.

The condemning limits for lubrication oil weredeveloped from experience with engine operationand from the analysis of used oil. The limits provideguidelines for determining the useful service life ofthe engine oil. Table 15 lists the limits for the servicelife of the oil.

Table 15

S·O·S Oil AnalysisCondemning Limits

Parameter Limit

Oxidation 100% defined by theS·O·S Oil Analysis

Nitration 100% defined by theS·O·S Oil Analysis

Water 0.5% maximum

Glycol 0%

Silicon (Bio-gas) 25 ppm

Wear Metals Based on Caterpillarnorms and on the trend ofthe Wear Rate Analysis(1)

Additional Oil Analysis

Viscosity at 100 �C (212 �F)by “ASTM D445”

Increase of 3 cSt fromnew oil

Total acid number (TAN) by“ASTM D664”

3.0 maximum TAN or2.0 greater TAN than

the new oil

Total base number by“ASTM D2896”

50% of new oil TBN

(1) A trend can be established from the results of three oil analyses.

46Maintenance SectionFuel Specifications

Fuel Specifications

i01489573

Fuel RecommendationsSMCS Code: 1280

General Fuel Information

Gaseous fuels consist primarily of hydrocarbons andsome inert gases. Pipeline natural gas and propanegas have been used for many years. Other types offuels such as wellhead, bio-gas, and manufacturedgas must be reviewed for acceptability.

Each commercial fuel gas is a mixture of gases. Thecompositions of these gas mixtures have extremevariations.

Caterpillar Gas Engines will operate successfullyon a broad range of gaseous fuels. Adjustmentsmust be made to the fuel system when the fuel ischanged. Consult your Caterpillar dealer about theproper adjustments.

Fuels must be analyzed in order to determine thefollowing characteristics:

• Composition

• Specific gravity

• Low heat value

• Methane number

The fuel analysis enables the requirements for thefollowing parameters to be established:

• Ignition timing

• Rated load

• Compression ratio

A fuel’s potential for detonation is indicated by amethane number. The methane number of any gas(fuel) can be determined with the following method:

1. Obtain a fuel analysis of the gas.

2. Enter the data from the fuel analysis into theCaterpillar Software Program, LEKQ6378,“Methane Number Program”.

This software program calculates the fuel’s methanenumber and the low heat value.

The methane number and the appropriate EnginePerformance, “Fuel Usage Guide” are used fordetermining the following parameters:

• Compression ratio

• Ignition timing

• Rated load

For a detailed explanation of methane numbers,refer to Application and Installation Guide,LEKQ7256, “Fuels/Fuel Systems”.

For information on fuel usage, consult yourCaterpillar dealer.

Dry Natural Gas

Dry natural gas is a mixture of methane, ethane,propane, and butane. Dry natural gas may alsohave traces of heavier hydrocarbons.

The Low Heat Value (LHV) of a gas is the highheat value (HHV) minus the heat that is required tovaporize the water that is formed by combustion.For more information on heat values, refer toApplication and Installation Guide, LEKQ7256,“Fuels/Fuel Systems”.

The heat value of dry natural gases may vary.This depends on the composition of the gas. Drynatural gas usually has an LHV that is between33.53 to 34.65 kJ/L (900 to 930 Btu/ft3). CaterpillarGas Engines are adjusted at the factory with a drynatural gas that is within this range.

For dry natural gas, the acceptable limit of hydrogensulfide is 0.43 mg H2S/MJ (.450 µg H2S/Btu).

Propane

NOTICEPropane and blends of propane will cause detonationin high compression engines. Do not use propane orblends of propane in high compression engines.

Propane is transported to a site as a liquid. Theliquid is converted into a gas at the site. Someregulations do not permit the use of liquid propaneinside of a facility. Review the local building codesbefore final plans are made for a propane system.

For the guidelines in this Operation andMaintenance Manual, propane must meet theseHD-5 specifications:

• 95 percent propane


Fuel Specifications

• Remaining 5 percent is not heavier than butane.

HD-5 propane can be used in all naturally aspiratedengines. Turbocharged engines can run on propanefuels. In either case, the engine must be properlyequipped for the use of propane. The use of pistonswith a low compression ratio and a derating isrequired.

Consult your Caterpillar dealer before operatingyour gas engine with this fuel.

HD-5 propane has an LHV between2427 to 2532 kJ/0.305 m3 (2300 to 2400 Btu/ft3).This is between two and three times the LHV ofprocessed dry natural gas.

Mixtures of Propane and Air

Mixtures of propane and air have an LHV thatis approximately the same LHV of natural gas.Mixtures of propane and air are generally usedas a standby fuel for occasions when the flow ofnatural gas is interrupted. Mixtures of propane andair require the ignition timing, the rated load, andthe compression ratio that is required by propane.Some derating may be required in order to usethis fuel. Consult your Caterpillar dealer beforeoperating the engine with this fuel.

Gaseous Fuel Filters

The customer is responsible for supplying clean,dry fuel to the engine.

Fuel filters are no less important than air filters toprotect gas engines from dirt and debris. A properfuel filter removes impurities that can damage theinternal components of the engine.

The gas must be supplied to the engine at apressure that is acceptable. For optimum operation,use a fuel filter that is properly sized for the gaspressure.

To prevent particles from entering the engine, installa one micron fuel filter 1 m (3 ft) before the fuelmetering valve.

Consult your Caterpillar dealer about therequirements for filtering your engine’s fuel.

48Maintenance SectionCooling System Specifications

Cooling SystemSpecifications

i01452811

General Coolant InformationSMCS Code: 1350; 1395

NOTICENever add coolant to a hot engine. Engine damagecould result. Allow the engine to cool first.

NOTICEIf the engine is to be stored in, or shipped to an areawith below freezing temperatures, the cooling systemmust be either protected to the lowest outside temper-ature or drained completely to prevent damage.

NOTICEIn cold weather, frequently check the specific gravityof the coolant solution to ensure adequate protection.

Clean the cooling system for the following reasons:

• Contamination of the cooling system

• Overheating of the engine

• Foaming of the coolant

Note: Air pockets can form in the cooling system ifthe cooling system is filled at a rate that is greaterthan 20 L (5 US gal) per minute.

After you drain the cooling system and after you refillthe cooling system, operate the engine without thefiller cap until the coolant reaches normal operatingtemperature and the coolant level stabilizes. Ensurethat the coolant is maintained to the proper level.

NOTICENever operate an engine without water temperatureregulators in the cooling system. Water temperatureregulators help to maintain the engine coolant at theproper operating temperature. Cooling system prob-lems can develop without water temperature regula-tors.

Refer to Special Instruction, SEBD0518, “KnowYour Cooling System” and Special Instruction,SEBD0970, “Coolant and Your Engine” for moredetailed information.

Many engine failures are related to the coolingsystem. The following problems are related tocooling system failures: overheating, leakage of thewater pump, plugged radiators or heat exchangers,and pitting of the cylinder liners.

These failures can be avoided with proper coolingsystem maintenance. Cooling system maintenanceis as important as maintenance of the fuel systemand the lubrication system. Quality of the coolantis as important as the quality of the fuel and thelubricating oil.

Coolant is normally composed of three elements:water, additives, and glycol.

Water

Water is used in the cooling system in order totransfer heat.

NOTICENever use water alone without Supplemental CoolantAdditive (SCA) or without conditioned coolant. Wa-ter alone is corrosive at engine operating tempera-tures. Water alone does not provide adequate protec-tion against boiling or freezing.

Distilled water or deionized water isrecommended for use in engine cooling systems.

DO NOT use the following types of water in coolingsystems: hard water, softened water that has beenconditioned with salt, and sea water.

If distilled water or deionized water is not available,use water with the characteristics that are listed inTable 16.

Table 16

Caterpillar Minimum Acceptable Water Requirements

Property Maximum Limit ASTM Test

Chloride (Cl) 40 mg/l(2.4 grains/US gal)

“D512”,“D4327”

Sulfate (SO4)100 mg/l

(5.9 grains/US gal) “D516”

Total Hardness 170 mg/l(10 grains/US gal) “D1126”

Total Solids 340 mg/l(20 grains/US gal) “D1888”

Acidity pH of 5.5 to 9.0 “D1293”

For a water analysis, consult one of the followingsources:

• Caterpillar dealer


Cooling System Specifications

• Local water utility company

• Agricultural agent

• Independent laboratory

Additives

Additives help to protect the metal surfaces ofthe cooling system. A lack of coolant additivesor insufficient amounts of additives enable thefollowing conditions to occur:

• Corrosion

• Formation of mineral deposits

• Rust

• Scale

• Pitting and erosion from cavitation of the cylinderliner


Many additives are depleted during engineoperation. These additives must be replacedperiodically. This can be done by addingSupplemental Coolant Additives (SCA) to DieselEngine Antifreeze/Coolant (DEAC).

Additives must be added at the properconcentration. Overconcentration of additives cancause the inhibitors to drop out-of-solution. Thedeposits can enable the following problems tooccur:

• Formation of gel compounds

• Reduction of heat transfer

• Leakage of the water pump seal

• Plugging of radiators, coolers, and smallpassages

Glycol

Glycol in the coolant helps provide protectionagainst the following conditions:

• Boiling

• Freezing

• Cavitation of the water pump and the cylinder liner

For optimum performance, Caterpillar recommendsa 1:1 mixture of a water/glycol solution.

Note: Use a mixture that will provide protectionagainst the lowest ambient temperature.

Note: 100 percent pure glycol will freeze at atemperature of −23 �C (−9 �F).

Most conventional heavy-duty coolant/antifreezesuse ethylene glycol. Propylene glycol may also beused. In a 1:1 mixture with water, ethylene andpropylene glycol provide similar protection againstfreezing and boiling. Refer to Tables 17 and 18.

Table 17

Ethylene Glycol

Concentration FreezeProtection

BoilProtection

50 Percent −36 �C (−33 �F) 106 �C (223 �F)

60 Percent −51 �C (−60 �F) 111 �C (232 �F)

NOTICEDo not use propylene glycol in concentrations that ex-ceed 50 percent glycol because of propylene glycol’sreduced heat transfer capability. Use ethylene glycolin conditions that require additional protection againstboiling or freezing.

Table 18

Propylene Glycol

Concentration FreezeProtection

Anti-BoilProtection

50 Percent −29 �C (−20 �F) 106 �C (223 �F)

To check the concentration of glycol, use the1U-7298 Coolant/Battery Tester (Degree Celsius)or use the 1U-7297 Coolant/Battery Tester (DegreeFahrenheit). The testers give readings that areimmediate and accurate. The testers can be usedwith ethylene or propylene glycol.

i01452829

Coolant RecommendationsSMCS Code: 1350; 1352; 1395

NOTICEDo not use a commercial coolant/antifreeze that onlymeets the ASTM D3306 or D4656 specification. Thistype of coolant/antifreeze is made for light duty auto-motive applications.

The following coolants are the primary types ofcoolants that are used in Caterpillar Gas Engines:


Preferred – Caterpillar Diesel EngineAntifreeze/Coolant (DEAC) or a commercialheavy-duty coolant/antifreeze that meets “ASTMD4985” or “ASTM D5345” specifications

Acceptable – A mixture of Caterpillar SupplementalCoolant Additive and water that has the acceptablecharacteristics

Caterpillar recommends a 1:1 mixture of water andglycol. This mixture will provide optimum heavy-dutyperformance as a coolant/antifreeze.

Note: Caterpillar DEAC DOES NOT require atreatment with an SCA at the initial fill. Commercialheavy-duty coolant/antifreeze that meets “ASTMD4985” or “ASTM D5345” specifications MAYrequire a treatment with an SCA at the initial fill.Read the label or the instructions that are providedby the OEM of the product.

In those engine applications that do not requireprotection from boiling or freezing, a mixtureof SCA and water is acceptable. Caterpillarrecommends a minimum of six percent to amaximum of eight percent SCA concentration inthose cooling systems. Distilled water or deionizedwater is preferred. Water which has the acceptablecharacteristics may be used. For the acceptablecharacteristics, see this publication, “GeneralCoolant Information” topic (Maintenance Section).

Note: Table 19 is a list of the coolants that arerecommended and the service life (calendar) ofthe coolants. The service life of coolant is alsolimited by use (service hours). Refer to the specificengine’s Operation and Maintenance Manual,“Maintenance Interval Schedule” (MaintenanceSection). To achieve this service life, the coolantsmust be properly maintained. The maintenanceprogram includes S·O·S coolant analysis.

Table 19

Coolant Service Life

Coolant Type Service Life (1)

Caterpillar DEAC Three Years

Commercial Heavy-DutyCoolant/Antifreeze thatmeets “ASTM D5345”

Two Years

Commercial Heavy-DutyCoolant/Antifreeze thatmeets “ASTM D4985”

One Year

Caterpillar SCA andWater Two Years

Commercial SCA andWater One Year

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

i01111753

Diesel Engine Antifreeze/Coolant (DEAC)SMCS Code: 1350; 1352; 1395

Caterpillar recommends using CaterpillarDiesel Engine Antifreeze/Coolant (DEAC) forcooling systems that require a heavy-dutycoolant/antifreeze. Caterpillar DEAC is an alkalinesingle-phase ethylene glycol type antifreeze thatcontains corrosion inhibitors and antifoam agents.

Caterpillar DEAC is formulated with the correctamount of Caterpillar Supplemental Coolant Additive(SCA). Do no use SCA at the initial fill when DEACis used.

Containers of several sizes are available. Consultyour Caterpillar dealer for the part numbers.

If concentrated DEAC is used, Caterpillarrecommends mixing the concentrate with distilledwater or with deionized water. If distilled water isnot available or deionized water is not available,use water which has the required properties. Forthe water properties, see this publication, “GeneralCoolant Information” topic (Maintenance Section).



i01164588

Commercial Heavy-DutyCoolant/Antifreeze and SCASMCS Code: 1350; 1352; 1395

If Caterpillar DEAC is not used, select acoolant/antifreeze with low silicate content forheavy-duty applications that meets “ASTM D5345”or “ASTM D4985” specifications.

Note: When you are not using Caterpillar DEAC thecooling system must be drained one time duringevery year. The cooling system must be flushed atthis time as well.

When a heavy-duty coolant/antifreeze is used,treat the cooling system with three to sixpercent Caterpillar SCA by volume. For moreinformation, see this publication, “ConventionalCoolant/Antifreeze Cooling System Maintenance”topic (Maintenance Section).

If Caterpillar SCA is not used, select a commercialSCA. The commercial SCA must provide a minimumof 1200 mg/L or 1200 ppm (70 grains/US gal) ofnitrites in the final coolant mixture.

Coolant/antifreeze that meets “ASTM D5345” or“ASTM D4985” specifications MAY require treatmentwith SCA at the initial fill. These coolants WILLrequire treatment with SCA on a maintenance basis.

When concentrated coolant/antifreeze is mixed,Caterpillar recommends mixing the concentrate withdistilled water or with deionized water. If distilledwater or deionized water is not available, waterwhich has the required properties may be used. Forthe water properties, see this publication, “GeneralCoolant Information” topic (Maintenance Section).

i01069295

Supplemental Coolant Additive(SCA)SMCS Code: 1350; 1352; 1395

The use of SCA helps to prevent the followingconditions from occurring:

• Corrosion


• Cavitation erosion of the cylinder liners


Caterpillar Diesel Engine Antifreeze/Coolant (DEAC)is formulated with the correct level of CaterpillarSCA. When the cooling system is initially filled withDEAC, adding more SCA is not necessary until theconcentration of SCA has been depleted. To ensurethat the correct amount of SCA is in the coolingsystem, the concentration of SCA must be testedon a scheduled basis. Refer to the specific engine’sOperation and Maintenance Manual, “MaintenanceInterval Schedule”.

Containers of SCA are available in several sizes.Consult your Caterpillar dealer for the part numbers.

i01166959

Conventional Coolant/Antifreeze Cooling SystemMaintenanceSMCS Code: 1350; 1352; 1395

NOTICENever operate an engine without water temperatureregulators in the cooling system. Water temperatureregulators help to maintain the engine coolant at theproper operating temperature. Cooling system prob-lems can develop without water temperature regula-tors.

Check the coolant/antifreeze (glycol concentration)in order to ensure adequate protection againstboiling or freezing. Caterpillar recommends theuse of a refractometer for checking the glycolconcentration. Use the 1U-7298 Coolant/BatteryTester (Celsius) or use the 1U-7297 Coolant/BatteryTester (Fahrenheit). The testers give readings thatare immediate and accurate. The testers can beused with ethylene or with propylene glycol.

Adding the SCA to ConventionalCoolant/Antifreeze at the Initial Fill

Note: Caterpillar DEAC DOES NOT require anaddition of SCA when the cooling system is initiallyfilled.

Commercial heavy-duty coolant/antifreezethat meets “ASTM D4985” or “ASTM D5345”specifications MAY require an addition of SCA whenthe cooling system is initially filled. Read the labelor the instructions that are provided by the OEMof the product.


The size of the cooling system determines theamount of SCA that is required. Use the equationthat is in Table 20 to determine the amount ofCaterpillar SCA that may be required when thecooling system is initially filled with heavy-dutycoolant/antifreeze that meets “ASTM D4985” or“ASTM D5345” specifications.

Table 20

Equation For Adding The SCA At The Initial FillCoolant/Antifreeze That Meets “ASTM D4985”

or “ASTM D5345” Specifications (1)

V × 0.045 = X

V is the total volume of the cooling system.

X is the amount of SCA that is required.

(1) Read the label or the instructions that are provided by the OEMof the product.

Table 21 is an example for using the equation thatis in Table 20.

Table 21

Example of the Equation For Adding TheSCA At The Initial Fill

Coolant/Antifreeze That Meets “ASTM D4985”or “ASTM D5345” Specifications

Total Volumeof the Cooling

System (V)

Factor forMultiplication

Amount of SCAthat is Required

(X)

946 L(250 US gal)

× 0.045 43 L(11 US gal)

Adding the SCA to ConventionalCoolant/Antifreeze ForMaintenance

Heavy-duty coolant/antifreeze of all types REQUIREperiodic additions of an SCA.

Test the coolant/antifreeze periodically for theconcentration of SCA. For the interval, see thespecific engine’s Operation and MaintenanceManual, “Maintenance Interval Schedule”(Maintenance Section). SCA test kits are availablefrom your Caterpillar dealer. Test the concentration ofSCA or submit a coolant sample to your Caterpillardealer. For more information on coolant analysis,see the Operation and Maintenance Manual, “S·O·SCoolant Analysis” topic (Maintenance Section).

Additions of SCA are based on the results of thetest or based on the results of the coolant analysis.The size of the cooling system determines theamount of SCA that is needed.

Use the equation that is in Table 22 to determinethe amount of Caterpillar SCA that is required.

Table 22

Equation For Adding The SCA To ConventionalCoolant/Antifreeze For Maintenance

V × 0.014 = X




Table 23

Example Of The Equation For Adding The SCA ToConventional Coolant/Antifreeze For Maintenance


System (V)



(X)

946 L(250 US gal)

× 0.014 13 L(3.5 US gal)

Note: Specific engine applications may requiremaintenance practices to be periodically evaluatedin order to properly maintain the engine’s coolingsystem.

Table 24 lists part numbers and quantities of SCAthat is available from your Caterpillar dealer.

Table 24

Caterpillar Liquid SCA

Part Number Quantity

8C-3680 19 L (5 US gal)

5P-2907 208 L (55 US gal)

Cleaning the Cooling System ofHeavy-Duty Coolant/Antifreeze

Caterpillar Cooling System Cleaner dissolvesmineral scale, corrosion products, light oilcontamination and sludge.

• Clean the cooling system after used coolant isdrained or before the cooling system is filled withnew coolant.

• Clean the cooling system whenever the coolant iscontaminated or whenever the coolant is foaming.



i01314838

Water/Supplemental CoolantAdditive (SCA)SMCS Code: 1350; 1352; 1395

NOTICETo help prevent water pump cavitation, Caterpillar rec-ommends a minimum of 30 percent of glycol in thecoolant/antifreeze mixture.

Use a mixture that will provide protection against thelowest ambient temperature.

100 percent pure glycol will freeze at a temperature of−13 �C (9 �F).

NOTICENever use water alone without Supplemental CoolantAdditives (SCA) or without inhibited coolant. Wateralone is corrosive at engine operating temperatures.Water alone does not provide adequate protectionagainst boiling or freezing.

Do not use water alone as an engine coolant.Supplemental Coolant Additive (SCA) helps toprevent the following conditions from occurring:

• Corrosion


• Cavitation of the cylinder liner


If Caterpillar SCA is not used, select a commercialSCA. The commercial SCA must provide a minimumof 2400 mg/L or 2400 ppm (140 grains/US gal) ofnitrites in the final coolant mixture.

The quality of the water is a very important factorin this type of cooling system. Distilled water ordeionized water is recommended for use in coolingsystems. If distilled water or deionized water is notavailable, water that has the required propertiesmay be used. For the water properties, see thisOperation and Maintenance Manual, “GeneralCoolant Information” topic (Maintenance Section).

A cooling system that uses a mixture of only SCAand water requires more SCA than a cooling systemthat uses a mixture of glycol and water. The SCAand water requires six to eight percent of SCA.

Adding the SCA to Water at theInitial Fill

The capacity of the cooling system determines theamount of SCA that is required. Use the equationthat is in Table 25 to determine the amount ofCaterpillar SCA that is required at the initial fill. Thisequation is for a mixture of only SCA and water.

Table 25

Equation For Adding The SCA To WaterAt The Initial Fill

V × 0.07 = X




Table 26

Example Of The Equation For Adding The SCATo Water At The Initial Fill


System (V)



(X)

946 L(250 US gal)

× 0.07 66 L(18 US gal)

Adding the SCA to Water forMaintenance

Test the mixture of SCA and water periodically forthe concentration of SCA. For the interval, seethe specific engine’s Operation and MaintenanceManual, “Maintenance Interval Schedule”(Maintenance Section).

Test the concentration of SCA with the 8T-5296Coolant Conditioner Test Kit or with S·O·S coolantanalysis. For more information on coolant analysis,see this Operation and Maintenance Manual, “S·O·SCoolant Analysis” topic (Maintenance Section).

Instructions are provided with the 8T-5296Coolant Conditioner Test Kit. Make the followingmodifications to Steps 3 and 5 of the instructions.These modifications are needed for mixtures of SCAand water:

STEP 3 – Add tap water to the vial up to the “20ml” mark.


STEP 5 – When the defined procedure is used,a concentration of six to eight percent will yieldbetween 20 drops and 27 drops. If the number ofdrops is below 20 drops, the concentration of SCAis low. If the number of drops is above 27 drops, theconcentration of SCA is high. Make the appropriateadjustments to the concentration of SCA.

Additions of SCA are based on the results of thetest or based on the results of the coolant analysis.The capacity of the cooling system determines theamount of SCA that is required.

Use the equation that is in Table 27 to determinethe amount of Caterpillar SCA that is required.

Table 27

Equation For Adding the SCA To WaterFor Maintenance

V × 0.023 = X




Table 28

Example Of The Equation For Adding the SCATo Water For Maintenance


System (V)



(X)

946 L(250 US gal)

× 0.023 22 L(6 US gal)

Note: Specific engine applications may requiremaintenance practices to be periodically evaluatedin order to properly maintain the engine’s coolingsystem.

Table 29 lists part numbers and quantities of SCAthat is available from your Caterpillar dealer.

Table 29

Caterpillar Liquid SCA

Part Number Quantity

8C-3680 19 L (5 US gal)

5P-2907 208 L (55 US gal)

i01069690

S·O·S Coolant AnalysisSMCS Code: 1350; 1352; 1395

Testing the engine coolant is important to ensurethat the engine is protected from internal cavitationand from corrosion. The analysis also tests theability of the coolant to protect the engine fromboiling and from freezing.

Coolant analysis can be performed at yourCaterpillar dealership. Caterpillar’s S·O·S coolantanalysis is an excellent way to monitor the conditionof your coolant and your cooling system.

The most critical aspect of coolant analysis isthe interpretation of the results. The analyst mustbe properly trained in order to provide a correctdiagnosis. The analyst must understand severalvariables.

Different coolants have different formulations anddifferent condemning limits. Different commerciallabs may use different methods to test for thesame variable. These other considerations are alsoimportant for interpreting the results of a coolantanalysis:

• The number of hours on the sample

• The equipment that uses the coolant

• The application of the equipment

Analysts at Caterpillar’s S·O·S fluid labs are trainedto determine the acceptability of coolants. Theseanalysts have knowledge of the equipment andapplications. These qualifications enable theanalysts to detect problems before damage occurs.

NOTICEDo not use the same vacuum sampling pump for ex-tracting oil samples that is used for extracting coolantsamples.

A small residue of either type sample may remain inthe pump and may cause a false positive analysis forthe sample being taken.

Always use a designated pump for oil sampling and adesignated pump for coolant sampling.

Failure to do so may cause a false analysis whichcould lead to customer and dealer concerns.



Caterpillar’s S·O·S coolant analysis is a programwith two levels. The program is based on periodicsamples. The samples are analyzed. The resultsare reported, and appropriate recommendations aremade according to the results.

S·O·S Coolant Analysis (Level I)

A coolant analysis (Level I) is a test of the propertiesof the coolant that includes the following items:

• Glycol concentration for protection from boilingand freezing

• Ability to protect from erosion and corrosion

• pH

• Conductivity

• Water hardness

• Visual analysis

• Analysis of the odor

The results are reported, and appropriaterecommendations are made.

S·O·S Coolant Analysis (Level II)

A coolant analysis (Level II) is a comprehensivechemical evaluation of the coolant. This analysis isalso a check of the overall condition of the insideof the cooling system. The following services areprovided:

• Full Level I analysis

• Identification of the source of metal corrosion andof contaminants

• Identification of buildup of the impurities thatcause corrosion

• Identification of buildup of the impurities thatcause scaling

• Determination of possible electrolysis within theengines’ cooling system

The results are reported, and appropriaterecommendations are made.

For more information on S·O·S coolant analysis,consult your Caterpillar dealer.

56Maintenance SectionRefill Capacities

Refill Capacities

i01453173

Refill CapacitiesSMCS Code: 1000; 1348; 1395; 7560

Lubrication System

The capacity of the Engine Crankcase includes thecapacity of the oil filters that are installed at thefactory. Auxiliary oil filter systems (if equipped) willrequire additional oil.

For the recommended oil, refer to this Operationand Maintenance Manual, “Engine Oil” topic(Maintenance Section).

Table 30

Approximate Refill Capacity for the G3516BEngine Lubrication System

Compartment or System Liters US Gallons

Engine Crankcase 423 112

Capacity of the ElectrohydraulicActuator’s System

Table 31

Approximate Refill Capacity for the ElectrohydraulicActuator’s System


Hydraulic Oil Tank 5.7 1.51

Cooling System

To properly maintain the cooling system, the TotalCooling System capacity must be determined. TheTotal Cooling System capacity will vary betweenindividual installations. The External Systemcapacity can include the following components:expansion tank, heat exchanger, radiator, andpiping. Record the Total Cooling System capacityin the appropriate Table.

For the recommended coolant, refer to thisOperation and Maintenance Manual, “CoolantRecommendations” (Maintenance Section).

Table 32

Approximate Refill Capacities for the G3516BEngine Cooling System


Jacket Water System Only 205 53

SCAC System Only 16.5 4.35

External System

Total Cooling System


Maintenance Interval Schedule

i01606256

Maintenance Interval ScheduleSMCS Code: 1000; 7500

Before performing any operation or maintenanceprocedures, ensure that the Safety Information,warnings, and instructions are read andunderstood.

Before each consecutive interval is performed, allof the maintenance requirements from the previousinterval must be performed.

Note: For information on generator maintenance,refer to the Operation and Maintenance Manual forthe generator.

When Required

Electrohydraulic System Oil Filter - Change ......... 71Engine Air Cleaner Element - Replace ................. 72Engine Oil Filter - Change .................................... 79Fumes Disposal Filter Element - Replace ............ 86Ignition System Spark Plugs - Replace ................ 92Overhaul Considerations .................................... 101Valve Stem Projection - Measure/Record ........... 105

Daily

Air Starting Motor Lubricator Oil Level - Check .... 60Air Tank Moisture and Sediment - Drain ............... 60Control Panel - Inspect ......................................... 62Cooling System Coolant Level - Check ................ 65Driven Equipment - Inspect/Replace/Lubricate ... 70Electrohydraulic System - Inspect ......................... 70Engine Air Cleaner Service Indicator - Inspect ..... 74Engine Oil Level - Check ...................................... 80Fuel System Fuel Filter Differential Pressure -Check .................................................................. 85

Fumes Disposal Filter Differential Pressure -Check .................................................................. 85

Walk-Around Inspection ...................................... 107

Initial 250 Service Hours

Crankcase Blowby - Measure/Record .................. 67Cylinder Pressure - Measure/Record ................... 69Engine Oil Sample - Obtain .................................. 81Valve Stem Projection - Measure/Record ........... 105

Every 250 Service Hours

Battery Electrolyte Level - Check .......................... 62


Fumes Disposal Filter - Drain ............................... 85

Initial 1000 Service Hours

Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 66

Engine Speed/Timing Sensor - Clean/Inspect ...... 82Valve Stem Projection - Measure/Record ........... 105


Aftercooler Condensation - Drain ......................... 59Alternator - Inspect ............................................... 61Alternator and Fan Belts - Inspect/Adjust/Replace ............................................................... 61

Crankcase Pressure - Measure ............................ 68Crankshaft Vibration Damper - Inspect ................. 68Engine Crankcase Breather - Clean ..................... 75Engine Oil - Change ............................................. 77Engine Oil Filter - Change .................................... 79Engine Oil Sample - Obtain .................................. 81Engine Valve Lash - Inspect/Adjust ...................... 83Exhaust Piping - Inspect ....................................... 84Gas Pressure Regulator Condensation - Drain .... 86Hoses and Clamps - Inspect/Replace .................. 87Ignition System Spark Plugs - Check/Adjust/Replace ............................................................... 88

Ignition System Timing - Check/Adjust ................. 95Inlet Air System - Inspect ...................................... 95Oxygen Sensor - Calibrate ................................. 103Radiator - Clean .................................................. 103


Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 66

Engine Speed/Timing Sensor - Clean/Inspect ...... 82


Ignition System Spark Plugs - Replace ................ 92


Air Starting Motor Lubricator Bowl - Clean ........... 59Crankcase Blowby - Measure/Record .................. 67Cylinder Pressure - Measure/Record ................... 69Driven Equipment - Check .................................... 70Electrohydraulic System Oil - Change .................. 71Electrohydraulic System Oil Filter - Change ......... 71Engine Mounts - Check ........................................ 77Engine Protective Devices - Check ....................... 82Exhaust Bypass - Inspect ..................................... 84Fuel Metering Valve Screen - Check .................... 84Starting Motor - Inspect ...................................... 104Water Pump - Inspect ......................................... 108


Cooling System Coolant Analysis (Level II) -Obtain ................................................................. 65

Fumes Disposal Filter Element - Replace ............ 86Turbocharger - Inspect ........................................ 104Water Temperature Regulator - Replace ............ 108

58Maintenance SectionMaintenance Interval Schedule

Between 10 000 and 20 000 Service Hours

Overhaul (Top End) ............................................... 99

Every 24 000 Service Hours or 3 Years

Cooling System Coolant (DEAC) - Change .......... 62


Overhaul (In-Frame) ............................................. 96


Overhaul (Major) ................................................... 97


Aftercooler Condensation - Drain

i01453210

Aftercooler Condensation -DrainSMCS Code: 1063

The air/fuel mixture that is compressed and warmedby the turbocharger compressor is directed throughthe aftercooler core. The air/fuel mixture is cooled inthe aftercooler.

Condensation can form in the housing of theaftercooler. A drain plug is provided for drainingthe condensation.

Note: An automatic drain is available for use with32� C (90 �F) separate circuit aftercoolers. Consultyour Caterpillar dealer for details.


Drain plug

Remove the drain plug. Drain the moisture into asuitable container. Install the plug.

i01490186

Air Starting Motor LubricatorBowl - CleanSMCS Code: 1451-070

Personal injury can result from removing hoses orfittings in a pressure system.

Failure to relieve pressure can cause personal in-jury.

Do not disconnect or remove hoses or fittings un-til all pressure in the system has been relieved.

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


(1) Filler plug(2) Bowl(3) Drain valve

2. Slowly loosen filler plug (1) in order to releasethe pressure from the lubricator.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

3. Place a suitable container under bowl (2) andopen drain valve (3) in order to drain the oil fromthe bowl.

4. Remove bowl (2). Clean the bowl with warmwater.

5. Dry the bowl. Inspect the bowl for cracks. If thebowl is cracked, replace the damaged bowl witha new bowl.

6. Install the bowl.

7. Make sure that drain valve (3) is closed. Fill bowl(2) through the hole for filler plug (1).

Use nondetergent “10W” oil for temperatures thatare greater than 0 �C (32 �F). Use air tool oil fortemperatures that are below 0 �C (32 �F).

8. Install filler plug (1).

60Maintenance SectionAir Starting Motor Lubricator Oil Level - Check

9. If necessary, adjust the lubricator in order torelease two drops of oil per 30 seconds. Forinstructions, see this Operation and MaintenanceManual, “Air Starting Motor Lubricator Oil Level -Check” topic (Maintenance Section).

i01490193

Air Starting Motor LubricatorOil Level - CheckSMCS Code: 1451-535

NOTICENever allow the lubricator bowl to become empty. Theair starting motor will be damaged by a lack of lubrica-tion. Ensure that sufficient oil is in the lubricator bowl.


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




2. Ensure that the air supply to the lubricator is OFF.Slowly loosen filler plug (4) in order to releasepressure from the lubricator bowl.

3. Remove filler plug (4). Pour oil into thelubricator bowl. Use nondetergent “10W” oil fortemperatures that are greater than 0 �C (32 �F).Use air tool oil for temperatures that are below0 �C (32 �F).

4. Install filler plug (4).

Adjust the Lubricator

Note: Adjust the lubricator with a constant rate of airflow. After the adjustment, the lubricator will releaseoil in proportion to variations of the air flow.

1. Ensure that the fuel supply to the engine is OFF.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

2. Operate the air starting motor. Observe the dropsof oil that are released in dome (1).

Note: Some lubricators have an adjustment screwrather than a knob.

3. If necessary, adjust the lubricator in order torelease two drops of oil per 30 seconds. Toincrease the rate, turn knob (2) counterclockwise.To decrease the rate, turn the knob clockwise.

i00351324

Air Tank Moisture andSediment - DrainSMCS Code: 1466-543-M&S

Moisture and sediment in the air starting systemcan cause the following conditions:

• Freezing

• Corrosion of internal parts

• Malfunction of the air starting system

When opening the drain valve, wear protectivegloves, a protective face shield, protective cloth-ing, and protective shoes. Pressurized air couldcause debris to be blown and result in personalinjury.

1. Open the drain valve that is on the bottom ofthe air tank. Allow the moisture and sedimentto drain.

2. Close the drain valve.


Alternator - Inspect

i00839754

Alternator - InspectSMCS Code: 1405-040

Inspect the alternator for the following conditions:


• Proper charging of the battery

Observe the ammeter during engine operation inorder to ensure proper battery performance and/orproper performance of the electrical system.

Make repairs, if necessary. See the Service Manualfor service procedures. Consult your Caterpillardealer for assistance.

i01368836

Alternator and Fan Belts -Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510; 1405

Inspection

Inspect the alternator belt and the fan drive belts forwear and for cracking. Replace the belts if the beltsare not in good condition.

Check the belt tension according to the informationin the Service Manual, “Specifications”.

Slippage of loose belts can reduce the efficiencyof the driven components. Vibration of loose beltscan cause unnecessary wear on the followingcomponents:

• Belts

• Pulleys

• Bearings

If the belts are too tight, unnecessary stress isplaced on the components. This reduces theservice life of the components.

Replacement

For applications that require multiple drive belts,replace the drive belts in matched sets. Replacingone drive belt of a matched set will cause the newdrive belt to carry more load because the olderdrive belts are stretched. The additional load on thenew drive belt could cause the new drive belt to fail.

Alternator Belt Adjustment


(1) Adjusting nuts(2) Mounting bolt

1. Remove the drive belt guard.

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

3. Turn adjusting nuts (1) in order to increase ordecrease the drive belt tension.

4. Tighten adjusting nuts (1). Tighten mounting bolt(2).

5. Reinstall the drive belt guard.

If new drive belts are installed, check the drive belttension again after 30 minutes of engine operationat the rated rpm.

Fan Drive Belt Adjustment

1. Loosen the mounting bolt for the pulley.

2. Loosen the adjusting nut for the pulley.

3. Move the pulley in order to adjust the belttension.

4. Tighten the adjusting nut.

5. Tighten the mounting bolt.

62Maintenance SectionBattery Electrolyte Level - Check

i01206348

Battery Electrolyte Level -CheckSMCS Code: 1401-535-FLV

When the engine is not run for long periods oftime or when the engine is run for short periods,the batteries may not fully recharge. Ensure a fullcharge in order to help prevent the battery fromfreezing. If batteries are properly charged, ammeterreading should be very near zero.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

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

If the addition of water is necessary, use distilledwater. If distilled water is not available useclean water that is low in minerals. Do not useartificially softened water.

2. Check the condition of the electrolyte with the1U-7298 Coolant/Battery Tester (�C) or the1U-7297 Coolant/Battery Tester (�F).

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• A mixture of 0.1 L (0.11 qt) of baking soda and1 L (1 qt) of clean water

• A mixture of 0.1 L (0.11 qt) of ammonia and1 L (1 qt) of clean water

Thoroughly rinse the battery case with cleanwater.

Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fitproperly. Coat the clamps and the terminals with5N-5561 Silicone Lubricant, petroleum jelly orMPGM grease.

i00709765

Control Panel - InspectSMCS Code: 4490-040; 7451-040

Inspect the condition of the panel. If a componentis damaged, ensure that the component is repairedor that the component is replaced. Ensure that theelectronic displays are operating properly.

Inspect the wiring for good condition. Ensure thatthe wiring connections are secure.

Record the Data and Review theData

Check the gauges and indicators frequentlyduring normal operation. Record the data in alog. Compare the new data to the data that waspreviously recorded. Comparing the new data tothe recorded data will establish the normal gaugereadings for the engine. A gauge reading that isabnormal may indicate a problem with operationor with the gauge.

i01453299

Cooling System Coolant(DEAC) - ChangeSMCS Code: 1350-044

Clean the cooling system before the recommendedmaintenance interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

NOTICEUse of commercially available cooling system clean-ers may cause damage to cooling system compo-nents. Use only cooling system cleaners that are ap-proved for Caterpillar engines.

Draining the Cooling System

Stop the engine and allow the engine to cool.Ensure that the engine will not start when thecooling system is drained.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Service TechnologyGroup:


Cooling System Coolant (DEAC) - Change

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

Draining the Jacket Water

1. Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.


Locations of the drain plugs

(1) Oil cooler(2) Cylinder block


(3) Drain plug in the elbow before the water pump on the frontof the engine

Note: If the engine is equipped with a jacket waterheater, a water line will be installed in the locationof drain plug (2).

2. Open the cooling system drain valves (ifequipped). If the cooling system is not equippedwith drain valves, remove drain plugs (1), (2),and (3).

Drain the coolant from the bottom of the jacketwater heater (if equipped).

Draining the Separate Circuit


(1) Vent plug on the aftercooler

A heat exchanger or a radiator is provided by thecustomer for the separate circuit aftercooler. Eachside of the aftercooler has vent plug (1). Removethe vent plugs. Remove the cooling system fillercap and drain the water from the heat exchangeror the radiator.

Clean the Cooling System

1. After the cooling system has been drained, flushthe cooling system with clean water in order toremove any debris.

2. Close the cooling system drain valves (ifequipped). Clean the drain plugs and install thedrain plugs.

NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

64Maintenance SectionCooling System Coolant (DEAC) - Change


(1) Vent plug on the aftercooler

NOTICEIf the aftercooler circuit has been drained, the ventplug must be opened to allow the aftercooler to fillproperly. Failure to do this will cause an air lock re-sulting in engine damage.

3. When the separate circuit is filled, be sure toremove vent plugs (1) from the aftercooler.

4. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add .5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap. Install vent plugs(1).

5. Start the engine. Operate the engine fora minimum of 30 minutes with a coolanttemperature of at least 82 �C (180 �F).

6. Stop the engine and allow the engine to cool. Forthe jacket water and the separate circuit, loosenthe cooling system filler cap slowly in order torelieve any pressure. Remove the cooling systemfiller cap. Open the cooling system drain valves(if equipped) or remove the drain plugs. Removethe vent plugs from the aftercooler.

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

7. Allow the water to drain. Flush the cooling systemwith clean water until the water that drains isclean. Close the cooling system drain valves (ifequipped). Clean the drain plugs and install thedrain plugs.

Cleaning a Cooling System thathas Heavy Deposits or Plugging

Note: For the following procedure to be effective,there must be an active flow through the coolingsystem components.

1. After the cooling system has been drained, flushthe cooling system with clean water in order toremove any debris.

2. Close the cooling system drain valves (ifequipped). Clean the drain plugs and install thedrain plugs.

3. Remove the vent plugs from the aftercooler.

4. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting CoolingSystem Cleaner. Add .5 L (1 pint) of cleaner per3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity. Install the cooling system filler cap.Install vent plugs into the aftercooler.

5. Start the engine. Operate the engine fora minimum of 90 minutes with a coolanttemperature of at least 82 �C (180 �F).

6. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the coolingsystem drain valves (if equipped) or removethe drain plugs. Remove the vent plug from theaftercooler. Allow the water to drain.

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

7. Flush the cooling system with clean water untilthe water that drains is clean. Close the coolingsystem drain valves (if equipped). Clean thedrain plugs and install the drain plugs.


Cooling System Coolant Analysis (Level II) - Obtain

Fill the Cooling System

NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

Note: For information about the proper coolantto use, refer to this Operation and MaintenanceManual, “Coolant Recommendations” (MaintenanceSection). For the capacity of the cooling system,refer to this Operation and Maintenance Manual,“Refill Capacities” (Maintenance Section).

1. Remove the vent plugs from the aftercooler.

2. Fill the cooling system with coolant/antifreeze.Install the vent plugs for the aftercooler. Do notinstall the cooling system filler cap yet.

3. Start the engine. Operate the engine in orderto purge the air from the cavities of the engineblock. Allow the coolant to warm and allow thecoolant level to stabilize. Stop the engine.

4. Check the coolant level. Maintain the coolant tothe proper level on the sight gauge (if equipped).If a sight gauge is not equipped, maintain thecoolant within 13 mm (.5 inch) below the bottomof the filler pipe.

5. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets of the cooling system filler cap aredamaged, discard the old cooling system fillercap and install a new cooling system filler cap.

6. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i01065859

Cooling System CoolantAnalysis (Level II) - ObtainSMCS Code: 1350

For conventional heavy-duty coolant/antifreeze,check the concentration of supplemental coolantadditive (SCA) regularly. The concentration of SCAcan be checked with an S·O·S coolant analysis(Level I). A more detailed coolant analysis isrecommended periodically.

For example, considerable deposits are found in thewater jacket areas on the external cooling system,but the concentrations of coolant additives werecarefully maintained. The coolant water probablycontained minerals which were deposited on theengine over time.

A coolant analysis can be conducted in order toverify the condition of the water that is being usedin the cooling system. A full water analysis may beobtained from the following sources:

• Caterpillar dealer

• Local water utility company

• Agricultural agent

• Independent laboratory

Caterpillar recommends an S·O·S coolant analysis(Level II). This is a comprehensive chemicalevaluation of the coolant. This analysis is also acheck of the overall condition of the inside of thecooling system. The following services are provided:

• Full Level I analysis

• Identification of the source of metal corrosion andof contaminants

• Identification of buildup of the impurities thatcause corrosion

• Identification of buildup of the impurities thatcause scaling

• Determination of possible electrolysis within theengines’ cooling system

A report of the results of the analysis is provided.Maintenance recommendations are based on theresults.

For more information about S·O·S coolant analysis,consult your Caterpillar dealer.

i01453521

Cooling System Coolant Level- CheckSMCS Code: 1350-535-FLV

Climbing equipment may be required to accessthis service point. Refer to the Operation andMaintenance Manual, “Mounting and Dismount-ing” topic for safety information.

66Maintenance SectionCooling System Supplemental Coolant Additive (SCA) - Test/Add

NOTICEOverfilling the overflow tank (if equipped) will result indamage to the cooling system.

If the cooling system has an overflow tank, maintainthe coolant level in the tank below 1/2 full in order toavoid damage to the cooling system.


Normal position of the coolant in the sight gauge during ratedoperation

Observe the coolant level in the sight gauge (ifequipped). When the engine is running at normaloperating temperature, the coolant should be in theupper half of the sight gauge. If the coolant level islow, add the proper coolant mixture.

If the cooling system does not have a sight gauge,maintain the coolant level within 13 mm (0.5 inch) ofthe bottom of the filler pipe.

Add Coolant

Note: For the proper coolant mixture to use, seethis Operation and Maintenance Manual, “CoolantRecommendations” topic (Maintenance Section).

1. Stop the engine. Allow the engine to cool.

2. Remove the cooling system filler cap slowly inorder to relieve any pressure. Pour the propercoolant mixture into the filler pipe.


Filler cap gaskets

3. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets are damaged, replace the old coolingsystem filler cap with a new cooling system fillercap. Install the cooling system filler cap.

4. Start the engine. Inspect the cooling system forleaks.

i01065856

Cooling System SupplementalCoolant Additive (SCA) -Test/AddSMCS Code: 1352-045; 1395-081

This maintenance procedure is required forconventional coolants such as DEAC and formixtures of water and SCA. This maintenance isNOT required for cooling systems that are filledwith Extended Life Coolant.

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and eyes. Do not drink cooling systemcoolant additive.

Note: Test the concentration of the SCA or obtain anS·O·S coolant analysis (Level I).

Test the Concentration of the SCA

Coolant/Antifreeze and SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.


Crankcase Blowby - Measure/Record

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit or the 4C-9301 CoolantConditioner Test Kit. Follow the instructions that areon the label of the test kit.

Water and SCA

NOTICEDo not exceed the recommended eight percent sup-plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Follow the instructionsthat are in this Operation and Maintenance Manual,“Water/Supplemental Coolant Additive (SCA)” topic(Maintenance Section).

S·O·S Coolant Analysis (Level I)

Level I is a basic analysis of the coolant. Thefollowing items are tested: SCA concentration,glycol concentration, pH, and conductivity.

The results are reported, and recommendationsare made according to the results. Consult yourCaterpillar dealer for information on the benefits ofmanaging your equipment with an S·O·S 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 systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Remove the cooling system filler cap slowly.

Note: Always dispose of fluids according to localregulations.

2. If necessary, drain some coolant in order to allowspace for the addition of the SCA.

NOTICEExcessive supplemental coolant additive concentra-tion can form deposits on the higher temperature sur-faces of the cooling system, reducing the engine’sheat transfer characteristics. Reduced heat transfercould cause cracking of the cylinder head and otherhigh temperature components.

Excessive supplemental coolant additive concentra-tion could also result in blockage of the heat exchang-er, overheating, and/or accelerated wear of the waterpump seal.

Do not exceed the recommended amount of supple-mental coolant additive concentration.

3. Add the proper amount of SCA. Theconcentration of the SCA depends on the typeof coolant that is used.

a. For cooling systems that use conventionalcoolant/antifreeze, see this Operationand Maintenance Manual, “ConventionalCoolant/Antifreeze Cooling SystemMaintenance” topic (Maintenance Section).

b. For cooling systems that use only a mixtureof water and SCA, see this Operation andMaintenance Manual, “Water/SupplementalCoolant Additive (SCA)” topic (MaintenanceSection).

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

i01453542

Crankcase Blowby -Measure/RecordSMCS Code: 1317

Note: For a G3500 Engine that is rated at 1500rpm with 1500 service hours, the typical rangeof the crankcase blowby is 327 to 361 L/min(693 to 765 ft3/hr).

Measure the crankcase blowby of new engines.Record the data. Continue to periodically measurethe blowby. Comparing the recorded data to thenew data provides information about the conditionof the engines.

Note: Crankcase blowby is one of the three factorsthat help to determine the in-frame overhaul interval.For more information, see this Operation andMaintenance manual, “Overhaul (In-Frame)” topic(Maintenance Section).

68Maintenance SectionCrankcase Pressure - Measure

After a new engine is used for a short time, theblowby can decrease as the piston rings areseated. The blowby will gradually increase as thefollowing components show wear:

• Piston rings

• Cylinder liners

Note: A problem with the piston rings causes theoil to deteriorate rapidly. Information regarding thecondition of the piston rings can be obtained fromthe measurement of the blowby and the results ofoil analysis.

The blowby of a worn engine may exceed theblowby of a new engine by two times or more.

A sudden increase in blowby could indicate abroken piston ring. The following conditions areother potential sources of blowby:

• Worn valve guides

• A turbocharger seal that leaks

A rebuilt engine can have a high blowby due to thefollowing factors:

• The piston rings are not seated properly.

• Worn parts such as valve guides were notreplaced.

Excessive blowby may indicate the need for anoverhaul. By keeping a record of the results, agradual increase in the amount of the blowby willbe noted until the amount has become excessive.

To measure the blowby, use the 1U-8860Large Engine Blowby Pickup Group with the8T-2701 Large Engine Blowby Pickup Group. Forinstructions, see Special Instruction, SEHS8984,“Using the 1U-8860 Large Engine Blowby PickupGroup” and Special Instruction, SEHS8712, “Usingthe 8T-2700 Blowby/Air Flow Indicator”.

For assistance, consult your Caterpillar dealer.

i01601829

Crankcase Pressure - Measure(Engines with Fumes DisposalFilters)SMCS Code: 1074

Measure the crankcase pressure during normaloperation.

With a fumes disposal filter that is properly installed,the crankcase pressure will be within 0.25 kPa(1 inch of H2O) of the atmospheric pressure.

i01607700

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040

The crankshaft vibration damper limits the torsionalvibration of the crankshaft. The visconic damperhas a weight that is located inside a fluid filled case.

Damage to the crankshaft vibration damper or failureof the damper can increase torsional vibrations.This can result in damage to the crankshaft and toother engine components. A deteriorating dampercan cause excessive gear train noise at variablepoints in the speed range.

A damper that is hot may be the result of excessivefriction. This could be due to excessive torsionalvibration or misalignment. Monitor the temperatureof the damper during operation.

The 8T-2821 Temperature Indicator or the8T-2822 Temperature Indicator are recommendedfor monitoring the temperature of the damper.Evenly space four of the adhesive indicators aroundthe outer diameter of the damper.

Note: If you use an infrared thermometer to monitorthe temperature of the damper, use the thermometerduring operation with similar loads and speeds.Keep a record of the data. If the temperaturebegins to rise, reduce the interval for inspecting thedamper.

If the temperature of the damper reaches 110 �C(230 �F), consult your Caterpillar dealer.

Inspect the damper for evidence of dents, cracks,and leaks of the fluid.

If a fluid leak is found, determine the type of fluid.The fluid in the damper is silicone. Silicone hasthe following characteristics: transparent, viscous,smooth, and sticky. If leaking silicone is found,repair the damper or replace the damper.

If the fluid leak is oil, inspect the crankshaft seals forleaks. If a leak is observed, replace all of the seals.

Inspect the damper and repair or replace thedamper for any of the following reasons.

• The damper is dented, cracked, or leaking.

• The paint on the damper is discolored from heat.


Cylinder Pressure - Measure/Record

• The engine has had a failure because of a brokencrankshaft.

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

• There is a large amount of gear train wear that isnot caused by a lack of oil.

Removal and Installation

Refer to the Service Manual, “Disassembly andAssebly” or consult your Caterpillar dealer forinformation about damper replacement.

i01617704

Cylinder Pressure -Measure/RecordSMCS Code: 1223-082-CC; 1223; 7450-082

Measure the cylinder pressure of new engines.Record the data. Continue to periodically measurethe cylinder pressure. Comparing the recorded datato the new data provides information about thecondition of the engine.

Note: Cylinder pressure is one of the three factorsthat help to determine the in-frame overhaul interval.For more information, see the Operation andMaintenance manual, “Overhaul (In-Frame)” topic inthe Maintenance Section.

Cylinder pressure can be measured duringinspection of the spark plugs. Use the followingguidelines for checking the cylinder pressure:

• Remove all of the spark plugs.

• Fully open the throttle plate.

• Minimize the cranking time. This will enable amaximum consistent cranking speed for thecheck. Also, the battery power will be conserved.

A loss of cylinder pressure or a change of pressurein one or more cylinders may indicate the followingconditions. These conditions may indicate aproblem with lubrication:

• Excessive deposits

• Guttering of valves

• A broken valve

• A piston ring that sticks

• A broken piston ring

• Worn piston rings

• Worn cylinder liners

If the cylinder pressure has risen by one or morecompression ratios, the engine needs a top endoverhaul in order to remove deposits. Failure toremove the deposits will increase the chance fordetonation. Severe guttering of the valves will occur.

To measure the cylinder pressure, use the193-5859 Cylinder Pressure Gauge Gp. Follow theprocedure in the Special Instruction, NEHS0798that is included with the gauge group. Recordthe pressure for each cylinder. Use the Operationand Maintenance Manual, “Valve Data Sheet”(Reference Materials Section).

Illustration 40 is a graph of typical cylinder pressuresfor engines with different compression ratios.


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

70Maintenance SectionDriven Equipment - Check

i00449093

Driven Equipment - CheckSMCS Code: 3279-535

To minimize bearing problems and vibration ofthe engine crankshaft and the driven equipment,the alignment between the engine and drivenequipment must be maintained properly.

Check the alignment according to the instructionsthat are provided by the following manufacturers:

• Caterpillar

• OEM of the coupling

• OEM of the driven equipment

i00935098

Driven Equipment -Inspect/Replace/LubricateSMCS Code: 3279-040

Observe the driven equipment during operation.Look for the following items:

• Unusual noise and vibration


• Damaged parts

Perform any maintenance that is recommendedby the OEM of the driven equipment. Refer to theliterature of the OEM of the driven equipment for thefollowing service instructions.

• Inspection

• Lubricating grease and lubricating oilrequirements

• Specifications for adjustment

• Replacement of components

• Requirements for ventilation

i01619721

Electrohydraulic System -InspectSMCS Code: 1716-040

Inspect the conditions of these items for theelectrohydraulic system:

• Oil level

• Filter indicator

• Hoses, lines, connections, and components

Check the Oil Level


(1) Sight gauge(2) Indicator

1. Check the oil level in sight gauge (1).

The oil should be between the “ADD” and “FULL”marks on the tank.

Note: For the proper oil to use, refer to thisOperation and Maintenance Manual, “Hydraulic Oil”topic (Maintenance Section).

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

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

Inspect the Filter Indicator

A plugged filter will have excessive differentialpressure. The pressure will cause indicator (2) toenter the red zone.

Inspect the indicator. If the indicator is in thered zone, change the filter. For instructions,refer to this Operation and Maintenance Manual,“Electrohydraulic System Oil Filter - Change” topic(Maintenance Section).


Electrohydraulic System Oil - Change

Inspect the Lines, Connections,and Components

The linkage can move and form a pinch pointwhich can cause personal injury. Keep handsaway from the linkage.

Inspect the hoses and lines for wear and leaks.Ensure that the hoses and lines are properlyclamped. Inspect the connections for leaks. Ensurethat the connections are secure.

Inspect the following items for leaks and goodcondition:

• Actuator

• Pressure relief valve

• Pump

Make repairs, if necessary.

i01619707

Electrohydraulic System Oil -ChangeSMCS Code: 1716-510-OC


(1) Filler cap(2) Drain plug

1. Remove filler cap (1).




2. Place a suitable container under plug (2).Remove the plug. Allow the oil to drain. After theoil has drained, clean the plug. Install the plug.


3. Pour the proper oil into the oil filler. Clean the oilfiller cap. Install the oil filler cap.

4. Clean up any oil that may have spilled.

i01619713

Electrohydraulic System OilFilter - ChangeSMCS Code: 1716-510-FI


(1) Indicator(2) Filter(3) Sight gauge(4) Filler cap

A plugged filter will have excessive differentialpressure. The pressure will cause indicator (1) toenter the red zone. If the indicator is in the redzone, change the filter.

72Maintenance SectionEngine Air Cleaner Element - Replace

1. Remove filter (2) with a 1U-8760 Chain Wrench.

2. Clean the sealing surface of the filter mountingbase. Ensure that all of the old filter gasket isremoved.


Typical filter mounting base and gasket


3. Apply clean oil to the new filter gasket.

4. Install the filter by hand. Tighten the filter until thegasket contacts the mounting base. Tighten thefilter according to the instructions that are shownon the filter. Do not overtighten the filter.

5. Start the engine. Check the oil level in sightgauge (3). The oil should be between the “ADD”and “FULL” marks on the tank. If necessary,remove filler cap (4). Pour the correct oil into theoil filler. Clean the filler cap. Install the filler cap.

i01600805

Engine Air Cleaner Element -ReplaceSMCS Code: 1051-510; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the airpressure can split the filter material of the element.Unfiltered air will drastically accelerate internalengine wear. Your Caterpillar dealer has the properair cleaner elements for your application.

• Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

• Operating conditions (dust, dirt and debris) mayrequire more frequent service of the air cleanerelement.

• The air cleaner element may be cleaned up tosix times if the element is properly cleaned andinspected.

• The air cleaner element should be replacedat least one time per year. This replacementshould be performed regardless of the numberof cleanings.

Replace the dirty paper elements with cleanelements. Before installation, thoroughly inspect theelement for tears and/or holes in the filter material.Inspect the gasket or the seal of the element fordamage. Maintain a supply of suitable elements forreplacement purposes.


Fasteners for the air cleaner cover


Engine Air Cleaner Element - Replace


(1) Cover(2) Element(3) Air inlet

1. Release the fasteners for cover (1).

2. Remove the cover and element (2).

3. Cover air inlet (3) with tape in order to keep dirtout.

4. Clean the inside of the cover and the body witha clean, dry cloth.

5. Remove the tape for the air inlet. Install a newelement or a clean element.

6. Install the cover.

7. If necessary, reset the air cleaner serviceindicator.

Cleaning the Primary Air CleanerElements

The primary air cleaner element can be used upto six times if the element is properly cleaned andinspected. When the element is cleaned, check thefilter material for rips or tears. Replace the elementat least one time per year regardless of the numberof cleanings.

Use clean elements while dirty elements are beingcleaned.

NOTICEDo not clean the air cleaner elements by bumping ortapping. This could damage the seals. Do not use el-ements with damaged pleats, gaskets or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the elements before cleaning.Inspect the elements for damage to the seal, thegaskets, and the outer cover. Discard any damagedelements.

Air cleaner elements can be cleaned withpressurized air and with a vacuum.

Pressurized Air

Pressurized air can be used to clean elementsthat have not been cleaned more than two times.Pressurized air will not remove deposits of carbonand oil. Use filtered, dry air with a maximumpressure of 207 kPa (30 psi).


Note: When the elements are cleaned, always beginwith the clean side (inside) in order to force dirtparticles toward the dirty side (outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the streamof air directly at the primary air cleaner element.Dirt could be forced into the pleats.

Note: Refer to “Inspecting the Primary Air CleanerElements”.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningelements which require daily cleaning because of adry, dusty environment. Cleaning with pressurizedair is recommended prior to vacuum cleaning.Vacuum cleaning will not remove deposits of carbonand oil.

Note: Refer to “Inspecting the Primary Air CleanerElements”.

74Maintenance SectionEngine Air Cleaner Service Indicator - Inspect

Inspecting the Primary Air CleanerElements


Inspect the clean, dry element. Use a 60 watt bluelight in a dark room or in a similar facility. Placethe blue light in the element. Rotate the element.Inspect the element for tears and/or holes. Inspectthe element for light that may show through the filtermaterial. If it is necessary in order to confirm theresult, compare the element to a new element thathas the same part number.

Do not use an element that has any tears and/orholes in the filter material. Do not use an elementwith damaged pleats, gaskets or seals. Discarddamaged elements.

Storing Primary Air Cleaner Elements

If an element that passes inspection will not beused immediately, store the element for future use.


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. Restricted air flowmay result. To protect against dirt and damage,wrap the elements in Volatile Corrosion Inhibited(VCI) paper.

Place the element into a cardboard box for storage.For identification, mark the outside of the containerand mark the element. Include the followinginformation:

• Date of cleaning

• Number of cleanings

Store the container in a dry location.

For more detailed information on cleaning theprimary air cleaner element, refer to SpecialPublication, SEBF8062, “Procedure to Inspect andClean Air Filters”.

i01453640

Engine Air Cleaner ServiceIndicator - InspectSMCS Code: 7452-040

A service indicator may be mounted on the aircleaner element or in a remote location.


Service indicator

Some engines may be equipped with a differentservice indicator.

Observe the service indicator. Clean the air cleanerelement or replace the element when any of thefollowing conditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

• The air restriction reaches 3.75 kPa(15 inches of H2O).


Engine Crankcase Breather - Clean


Service indicator on an air cleaner for crankcase ventilation

Some engines are equipped with an air cleaner forcrankcase ventilation. The air cleaner is mountedon a camshaft cover. Clean the air cleaner elementor replace the element when any of the followingconditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

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

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

Test the Service Indicator

Service indicators are important instruments.

• Apply vacuum (suction) to the service indicator.

• Reset the service indicator.

If the yellow core does not latch at the greatestvacuum, or if service indicator does not reset easily,obtain a new service indicator. If the new serviceindicator will not reset, the fitting for the serviceindicator may be plugged.


Porous filter

A porous filter is part of the fitting that is used formounting of the service indicator. Inspect the filterfor cleanliness. Clean the filter, if necessary. Usecompressed air or a clean, nonflammable solvent.

Note: When service indicator is installed, excessivetightening may crack the top of the service indicator.Tighten the service indicator to a torque of 2 N·m(18 lb in).

Replace the service indicator annually regardless ofthe operating conditions.

i01601554

Engine Crankcase Breather -CleanSMCS Code: 1317-070

Clean the crankcase breather regularly in orderto prevent excessive crankcase pressure that willdamage the engine’s seals.

Perform this maintenance when the engine isstopped.

The cleaning procedure depends on the type ofcrankcase breather.

76Maintenance SectionEngine Crankcase Breather - Clean

Canisters


Crankcase breather (canister)

(1) Wing nuts

1. Remove wing nuts (1) and the covers.

2. Remove the elements and discard the elements.

3. Clean the inside of the breathers’ bodies andthe covers. Inspect the covers’ gaskets for goodcondition.

4. Install new elements.

5. Install the covers with wing nuts (1).

Breather Assemblies


(1) Clamp(2) Tube() Clamp

1. Loosen clamp (1). Slide the clamp down tube (2).

2. Loosen clamps (3). Remove both breathers as aunit.


(4) O-ring seal

3. Remove O-ring seals (4) from the valve covers.Inspect the O-ring seals for good condition.Obtain new O-ring seals, if necessary.


(5) Breather assembly(6) Clamp(7) Hose tee

4. Remove two clamps (6). Remove both breatherassemblies (5) from hose tee (7).

Inspect the hose tee for cracks. If the tee iscracked, discard the old tee and obtain a newtee for installation.

5. Turn the breathers upside-down in order toinspect the condition of the breather elements.

Clean the breather elements with clean,nonflammable solvent. If the breather elementsremain contaminated after the cleaning, discardthe breather assemblies and obtain new breatherassemblies. Do not attempt to disassemble thebreather assemblies.

Allow the breather elements to dry beforeinstallation.


Engine Mounts - Check

Note: Coat the rubber parts with clean engine oil orpetroleum jelly in order to make installation easier.

6. Place clamps (6) over the parts of hose tee (7)that will receive breather assemblies (5). Installthe breather assemblies into the tee. Tighten theclamps to the torque that is listed in the ServiceManual, “Specifications”.

7. Coat O-ring seals (4) with clean engine oil. Placethe O-ring seals on the valve covers.

8. Place clamps (3) around the parts of the breatherassemblies that will be attached to the valvecovers. Install both breather assemblies as aunit. Tighten the clamps.

9. Place clamp (1) on the part of the hose tee thatwill receive tube (2). Install the tube into the hosetee. Tighten the clamp to the torque that is listedin the Service Manual, “Specifications”.

i01397742

Engine Mounts - CheckSMCS Code: 1152-535


(1) Mounting bolts for the engine(2) Mounting bolts for the generator(3) Levelling bolts for the isolators

Misalignment of the engine and the drivenequipment will cause extensive damage. Excessivevibration can lead to misalignment. Excessivevibration of the engine and the driven equipmentcan be caused by the following conditions:

• Improper mounting

• Loose bolts

• Deterioration of the isolators

Ensure that the mounting bolts are tightened tothe proper torque. For standard torques, seethe Operation and Maintenance Manual, “TorqueSpecifications” in the Maintenance Section.

Ensure that the isolators are free of oil andcontamination. Inspect the isolators for deterioration.Ensure that the bolts for the isolators are tightenedto the proper torque.

Replace any isolator that shows deterioration. Formore information, see the literature that is providedby the OEM of the isolators. Also see the Applicationand Installation Guide for the engine. Consult yourCaterpillar dealer for assistance.

i01617733

Engine Oil - ChangeSMCS Code: 1348-044; 1348

Hot oil and components can cause personal in-jury.

Do not allow hot oil or components to contact skin.

NOTICEEnsure that the engine is stopped before performingthis procedure. Attach a DO NOT OPERATE tag to thestarting controls.

Drain the crankcase with the engine oil warm,immediately after the engine is stopped. Thisdraining method allows the waste particles that aresuspended in the engine oil to be drained properly.

1. After the engine has been operated at normaloperating temperature, STOP the engine.




2. Drain the engine oil by using one of the followingmethods. Use the method that corresponds tothe equipment on the engine.

Note: If a suction device is used in order to removethe engine oil, ensure that the suction device isclean. This will prevent dirt from entering the engineoil pan. Be careful not to strike the engine oilpump’s suction tubes or the piston cooling jets.

78Maintenance SectionEngine Oil - Change


Location of the drain or plug for the engine oil

a. If the engine has an drain valve, open thevalve. After the engine oil has drained, closethe valve.

b. If the engine has a pump for removing theengine oil, connect one end of the hose to theoutlet of the pump. Place the other end of thehose in a suitable container. Open the valvefor the drain line. Operate the pump until thecrankcase is empty. Close the valve to thedrain line. Disconnect the hose.

c. If the drain valve has a quick connect coupler,attach the coupler. Open the drain valve. Afterthe engine oil has drained, close the drainvalve. Disconnect the coupling.

d. If the engine does not have a drain valve or apump, remove the engine oil drain plug. Afterthe engine oil has drained, clean the drainplug and clean the fitting for the drain plug.Install the drain plug. Tighten the drain plugto 145 ± 15 N·m (105 ± 10 lb ft).

Note: Make sure that all of the used engine oil isremoved. If necessary, remove a side cover andinspect the engine oil pan. Dirty engine oil thatremains in the oil pan will act as a catalyst whichdrastically reduces the service life of the newengine oil. If care is not taken, as much as 95 L(25 US gal) of used engine oil can remain in theengine oil pan.

3. Replace the engine oil filter elements beforefilling the crankcase with new engine oil.

For the procedure to change the engine oil filters,refer to this Operation and Maintenance Manual,“Engine Oil Filter - Change” topic (MaintenanceSection).

NOTICEOnly use oils that are recommended by Caterpillar.For the proper oil to use, refer to this Operation andMaintenance Manual, “Engine Oil” topic (MaintenanceSection).

NOTICEIf the engine is equipped with an auxiliary oil filtersystem, extra oil must be added when filling thecrankcase. If equipped with an auxiliary oil filtersystem that is not supplied by Caterpillar, follow therecommendations of the OEM.

NOTICEEngine damage can occur if the crankcase is filledabove the “FULL” mark on the oil level gauge (dip-stick).

An overfull crankcase can cause the crankshaft to dipinto the oil. This will reduce the power that is devel-oped and also force air bubbles into the oil. Thesebubbles (foam) can cause the following problems: re-duction of the oil’s ability to lubricate, reduction of oilpressure, inadequate cooling, oil blowing out of thecrankcase breathers, and excessive oil consumption.

Excessive oil consumption will cause deposits to formon the pistons and in the combustion chamber. De-posits in the combustion chamber lead to the followingproblems: guttering of the valves, packing of carbonunder the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil levelgauge, drain some of the oil immediately.

Note: For the amount of engine oil to use, refer tothis Operation and Maintenance Manual, “RefillCapacities” (Maintenance Section).


(1) Filler cap(2) Engine oil level gauge (dipstick)


Engine Oil Filter - Change

4. Remove filler cap (1). Fill the crankcase throughthe filler tube only. Clean the filler cap. Installthe filler cap.

NOTICETo prevent crankshaft damage or bearing damage,crank the engine with the fuel supply line closed. Thiswill ensure that all of the oil filters are filled with oil be-fore the engine is started. Do not crank the engine formore than 30 seconds. Allow the starting motor to coolfor two minutes before cranking again.

5. Close the fuel supply line. Crank the engine untilengine oil pressure is indicated on the engineoil pressure gauge. Open the fuel supply line.Allow the starting motor to cool for two minutesbefore cranking again.

6. Follow this Operation and Maintenance Manual,“Starting The Engine” procedure (OperationSection). Start the engine and inspect the enginefor leaks. Ensure that the engine oil level is at the“FULL” mark on the “LOW IDLE” side of engineoil level gauge (2).

i01453731

Engine Oil Filter - ChangeSMCS Code: 1308-510; 1308

Replace the engine oil filters when any of thefollowing conditions are met:

• Every oil change

• The engine oil filter differential pressure reaches100 kPa (15 psi).

• The engine oil filters have been used for 1000operating hours.

Service tools are available to aid in the service ofoil filters. Consult your Caterpillar dealer for the partnames and the part numbers. Follow the instructionsthat are supplied with the service tools. If theservice tools are not used, perform the followingappropriate procedure.

Replacing the Engine Oil FiltersWith the Engine Stopped



Perform the following procedure after the oil hasbeen drained.


(1) Drain(2) Drain valve(3) Plug(4) Bolts(5) Cover

1. Connect a hose to drain (1). Place the other endof the hose into a suitable container in order tocollect the oil.

2. Open drain valve (2). Remove plug (3). Allowthe oil to drain. Clean the plug and install theplug. Close the drain valve. Remove the hosefrom the drain.

Note: Some oil will remain in the housing after theoil has been drained. This oil will pour out of thehousing when cover (5) is removed. Prepare tocatch the oil in a suitable container. Clean up anyspilled oil with absorbent pillows or towels. DO NOTuse absorbent particles to clean up the oil.


Section view

(4) Bolt(5) Cover(6) O-ring seal(7) Oil filter element

80Maintenance SectionEngine Oil Level - Check

3. Remove Bolts (4) and the washers in order toremove cover (5) and O-ring seal (6). Remove oilfilter elements (7).

4. Clean cover (5), O-ring seal (6), and the insideof the oil filter housing.

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

5. Ensure that the new oil filter elements are in goodcondition. Install the new oil filter elements.

6. Inspect O-ring seal (6). Ensure that the surfacesfor the O-ring seal are clean. Install a newO-ring seal if the old O-ring seal is damaged ordeteriorated.

7. Install cover (5) and O-ring seal (6). Ensure thatthe cover’s retainer is properly seated.

8. Start the engine. Check for oil leaks.

9. Check the oil level on the “LOW IDLE” side ofthe oil level gauge. Maintain the oil level betweenthe “ADD” and “FULL” marks on the “LOW IDLE”side of oil level gauge.

Replacing the Engine Oil FiltersDuring Engine Operation

Filter contains hot pressurized fluid when engineis running.

Follow instructions on control valve to avoid per-sonal injury.

If rapid air movement exists to blow fluid, Stop theengine to avoid fire.

If the engine is equipped with duplex oil filters, theengine oil filter elements can be changed whilethe engine is operation. This is useful if the oil filterelements require more frequent replacement thanthe engine oil.

1. Move the control valve to the “AUX RUN” positionin order to change the main oil filter elements.Move the selector valve to the “MAIN RUN”position in order to change the auxiliary oil filterelements.

2. Allow the oil pressure gauge for the oil filter thatis being changed to reach a “ZERO” pressurereading.

3. Perform Step 1 through Step 7 of “Replacing theEngine Oil Filters With the Engine Stopped”.

4. Open the “FILL” valve for a minimum of fiveminutes in order to fill the new oil filter elements.

5. Close the “FILL” valve. Rotate the control valveto the “RUN” position for the oil filter that wasserviced.

Inspect the Used Oil Filter Elements

Cut the used oil filter element open with a utilityknife. Cut the filter element free from the end caps.Spread apart the pleats and inspect the elementfor metal debris. An excessive amount of debris inthe element may indicate early wear or a pendingfailure.

Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are foundin the element. Ferrous metals may indicate wearon the steel and the cast iron parts of the engine.Nonferrous metals may indicate wear on thealuminum parts, the brass parts, or the bronze partsof the engine. Parts that may be affected include thefollowing components: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Pieces of aluminum may indicate problems with thebearings of the front gear train or the rear gear train.If aluminum is found inspect the vibration damperand the idler gear bearings.

Due to normal wear and friction, it is not uncommonto find small amounts of debris in the oil filterelement. If an excessive amount of debris is foundin the oil filter element, consult your Caterpillardealer in order to arrange for further oil analysis.

i01617747

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

The most accurate check of the engine oil level isobtained when the engine is stopped.


Engine Oil Sample - Obtain


(1) Engine oil level gauge (dipstick)(2) Filler cap

1. Remove filler cap (2) in order to ensure that thecrankcase pressure is equal to the atmosphericpressure.

Excess pressure or a slight vacuum will affectengine oil level that is measured.

2. Ensure that engine oil level gauge (1) is seated.


(3) “ENGINE STOPPED WITH OIL COLD” side(4) “ENGINE AT LOW IDLE WITH WARM OIL” side(5) “ADD” mark(6) “FULL” mark

a. If the engine is stopped, remove the engineoil level gauge. Observe the engine oil levelon “ENGINE STOPPED WITH OIL COLD” side(3).

b. If the engine is operating, reduce the enginespeed to low idle. Remove the engine oil levelgauge and observe the engine oil level on“ENGINE AT LOW IDLE WITH WARM OIL”side (4).

The engine oil level should be between “ADD”mark (5) and “FULL” mark (6).

NOTICEEngine damage can occur if the crankcase is filledabove the “FULL” mark on the oil level gauge (dip-stick).

An overfull crankcase can cause the crankshaft to dipinto the oil. This will reduce the power that is devel-oped and also force air bubbles into the oil. Thesebubbles (foam) can cause the following problems: re-duction of the oil’s ability to lubricate, reduction of oilpressure, inadequate cooling, oil blowing out of thecrankcase breathers, and excessive oil consumption.

Excessive oil consumption will cause deposits to formon the pistons and in the combustion chamber. De-posits in the combustion chamber lead to the followingproblems: guttering of the valves, packing of carbonunder the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil levelgauge, drain some of the oil immediately.

3. If necessary, add engine oil. For the correctengine oil to use, refer to this Operationand Maintenance Manual, “Engine Oil” topic(Maintenance Section). Do not fill the crankcaseabove the “FULL” mark on the engine oil levelgauge. Clean the filler cap (2). Install the fillercap.

4. Record the amount of engine oil that is added.For the next engine oil sample and analysis,include the total amount of engine oil that hasbeen added since the previous oil change. Thiswill help to provide the most accurate analysis.

i01534451

Engine Oil Sample - ObtainSMCS Code: 1348-554-SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine.

Obtain the Sample and the Analysis

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

82Maintenance SectionEngine Protective Devices - Check

Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

• Engine model

• Service hours on the engine

• The number of hours that have accumulatedsince the last oil change

• The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of theoil in the crankcase, obtain a warm, well mixed oilsample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.

NOTICEDo not use the same vacuum sampling pump for ex-tracting oil samples that is used for extracting coolantsamples.

A small residue of either type sample may remain inthe pump and may cause a false positive analysis forthe sample being taken.

Always use a designated pump for oil sampling and adesignated pump for coolant sampling.

Failure to do so may cause a false analysis whichcould lead to customer and dealer concerns.

If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEHP6001,“How To Take A Good Oil Sample”. Consult yourCaterpillar dealer for complete information andassistance in establishing an S·O·S program foryour engine.

i00626013

Engine Protective Devices -CheckSMCS Code: 7400-535

Alarms and shutoffs must function properly. Alarmsprovide timely warning to the operator. Shutoffs helpto prevent damage to the engine. It is impossibleto determine if the engine protective devices arein good working order during normal operation.Malfunctions must be simulated in order to test theengine protective devices.

A calibration check of the engine protective deviceswill ensure that the alarms and shutoffs activateat the setpoints. Ensure that the engine protectivedevices are functioning properly.

NOTICEDuring testing, abnormal operating conditions must besimulated.

The tests must be performed correctly in order to pre-vent possible damage to the engine.

To prevent damage to the engine, only authorizedservice personnel or your Caterpillar dealer shouldperform the tests.

Visual Inspection

Visually check the condition of all gauges, sensorsand wiring. Look for wiring and components thatare loose, broken, or damaged. Damaged wiringor components should be repaired or replacedimmediately.

i01617784

Engine Speed/Timing Sensor -Clean/InspectSMCS Code: 1905-040; 1905-070; 1907-040;

1907-070

An engine speed/timing sensor is mounted in theflywheel housing. The speed/timing sensor providesinformation about engine speed and the position ofthe crankshaft to the ECM.


Engine Valve Lash - Inspect/Adjust


1. Remove engine speed/timing sensor (1). Inspectthe condition of the end of the magnet. Look forsigns of wear and contaminants.

2. Clean any debris from the face of the magnet.


3. Check the tension of the sliphead. Gently extendsliphead (2) for a minimum of 4 mm (0.16 inch).Then push back the sliphead.

When the sliphead has the correct tension, atleast 22 N (5 lb) of force is required to push inthe sliphead from the extended position.

NOTICEThe sliphead must be fully extended when the speed/timing sensor is installed so that the sensor maintainsthe correct clearance with the speed-timing wheel.If the correct clearance is not maintained, the signalfrom the sensor will not be generated.

Do not install the sensor between the teeth of thespeed-timing wheel. Damage to the sensor would re-sult. Before installing the sensor, ensure that a toothof the wheel is visible in the mounting hole for the sen-sor.

4. Install the engine speed/timing sensor.

a. Ensure that a tooth on the speed-timing wheelis visible in the mounting hole for the sensor.

b. Extend sliphead (2) by a minimum of 4 mm(0.16 inch).

c. Coat the threads of the sensor with 4C-5597Anti-Seize Compound.

Note: The sliphead is designed to contact a toothduring the first revolution of the speed-timing wheel.For the maximum allowable clearance betweenthe sliphead and the tooth, refer to the engine’sSpecifications manual.

d. Install the sensor. Tighten the locknut tothe torque that is listed in the engine’sSpecifications manual.

i01491682

Engine Valve Lash -Inspect/AdjustSMCS Code: 1102-025

Ignition systems can cause electrical shocks.Avoid contacting the ignition system componentsand wiring.

Do not attempt to remove the valve covers whenthe engine is operating. The transformers aregrounded to the valve covers. Personal injury ordeath may result and the ignition system will bedamaged if the valve covers are removed duringengine operation. The engine will not operatewithout the valve covers.

For procedures on adjusting the valve bridge andthe engine valve lash, see the following publications:

• Special Instruction, REHS0128, “Using the147-5482 Indicator Gauge for Valve Lash andValve Bridge Adjustment”

• Service Manual, “Systems Operation/Testing andAdjusting”

Consult your Caterpillar dealer for assistance.

Valve Bridge

Check the valve bridge and adjust the valve bridge,if necessary. Perform the procedure for both valvebridges for each cylinder.

After the valve bridge for each cylinder issatisfactory, measure the valve lash.

84Maintenance SectionExhaust Bypass - Inspect

Engine Valve Lash

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

If the valve lash is within the tolerance, anadjustment of the valve lash is NOT necessary.

Perform valve lash adjustment if the dimension is notwithin the tolerance. The valve bridge adjustmentmust be performed before making a valve lashadjustment.

Perform the valve lash setting when the engine iscold. After the engine has been shut down and thevalve covers are removed, the engine is consideredcold.

Before performing maintenance, prevent the entryof foreign matter into the top of the cylinder headand the valve mechanism. Thoroughly clean thearea around the valve mechanism covers.

For the valve lash setting, see this Operationand Maintenance Manual, “Specifications” topic(Product Information Section).

i01491702

Exhaust Bypass - InspectSMCS Code: 1057-040

The exhaust bypass valve cover is under springcompression. To prevent personal injury, use cau-tion when removing the cover.

The exhaust bypass valve must be removed inorder to be inspected. For instructions on removaland assembly, see the engine’s Disassembly andAssembly and Specifications.

Inspect the exhaust bypass valve for binding andexcess play. Inspect the valve stem and valve guidefor wear. Inspect the diaphragm for good condition.Clean the breather with nonflammable solvent. Ifany parts are worn or damaged, replace the parts.

After assembly and installation of the exhaustbypass, adjust the exhaust bypass according tothe engine’s Testing and Adjusting instructions inorder to help obtain the desired turbocharger boostpressure.


i01003546

Exhaust Piping - InspectSMCS Code: 1061-040

Hot engine components can cause injury fromburns. Before performing maintenance on theengine, allow the engine and the components tocool.

Inspect the components of the exhaust system.Repair the components or replace the componentsfor any of the following conditions:

• Damage

• Cracks

• Leaks


For information on removal and installation, seethe Service Manual, “Disassembly and Assembly”module. Consult your Caterpillar dealer forassistance.

i01454081

Fuel Metering Valve Screen -CheckSMCS Code: 1741-535

1. Turn OFF the gas supply.


Inlet of the fuel metering valve


Fuel System Fuel Filter Differential Pressure - Check

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

2. Remove the pipe from the inlet of the fuelmetering valve.

3. Visually inspect the screen at the inlet of the fuelmetering valve. Clean the screen, if necessary.

Usually, contamination can be removed with asoft brush and a vacuum. Make sure that nodebris will enter the fuel metering valve.

If necessary, use internal retaining ring pliers inorder to remove the screen for cleaning. Reinstallthe screen after cleaning.

4. Attach the pipe to the inlet of the fuel meteringvalve.

5. Turn ON the gas supply.

i01376393

Fuel System Fuel FilterDifferential Pressure - CheckSMCS Code: 1261-535

A fuel filter differential pressure gauge must beinstalled in order to determine when the fuel filterrequires service. This gauge and the fuel filter aresupplied by the customer.

A fuel filter differential pressure gauge indicates thedifference in fuel pressure between the inlet sideand the outlet side of the fuel filter. The differentialpressure increases as the fuel filter becomesplugged.

Operate the engine at the rated rpm and at thenormal operating temperature. Check the fuel filterdifferential pressure. Service the fuel filter whenthe fuel filter differential pressure reaches 1.7 kPa(0.25 psi).

For instructions, refer to Special Instruction,SEHS9298, “Installation and Maintenance ofGaseous Fuel Filters”. Consult your Caterpillardealer for assistance.

i01601766

Fumes Disposal FilterDifferential Pressure - CheckSMCS Code: 1074


Pressure gauge on top of the filter

Check the differential pressure across the filterelement. Observe the pressure that is indicated bythe pressure gauge on top of the filter. Record themeasurement.

The restriction of a new element is approximately1.7 kPa (7 inches of H2O).

The normal restriction of the elementis approximately 5.7 to 9.95 kPa(23 to 40 inches of H2O).

• Replace the filter element when the differentialpressure reaches 11.2 kPa (45 inches of H2O).

• Replace the element after every year regardlessof the differential pressure.

i01601838

Fumes Disposal Filter - DrainSMCS Code: 1074



Note: Always disconnect power to the fumescollector prior to servicing. The motor is protectedby a thermal protector. If the motor is shut downdue to excessive heat, the motor will automaticallyrestart when the protector resets.

86Maintenance SectionFumes Disposal Filter Element - Replace

1. Shut down the engine and the fumes disposalfilter.


(1) Drip leg(2) Condensation trap drain valve

2. Open drip leg (1) and drain the fluid into asuitable container.

If the filter is installed and maintained properly, nomore than 28 g (1 ounce) of fluid will be drained.

If more than one 28 g (1 ounce) is drained, makesure that the filter is installed according to theinstructions in Special Instruction, REHS0883.Ensure that the system is operating properly.

3. Close the drip leg.

4. Open condensation trap drain valve (2) anddrain the fluid into a suitable container.

5. Close the condensation trap drain valve.

Resume normal operation.

i01601853

Fumes Disposal Filter Element- ReplaceSMCS Code: 1074



Note: Always disconnect power to the fumescollector prior to servicing. The motor is protectedby a thermal protector. If the motor is shut downdue to excessive heat, the motor will automaticallyrestart when the protector resets.


(1) Nuts and washers(2) Cover(3) Body(4) Filter element

1. Remove three nuts and washers (1) in order toremove cover (2) from body (3).

2. Remove element (4).

3. Clean the inside of cover (2) and body (3).

4. Install new element (4) into body (3).

5. Place cover (2) in position and install three nutsand washers (1).

i01601873

Gas Pressure RegulatorCondensation - DrainSMCS Code: 1270-543

To collect condensation, drip legs should beinstalled in the following locations:

• Supply line for the gas pressure regulator

• Balance line for the gas pressure regulator

• Supply line to the gas shutoff valve


Hoses and Clamps - Inspect/Replace


(1) Cap on the drip leg for the balance line(2) Cap on the drip leg for the gas supply line to the gas pressure

regulator

1. Close the main gas supply valve.

2. Remove caps (1) and (2) from the drip legs.

3. Allow the moisture to drain into a suitablecontainer. Inspect the drip legs for debris. Cleanthe drip legs, if necessary.

4. Clean the caps. Install the caps.

5. Perform Step 2 through Step 4 for the drip legon the supply line to the gas shutoff valve.

6. Open the main gas supply valve.

7. Check the differential pressure in order tomaintain the correct pressure for the fuel that isbeing burned and the application of the engine.Refer to the engine’s Systems Operation/Testingand Adjusting.

i01491773

Hoses and Clamps -Inspect/ReplaceSMCS Code: 7554-040; 7554-510

Inspect all hoses. Leaks can be caused by thefollowing conditions:

• Cracking

• Softness

• Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubesand hoses carefully. Tighten all connections to the rec-ommended torque.

Check for the following conditions:

• Fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

Each installation application can be different. Thedifferences depend on the following factors:

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of thehose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps

1. Service the hoses and clamps according to thesystem:




88Maintenance SectionIgnition System Spark Plugs - Check/Adjust/Replace

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

a. Before servicing a coolant hose, stop theengine. Allow the engine to cool. Loosen thecooling system filler cap slowly in order torelieve any pressure. Remove the coolingsystem filler cap. Drain the coolant from thecooling system to a level that is below thehose that is being replaced.



b. Before servicing an oil hose, stop the engine.Allow the engine to cool. Drain the oil fromthe system to a level that is below the hosethat is being replaced.




c. Before servicing a pressurized air hose, stopthe engine. Ensure that the air supply to thehose is OFF. Slowly release pressure fromthe system.

2. Remove the hose clamps.

3. Disconnect the old hose. Discard the hose.

4. Install a new hose.

Note: For torques on hose clamps, see thisOperation and Maintenance Manual, “TorqueSpecifications” (Maintenance Section).

5. Install the hose clamps with a torque wrench.

6. After servicing the hose, restore the system to anoperational state according to the requirementsof the system:

a. If a coolant hose was serviced, refill thecooling system. Install the cooling systemfiller cap. Start the engine. Inspect the coolingsystem for leaks.

b. If an oil hose was serviced, refill the systemto the proper level. Start the engine. Inspectthe system for leaks.

Personal injury or death can result from improper-ly checking for a leak.

Always use a board or cardboard when checkingfor a leak. Escaping air or fluid under pressure,even a pin-hole size leak, can penetrate body tis-sue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treatedimmediately by a doctor familiar with this type ofinjury.

c. If a pressurized air hose was serviced, restoreair pressure to the system. Check for air leaks.

i01618940

Ignition System Spark Plugs -Check/Adjust/Replace(Spark Plugs with AdjustableElectrode Gaps)SMCS Code: 1555-535



Maintenance of the spark plugs is required in orderto achieve the following benefits:

• Normal fuel consumption


Ignition System Spark Plugs - Check/Adjust/Replace

• Normal level of emissions

• Maximum service life of the spark plugs

The service life of the spark plugs is affected byfouling due to deposits from the oil and by peakvoltage. Maintenance of the ignition system is alsoaffected by voltage. Higher voltage is requiredby higher inlet manifold air pressure and a highercompression ratio. Higher voltage reduces theservice life of components such as spark plugs,wires, and transformers.

Removing the Spark Plug


(1) Bolt(2) Valve cover(3) O-ring seal

1. Remove bolts (1). Remove valve cover (2).Inspect O-ring seal (3). If the seal appears to beworn or damaged, discard the seal and use anew seal for assembly.

NOTICEPulling on the wiring harness may break the wires. Donot pull on the wiring harness.


(4) Wiring harness(5) Transformer(6) Lip seal(7) Spark plug

2. Disconnect wiring harness (4) from transformer(5). Be careful to completely depress the retainerclip away from the connector. Pull transformer (5)straight away from the cylinder head.

3. Inspect lip seal (6). If the seal is worn ordamaged, discard the seal and use a new sealfor assembly.


(8) O-ring seal

4. Inspect O-ring seal (8). If the seal is hard,cracked, or melted, install a new seal.

Pressurized air can cause personal injury. Whenpressurized air is used for cleaning, wear a protec-tive face shield, protective clothing, and protectiveshoes.

Note: Excessive buildup of oil in the spark plugwell is an indication of a damaged lip seal on thetransformer. If this condition is found, clean thesurface of the seal groove. Replace seal (6).

90Maintenance SectionIgnition System Spark Plugs - Check/Adjust/Replace

5. Debris may have collected in the spark plug well.Thoroughly remove any debris. Use compressedair. The maximum air pressure for cleaningpurposes must be below 207 kPa (30 psi).Ensure that the area around the spark plug isclean and free of dirt and debris.

6. Use a 177.8 mm (7/8 inch), 4C-4601 SparkPlug Socket, an extension, and a breaker bar toloosen spark plug (7). After the spark plug hasbeen loosened, use the socket and extensionto remove the spark plug by hand in order todetect problems with the threads. After the sparkplug has been removed, discard the used sparkplug gasket.

If the spark plug resists removal by hand, applypenetrating oil to the threads. To help the oilpenetrate the threads, turn the spark plug back andforth until the spark plug is loose.

If the spark plug cannot be removed by hand, cleanthe threads with 9U-7511 Spark Plug Seat Cleaner.This tool scrapes debris from the seat and from thethreads in the cylinder head. Be sure to clean anydebris from the cylinder.

NOTICEDo not use a thread tap. A thread tap will remove metalunnecessarily. The threads could be stripped and thecylinder head could be damaged.

Inspecting the Spark Plug

Inspect the spark plug closely for damage. Thecondition of the spark plug can indicate theoperating condition of the engine.


(1) Terminal post(2) Insulator(3) Shell(4) Gasket(5) Electrode

Terminal post (1) must not move. If the terminal postcan be moved by hand, carefully tighten the postinto the threads of the insulator. If the post cannotbe tightened, discard the spark plug.

Inspect insulator (2) for cracks. If a crack is found,discard the spark plug.

Faint marks may extend from shell (3) onto theinsulator. The marks may be a result of coronathat forms at the top of the shell. The conductorwill develop a corona when a very high voltagepotential ionizes the air. This is a normal condition.This is not an indication of leakage between theshell and the insulator.

Inspect shell (3) for damage. Cracks can be causedby overtightening the spark plug. Overtighteningcan also yield the metal which loosens the shell.Discard any spark plug that has a shell that iscracked or loose.


(6) Precious metal tips on the electrode and the ground strap

Caterpillar spark plugs have precious metal tips (6)on the electrode and the ground strap. This materialwill gradually erode. Use extreme care when youset the electrode gap. Maintain even spacing andproper alignment between the two precious metalsurfaces.

Replace the spark plug if the precious metal isworn off.

A light brown deposit or a beige deposit around theelectrode is produced by normal operation.

Deposits that are gray or black may be caused bythe following substances:

• Excessive oil

• Use of the wrong oil

• A substance that is introduced through the fuelsystem or the air system


Ignition System Spark Plugs - Check/Adjust/Replace

• Poor combustion because of a rich air/fuel mixture

A spark plug can operate despite a buildup of ash.However, a buildup of ash can cover the electrodegap. This will cause misfire. Large deposits mayretain heat which can cause premature fuel ignition.This can lead to uncontrollable detonation.

Cleaning the Spark Plug

Thoroughly clean the spark plug. Do not use a wirebrush. Glass beads are the preferred method forcleaning.

Follow these guidelines for using glass beads:

• Always use clean glass beads.

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

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

Installing the Spark Plug

Note: Use the 9U-7516 Spark Plug Gauge tomeasure the electrode gap. Do not use a flat feelergauge for measuring the electrode gap of usedspark plugs. A feeler gauge will incorrectly measurethe actual electrode gap because the used preciousmetal tips are curved.

1. Before installing the spark plug, set the electrodegap according to the engine’s Specificationsmanual.

Adjust the electrode gap, if necessary. Bend theground strap at the existing bend. Then bend thestrap near the weld in order to achieve properalignment and even spacing between the twoprecious metal surfaces. Measure the electrodegap after the alignment. Correct the electrodegap, if necessary.

Note: Do not use anti-seize compound on sparkplugs. Most of the heat is transferred through thethreads and the seat area of the spark plug. Contactof the metal surfaces must be maintained in orderto provide the heat transfer that is required.

2. Ensure that the spark plug is clean and free ofdirt and oil.

3. Always use a new gasket when a spark plugis installed. If a used spark plug is installed,place a new 9Y-6792 Spark Plug Gasket on thespark plug. Orient the tabs of the gasket towardthe spark plug’s electrode gap. Otherwise,the gasket may not seat properly. If a gasketfor a spark plug is installed incorrectly, do notincrease the torque on the spark plug in order toimprove the seal. Do not reuse the gasket. Installa new gasket.

NOTICEDo not overtighten the spark plug. The shell can becracked and the gasket can be deformed. The metalcan deform and the gasket can be damaged. The shellcan be stretched. This will loosen the seal that is be-tween the shell and the insulator, allowing combustionpressure to blow past the seal. Serious damage to theengine can occur.

Use the proper torque.

4. Install the spark plug by hand until the spark plugbottoms out. Tighten the spark plug according tothe engine’s Specifications manual.

5. Ensure that the transformer and the extensionare clean and free from dirt and oil. LubricateO-ring seal (8) (Illustration 73) with one of thefollowing lubricants:

• 4C-9504 Dielectric Grease

• 5N-5561 Silicone Lubricant

• 8T-9020 Dielectric Grease

6. Install the transformer. Orient the transformertoward the wiring harness. Carefully align thesocket of the transformer with the wiring harnessconnector. Connect the wiring harness.

Note: If the connector’s locking tab or thetransformer’s connector are damaged, install aretainer onto the transformer’s connector for thewiring harness. For connectors with a width of22.3 mm (0.88 inch), use the 178-0565 Retainer.For connectors with a width of 17.1 mm (0.67 inch),use the 179-1500 Retainer.

92Maintenance SectionIgnition System Spark Plugs - Replace


Retainer on the transformer’s connector for the wiring harness

7. Install the valve cover.

i01623427

Ignition System Spark Plugs -Replace(Spark Plugs that havePrecombustion Chambers)SMCS Code: 1555-510

The use of spark plugs with precombustionchambers is restricted to certain applications.The requirements are listed in Table 33.

Table 33

Requirements for Using Spark Plugs that havePrecombustion Chambers

The engine is used for electrical power generation.

The minimum methane number of the engine’s fuel is 65.

The engine does not use propane, landfill gas, orbio-gas.

Caterpillar Air/Fuel Ratio Control

Control of detonation for individualcylinders

199-9011 Ignition Transformer Gp

50 Hz applications with the 192-3896Piston Body As

60 Hz applications with the 197-3765Piston Body As

The maximum for the exhaustemission of NOx is 1.1 grams per brakehorsepower hour (TA Luft). (1)

The enginemust havethesecharacteristics:

Use of the spark plug is specified bythe engine’s “Technical MarketingInformation”.

(1) TA Luft is the equivalent European standard.

Note: Condensation can form in spark plugs thathave precombustion chambers. This can causedifficulty for cold start-ups. To avoid condensation,maintain the coolant in the cylinder block at aminimum temperature of 43 �C (110 �F) continuously.

The service life of the spark plugs is affectedby fouling due to deposits from the oil and bypeak voltage. Maintenance of the ignition systemis also affected by voltage. Higher voltage isrequired by higher inlet manifold air pressure, ahigher compression ratio, or retardation of thetiming. Higher voltage reduces the service lifeof components such as spark plugs, wires, andtransformers.

The service life of the spark plug is different fordifferent applications. The minimum service life ofthe spark plug is approximately 3000 service hours.The spark plug may be good for a considerableperiod beyond 3000 service hours. Experience atthe particular site will help to determine the properinterval for replacement of the spark plugs.

If a diagnostic code is generated for the ignitiontransformer’s secondary circuit, the spark plug mayneed to be replaced. Misfire and a cold cylinderare other indications of a worn spark plug. Use ETto monitor the exhaust port temperatures in orderto locate a cold cylinder.

Removing the Spark Plug




Ignition System Spark Plugs - Replace


(1) Bolt(2) Valve cover(3) O-ring seal

1. Remove bolts (1). Remove valve cover (2).Inspect O-ring seal (3). If the seal appears to beworn or damaged, discard the seal and use anew seal for assembly.

NOTICEPulling on the wiring harness may break the wires. Donot pull on the wiring harness.


(4) Wiring harness(5) Transformer(6) Lip seal(7) Spark plug

2. Disconnect wiring harness (4) from transformer(5). Be careful to completely depress theretainer clip away from the connector. Removetransformer (5).

3. Inspect lip seal (6). If the seal is worn ordamaged, discard the seal and install a newseal.


(8) O-ring seal

4. Inspect O-ring seal (8). If the seal is hard,cracked, or melted, install a new seal.

Pressurized air can cause personal injury. Whenpressurized air is used for cleaning, wear a protec-tive face shield, protective clothing, and protectiveshoes.

Note: Excessive buildup of oil in the spark plugwell is an indication of a damaged lip seal on thetransformer. If this condition is found, clean thesurface of the seal groove. Replace seal (6).

5. Debris may have collected in the spark plug well.Thoroughly remove any debris. Use compressedair. The maximum air pressure for cleaningpurposes must be below 207 kPa (30 psi).Ensure that the area around the spark plug isclean and free of dirt and debris.

6. Use a 20.638 mm (13/16 inch) deep well socket,an extension, and a breaker bar to loosen sparkplug (7). After the spark plug has been loosened,use the socket and extension to remove thespark plug by hand in order to detect problemswith the threads. After the spark plug has beenremoved, discard the used spark plug gasket.

If the spark plug resists removal by hand, applypenetrating oil to the threads. To help the oilpenetrate the threads, turn the spark plug back andforth until the spark plug is loose.

If the spark plug could not be removed by hand,clean the threads with the 9U-7511 Spark PlugSeat Cleaner. This tool scrapes debris from the seatand from the threads in the cylinder head. Be sureto clean any debris from the cylinder.

94Maintenance SectionIgnition System Spark Plugs - Replace

NOTICEDo not use a thread tap. A thread tap will remove metalunnecessarily. The threads could be stripped and thecylinder head could be damaged.

Inspecting the Spark Plug


(1) Terminal post(2) Insulator(3) Shell(4) Gasket(5) Hole in the spark plug’s precombustion chamber

Inspect the spark plug closely for damage. Thecondition of the spark plug can indicate theoperating condition of the engine.

Terminal post (1) must not move. If the terminal postcan be moved by hand, carefully tighten the postinto the threads of the insulator. If the post cannotbe tightened, discard the spark plug.

Insulator (2) is covered with Teflon. If the cover iscracked or loose, discard the spark plug.

Faint marks may extend from shell (3) onto theinsulator. The marks may be a result of a coronathat forms at the top of the shell. The conductorwill develop a corona when a very high voltagepotential ionizes the air. This is a normal condition.This is not an indication of leakage between theshell and the insulator.

Inspect shell (3) for damage. Cracks can be causedby overtightening the spark plug. Overtighteningcan also yield the metal which loosens the shell.Discard any spark plug that has a shell that iscracked or loose.

Inspect the spark plug’s precombustion chamberfor deposits. Make sure that holes (5) in the sparkplug’s precombustion chamber are not blocked.

A light brown deposit or a beige deposit isproduced by normal operation.

Deposits that are gray or black may be caused bythe following substances:

• Excessive oil

• Use of the wrong oil

• A substance that is introduced through the fuelsystem or the air system

• Poor combustion because of a rich air/fuel mixture

A spark plug can operate despite a buildup ofash. Large deposits may retain heat which cancause premature fuel ignition. This can lead touncontrollable detonation.

Cleaning the Spark Plug

Do not use glass beads to clean the spark plug.The beads could enter the precombustion chamberthrough the holes. The beads could clog the holesin the spark plug’s precombustion chamber.

Use a brass wire brush to clean the spark plug. Becareful not to damage the Teflon cover.

Installing the Spark Plug

Note: Do not use anti-seize compound on sparkplugs. Most of the heat is transferred through thethreads and the seat area of the spark plug. Contactof the metal surfaces must be maintained in orderto provide the heat transfer that is required.

1. Ensure that the spark plug is clean and free ofdirt and oil.

2. Always use a new gasket when a spark plug isinstalled. If a used spark plug is installed, placea new 9Y-6792 Spark Plug Gasket on the sparkplug. Orient the tabs of the gasket toward thespark plug’s precombustion chamber. Otherwise,the gasket may not seat properly. If a gasketfor a spark plug is installed incorrectly, do notincrease the torque on the spark plug in order toimprove the seal. Do not reuse the gasket. Installa new gasket.

NOTICEDo not overtighten the spark plug. The shell can becracked and the gasket can be deformed. The metalcan deform and the gasket can be damaged. The shellcan be stretched. This will loosen the seal that is be-tween the shell and the insulator, allowing combustionpressure to blow past the seal. Serious damage to theengine can occur.

Use the proper torque.

3. Install the spark plug by hand until the sparkplug contacts the gasket. Tighten the spark plugaccording to the engine’s Specifications manual.


Ignition System Timing - Check/Adjust

4. Ensure that the transformer and the extensionare clean and free from dirt and oil. LubricateO-ring seal (8) (Illustration 79) with one of thefollowing lubricants:

• 4C-9504 Dielectric Grease

• 5N-5561 Silicone Lubricant

• 8T-9020 Dielectric Grease

5. Install the transformer. Orient the transformertoward the wiring harness. Carefully align thesocket of the transformer with the wiring harnessconnector. Connect the wiring harness.

Note: If the connector’s locking tab or thetransformer’s connector are damaged, install a178-0565 Retainer on the transformer’s connectorfor the wiring harness.


178-0565 Retainer on the transformer’s connector for the wiringharness

6. Install the valve cover.

i01022787

Ignition System Timing -Check/AdjustSMCS Code: 1550-025; 1550-535

After maintenance has been performed on theignition system, check the timing of the ignitionsystem. Adjust the timing, if necessary.

Ignition timing for gas engines varies with thegas chemistry. Obtain a fuel analysis in order todetermine if the timing for the ignition system iscorrect. Enter the data from the fuel analysis into theCaterpillar Software Program, LEKQ6378, “MethaneNumber Program”.

For the correct timing, refer to Engine Performance,LEBQ6169, “G3500 Generator Set” or see atechnical specification sheet that is provided byyour Caterpillar dealer.

Use the Caterpillar Electronic Technician (ET) toadjust the timing. Adjust the timing according to theinstructions in Special Instruction, “Installation andInitial Start-Up Procedures For G3500B Engines”.Consult your Caterpillar dealer for assistance.

i01492320

Inlet Air System - InspectSMCS Code: 1058-040; 1071-040; 1087-040

Inspect the components of the air inlet system forthe following conditions:

• Cracks

• Leaks



Rubber hoses in the air lines of a G3516B Engine

Inspect the following components:

• Piping between the air cleaner and theturbocharger

• Rubber hoses in the air lines

• Turbocharger

• Piping between the turbocharger and theaftercooler

• Aftercooler

• Connection of the aftercooler to the air plenum

• Connection of the air plenum to the cylinder head

96Maintenance SectionOverhaul (In-Frame)

Ensure that all of the connections are secure.Ensure that the components are in good condition.

Make repairs, if necessary. For information regardingremoval and installation of the components, referto Service Manual, “Disassembly and Assembly”.Consult your Caterpillar dealer for assistance.

i01617891

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

Scheduling an In-Frame Overhaul

Note: For information on estimating operatinghours before an overhaul, refer to MaintenanceManagement Schedules, SEBU6127.

Generally, an in-frame overhaul is performed forevery third top end overhaul. Scheduling an in-frameoverhaul normally depends on the following threeconditions:

• An increase of oil consumption

• An increase of crankcase blowby

• A decrease and a variation of cylindercompression

Each individual condition may not indicate a needfor an overhaul. However, evaluating the threeconditions together is the most accurate method ofdetermining when an overhaul is necessary.

The engine does not require an overhaul if theengine is operating within acceptable limits foroil consumption, crankcase blowby, and cylindercompression.

Periodically measure each of the three conditions.The first measurement should occur during theengine commissioning. This establishes a baselinefor future measurements. Additional measurementsare scheduled at regular intervals in order todetermine a schedule for the next in-frame overhaul.

The following changes in the three conditionsnormally require a scheduled overhaul:

• A 300 percent increase in oil consumption

• A 200 percent increase in crankcase blowby

• A 20 percent loss of cylinder compression

Note: These indications do not require an engineto be shut down for service. These indicationsonly mean that an engine should be scheduled forservice in the near future. If the engine operationis satisfactory, an immediate overhaul is not arequirement.

Monitor the engine as the engine accumulatesservice hours. Consult your Caterpillar dealer aboutscheduling a major overhaul.

Usually, an in-frame overhaul does not requireremoval of the engine. Instead, the service isperformed with the engine in place. If the customerrequires a minimum disruption in the production ofpower, the engine can be replaced with a rebuiltmodel of identical specifications.

Note: The generator or the driven equipment mayalso require service when the engine overhaul isperformed. Refer to the literature that is provided bythe OEM of the driven equipment.

In-Frame Overhaul Information

An in-frame overhaul includes all of the workthat is done for a top end overhaul. Additionally,some other components that wear are replaced.The condition of components is inspected. Thosecomponents are replaced, if necessary.

Your Caterpillar dealer can provide these servicesand components. Your Caterpillar dealer can ensurethat the components are operating within theappropriate specifications.

The following definitions explain the terminology forthe services that are performed during an overhaul:

Inspect – Inspect the components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”. The guidelines were developed in order tohelp Caterpillar dealers and customers to avoidunnecessary expenditures. New parts are notrequired if the existing parts can still be used,reconditioned, or repaired. If the components arenot in the reusability guidelines, refer to the ServiceManual, “Specifications” module.

Rebuild – The component can be reconditioned inorder to comply with reusability guidelines.


Overhaul (Major)

Replace – The service life of the part is exhausted.The part may fail before the next maintenanceinterval. The part must be replaced with a part thatmeets functional specifications. The replacementpart may be a new part, a CAT remanufacturedpart, a rebuilt part, or a used part. Some worncomponents may be exchanged with yourCaterpillar dealer. Consult your Caterpillar dealerabout repair options for your engine.

If you elect to perform an overhaul without theservices of a Caterpillar dealer, be aware of therecommendations in Table 34.

Table 34

In-Frame Overhaul

Clean Oil suction screen

CleanInspectTest

Aftercooler core

Fuel metering valve

Electrohydraulic actuator

Hydraulic oil pump

Oil cooler

Oil pump

Pistons

InspectRebuildReplace

Transformers

Exhaust bypass

Prelube pump

Starting motor

Turbochargers

Rebuild

Water pumps

Connecting rod bearings

Cylinder head assemblies

Cylinder liners

Main bearings

Oil temperature regulators

Piston rings

Replace

Water temperature regulators

i01617881

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

Scheduling a Major Overhaul


Generally, a major overhaul is performed for everyfifth top end overhaul. The need for a major overhaulis determined by several factors. Some of thosefactors are the same factors that determine thein-frame overhaul:

• An increase of oil consumption

• An increase of crankcase blowby

• A decrease and variation of cylinder compression

Other factors must also be considered fordetermining a major overhaul:

• Power output

• The service hours of the engine

• Reduced oil pressure

• The wear metal analysis of the lube oil

• An increase in the levels of noise and vibration

An increase of wear metals in the lube oil indicatesthat the bearings and the surfaces that wear mayneed to be serviced. An increase in the levels ofnoise and vibration indicates that rotating partsrequire service.

Note: It is possible for oil analysis to indicate adecrease of wear metals in the lube oil. The cylinderliners may be worn so that polishing of the boreoccurs. Also, the increased use of lube oil will dilutethe wear metals.

Monitor the engine as the engine accumulatesservice hours. Consult your Caterpillar dealer aboutscheduling a major overhaul.

Note: The generator or driven equipment may alsorequire service when the engine is overhauled.Refer to the literature that is provided by the OEMof the driven equipment.

98Maintenance SectionOverhaul (Major)

Major Overhaul Information

A major overhaul includes all of the work that isdone for top end overhauls and in-frame overhauls.A major overhaul includes additional parts andlabor. Additional parts and labor are required inorder to completely rebuild the engine. In somecases, the engine is relocated for disassembly.

For the major overhaul, all of the bearings,seals, gaskets, and components that wearare disassembled. The parts are cleaned andinspected. If necessary, the parts are replaced. Thecrankshaft is measured for wear. The crankshaftmay require regrinding. Alternatively, the crankshaftmay be replaced with a Caterpillar replacementpart.

Your Caterpillar dealer can provide these servicesand components. Your Caterpillar dealer can ensurethat the components are operating within theappropriate specifications.




Replace – The service life of the part is exhausted.The part may fail before the next maintenanceinterval. The part must be replaced with a part thatmeets functional specifications. The replacementpart may be a new part, a CAT remanufacturedpart, a rebuilt part, or a used part. Some worncomponents may be exchanged with yourCaterpillar dealer for credit on replacement parts.Consult your Caterpillar dealer about repair optionsfor your engine.

If you elect to perform an overhaul without theservices of a Caterpillar dealer, be aware of therecommendations in Table 35. Your Caterpillardealer can provide these services and components.

Table 35

Major Overhaul


CleanInspectTest

Aftercooler core

Camshafts

Camshaft followers

Connecting rods

Crankshaft

Fuel metering valve

Gear train gears


Hydraulic oil pump

Inlet air piping

Oil cooler

Oil pump

Pistons

InspectRebuildReplace

Transformers

Exhaust bypass

Prelube pump

Starting motor

Turbochargers

Water pumps

Rebuild

Vibration damper

Camshaft bearings

Connecting rod bearings

Coupling (tandem engines)

Cylinder liners

Gaskets and seals

Gear train bushings

Main bearings


Piston rings


Replace

Wiring harnesses


Overhaul (Top End)

i01617868

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

Scheduling a Top End Overhaul


Top end overhauls are scheduled according tothe recession of the exhaust valve stems. Thismeasurement provides an accurate indication ofthe rate of valve wear. This measurement can beused to predict when a cylinder head requiresreplacement.

To determine a baseline, measure the projection ofthe exhaust valve stems after 100 to 250 servicehours. The baseline is a reference for subsequentmeasurements. Continue to periodically measurethe projection.

Plan for the top end overhaul as the valve stemprojection approaches the maximum limit. Performthe top end overhaul when the valve stem projectionhas increased by a total of 2.3 mm (.09 inch). Donot allow the projection of the exhaust valve stemsto exceed this limit.

Note: Generally, cylinder heads wear out at differentrates. In some cases, servicing the cylinder headsat different times may be the most economicdecision. This depends on the valve stem projectionof the individual cylinders. However, this decisionmust include the costs of additional downtime thatis caused by this procedure. Perform an economicanalysis in order to determine if cylinder headsshould be serviced as a group or divided intosmaller groups.

Note: The generator or the driven equipment mayalso require service when the engine overhaul isperformed. Refer to the literature that is provided bythe OEM of the driven equipment.

Top End Overhaul Information

A top end overhaul involves servicing the cylinderheads and turbochargers. Also, some other enginecomponents are inspected.

Top end overhauls require more tools thanpreventive maintenance. The following toolsare needed for restoring the engine to factoryspecifications:

• Torque wrenches

• Dial indicators

• Accurate measurement tools

• Cleaning equipment

• Rebuilding equipment

Caterpillar dealers are equipped with these tools.Caterpillar dealers can provide a flat rate price for atop end overhaul.

Unexpected problems may be found during a topend overhaul. Plan to correct these problems, ifnecessary.

• Buildup in the cylinders from excessive oilconsumption

• Buildup in the cylinders from contamination ofthe fuel

• Plugging of the aftercooler from coolant that ispoorly maintained

• Plugging of the aftercooler from contaminationof the inlet air

• Degradation of the oil cooler from hydrogensulfide in the fuel




Replace – The service life of the part is exhausted.The part may fail before the next maintenanceinterval. The part must be replaced with a part thatmeets functional specifications. The replacementpart may be a new part, a CAT remanufacturedpart, a rebuilt part, or a used part. Some worncomponents may be exchanged with yourCaterpillar dealer. Consult your Caterpillar dealerabout repair options for your engine.

100Maintenance SectionOverhaul (Top End)

If you elect to perform an overhaul without theservices of a Caterpillar dealer, be aware of therecommendations in Table 36. Your Caterpillardealer can provide these services and components.Your Caterpillar dealer can ensure that thecomponents are operating within the appropriatespecifications.

Table 36

Top End Overhaul


CleanInspectTest

Aftercooler coreOil cooler core


Hydraulic oil pump

Inspect

Transformers

Exhaust bypass

Prelube pump

Starting motor

Turbochargers

Rebuild

Water pumps

Cylinder head assemblies


Replace


Cleaning and Inspection of Components

Aftercooler and Oil Cooler

Clean the aftercooler core and the oil coolercore. Pressure test the components. Replace thecomponents, if necessary.

Note: If the cooling system is not properlymaintained, cleaning of the aftercooler can bedifficult. The tank that is opposite of the inlet portand the outlet port can not be removed for cleaning.

Note: This procedure may be used for cleaning boththe aftercooler core and the oil cooler core.

1. Remove the core.

2. Turn the core upside-down in order to removedebris.

NOTICEDo not use a high concentration of caustic cleaner toclean the core. A high concentration of caustic cleanercan attack the internal metals of the core and causeleakage. Only use the recommended concentration ofcleaner.

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Consult your Caterpillar dealer forpart numbers and sizes of containers.

Use a two to five percent concentration of thecleaner at temperatures up to 93�C (200�F).

4. Steam clean the core in order to remove anyresidue. Flush the fins of the core. Remove anyother trapped debris.

5. Wash the core with hot, soapy water. Rinse thecore thoroughly with clean water.

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

6. Dry the core with compressed air. Direct the airin the reverse direction of the normal flow.

Note: The test pressure for the oil cooler is 790 kPa(115 psi). The maximum differential pressureof water for the aftercooler is 44 kPa (6 psi).The maximum differential pressure of air for theaftercooler is 5.1 kPa (0.74 psi).

7. Inspect the core in order to ensure cleanliness.Pressure test the core. Many shops that serviceradiators are equipped to perform pressure tests.If necessary, repair the core.

8. Install the core.

For more information on cleaning the cores, consultyour Caterpillar dealer.

Oil Suction Screen



Clean the oil suction screen after the engine oil panhas been drained.


Overhaul Considerations

Note: Approximately 1 L (1 qt) of engine oil willremain in the housing after the sump has beencompletely drained. This engine oil will pour out ofthe housing when cover (1) is removed. Prepareto catch the engine oil in a pan. Clean up anyspills with absorbent towels or pillows. DO NOT useabsorbent particles.


(1) Cover(2) O-ring seal(3) Screen assembly

1. Loosen the bolts from cover (1). Remove cover(1) and O-ring seal (2). Discard the seal. Removescreen assembly (3).

2. Wash screen assembly (3) in clean nonflammablesolvent. Allow the screen assembly to dry beforeinstallation.

3. Clean the engine oil sump. Remove the sidecovers in order to gain access to the sump. Afterthe sump is clean, install the side covers.

4. Inspect screen assembly (3) for good condition.Obtain a new screen assembly, if necessary.Install the screen assembly. Install a new O-ringseal (2). Install cover (1).

Transformers

The transformers produce a voltage increase. Forgood operation, the connections must be clean andsecure. Inspect the transformers for the followingconditions:

• Damaged O-rings

• Dirty insulator


• Loose connector

• Loose screws in the top ground spring

• Moisture

Measure the voltage of the diode for the primarycircuit and measure the resistance of the secondarycircuit according to Troubleshooting, RENR2270,“G3500B Engines”. Consult your Caterpillar dealerfor assistance.

i01604264

Overhaul ConsiderationsSMCS Code: 7595-043

Overhaul Information

An overhaul is replacing the major worn componentsof the engine. An overhaul is a maintenance intervalthat is planned. The engine is rebuilt with certainrebuilt parts or new parts that replace the wornparts.

An overhaul also includes the following maintenance:

• Inspection of all the parts that are visible duringthe disassembly

• Replacement of the seals and gaskets that areremoved

• Cleaning of the internal passages of the engineand the engine block

Most owners will save money by overhauling theengine at the intervals that are recommended inthe Operation and Maintenance Manual. It is notpractical to wait until the engine exhibits symptomsof excessive wear or failure. It is not less costly towait. A planned overhaul before failure may be thebest value for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according tothe guidelines for reusable parts.

• The service life of the engine can be extendedwithout the risk of a major catastrophe due toengine failure.

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

Overhaul Intervals


102Maintenance SectionOverhaul Considerations

Top end overhauls are determined by the projectionof exhaust valve stems. In-frame overhauls aredetermined by cylinder compression, crankcaseblowby, and oil consumption. Major overhauls aredetermined by the in-frame tests, and by results ofS·O·S oil analysis.

Some other factors that are important fordetermining the overhaul intervals include thefollowing considerations:

• Performance of preventive maintenance

• Use of recommended lubricants

• Use of recommended coolants

• Use of recommended fuels

• Proper installation

• Operating conditions

• Operation within acceptable limits

• Engine load

• Engine speed

Note: To avoid oil problems, engines that areturbocharged and aftercooled must be operated ata minimum of 60 percent of rated load.

Generally, engines that are operated at a reducedload and/or speed achieve more service life beforean overhaul. However, this is for engines that areproperly operated and maintained.

Overhaul Inspection

Refer to the Service Manual for the disassemblyand assembly procedures that are necessary inorder to perform the required maintenance on theitems that are listed. Consult your Caterpillar dealerfor assistance.

To determine the reusability publications that areneeded to inspect the engine, refer to Guidelines forReusable Parts and Salvage Operations, SEBF8029,“Index of Publications on Reusability or Salvage ofUsed Parts”.

The Guidelines For Reusable Parts and SalvageOperations is part of an established Caterpillarparts reusability program. These guidelineswere developed in order to assist Caterpillardealers and customers reduce costs by avoidingunnecessary expenditures for new parts. If theengine parts comply with the established inspectionspecifications, the parts can be reused. New partsare not necessary if the old parts can be reused,repaired, or salvaged.

If the parts are not within the inspectionspecifications, the parts should be salvaged,repaired, replaced, or exchanged. The use ofout-of-spec parts could result in unscheduleddowntime and/or costly repairs. The use ofout-of-spec parts can also contribute to increasedfuel consumption and reduction of engine efficiency.

Your Caterpillar dealer can provide the parts thatare needed to rebuild the engine at the leastpossible cost.

Overhaul Programs

An economical way to obtain most of the partsthat are needed for overhauls is to use Caterpillarremanufactured parts. Caterpillar remanufacturedparts are available at a fraction of the cost of newparts. These parts have been rebuilt by Caterpillarand certified for use. The following components areexamples of the remanufactured parts:

• Alternators

• Connecting rods

• Crankshafts

• Cylinder heads

• Oil Pumps

• Starting motors

• Turbochargers

• Water pumps

Consult your Caterpillar dealer for details and for alist of the remanufactured parts that are available.

Your Caterpillar dealer may be offering a variety ofoverhaul options.

A Flat Rate Overhaul guarantees the maximum pricethat you will pay for an overhaul. Flat rate prices onpreventive maintenance programs or major repairoptions are available from many servicing dealersfor all Caterpillar Engines. Consult your Caterpillardealer in order to schedule a before failure overhaul.


Oxygen Sensor - Calibrate

Overhaul Recommendation

Caterpillar recommends a scheduled overhaul inorder to minimize downtime. A scheduled overhaulwill provide the lowest cost and the greatest value.Schedule an overhaul with your Caterpillar dealer.

Overhaul programs vary between dealers. To obtainspecific information about the types of overhaulprograms and services, consult your Caterpillardealer.

i01454351

Oxygen Sensor - CalibrateSMCS Code: 1096

The oxygen sensor is very important for theseconsiderations:

• Control of emissions

• Engine performance

During operation, the oxygen sensor may reachtemperatures that exceed 700 �C (1292 �F). Severepersonal injury and property damage will resultfrom contact with a hot oxygen sensor.

Do not touch the sensor during engine operation,calibration, or testing. Allow the sensor to coolbefore moving the sensor. Wear gloves that resistheat. Do not place the sensor on or near anyflammable material or any surface that can bedamaged by high temperatures.

The sensor must be calibrated periodically inorder to ensure proper operation. If a new sensorwill be installed, calibrate the new sensor beforeinstallation.

During calibration, the sensor must be temporarilyremoved from the exhaust system. It is necessaryto expose the sensor to clean air.

Note: When you reinstall an oxygen sensor, alwaysuse a new 9Y-6792 Spark Plug Gasket.

DO NOT calibrate the sensor in an environment withthe following conditions:

• The ambient temperature is greater than 38 �C(100 �F).

• The relative humidity is greater than 90 percent.

For instructions, refer to Service Manual, RENR2270,“Troubleshooting”.

i01604510

Radiator - CleanSMCS Code: 1353-070

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

Inspect the radiator for these items: damaged fins,corrosion, dirt, grease, insects, leaves, oil, andother debris. Clean the radiator, if necessary.

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the fan’s air flow. Hold the nozzle approximately6 mm (0.25 inch) away from the fins. Slowly movethe air nozzle in a direction that is parallel with thetubes. This will remove debris that is between thetubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

Use a degreaser and steam for removal of oil andgrease. Clean both sides of the core. Wash the corewith detergent and hot water. Thoroughly rinse thecore with clean water.

After cleaning, start the engine and accelerate theengine to high idle rpm. This will help in the removalof debris and drying of the core. Stop the engine.Use a light bulb behind the core in order to inspectthe core for cleanliness. Repeat the cleaning, ifnecessary.

Inspect the fins for damage. Bent fins may beopened with a “comb”. Inspect these items forgood condition: welds, mounting brackets, air lines,connections, clamps, and seals. Make repairs, ifnecessary.

104Maintenance SectionStarting Motor - Inspect

For more detailed information on cleaning andinspection, refer to Special Publication, SEBD0518,“Know Your Cooling System”.

i01113939

Starting Motor - InspectSMCS Code: 1451-040; 1453-040

If the starting motor fails, the engine may not startin an emergency situation. A scheduled inspectionof the starting motor is recommended.

The starting motor pinion and the flywheel ring gearmust be in good condition in order for the engineto start properly. The engine will not start if thestarting motor pinion does not engage the flywheelring gear. The teeth of the starting motor pinion andthe flywheel ring gear can be damaged becauseof irregular engagement.

Inspect the starting motor for proper operation.Listen for grinding when the engine is started.Inspect the teeth of the starting motor pinion andthe flywheel ring gear. Look for patterns of wear onthe teeth. Look for teeth that are broken or chipped.If damaged teeth are found, the starting motorpinion and the flywheel ring gear must be replaced.

Electric Starting Motor

Note: Problems with the electric starting motor canbe caused by the following conditions: malfunctionof the solenoid and malfunction of the electricstarting system.

Inspect the electrical system for the followingconditions:


• Corrosion

• Wires that are worn or frayed

• Cleanliness

Make repairs, if necessary.

Air Starting Motor

Personal injury or death can result from improper-ly checking for a leak.

Always use a board or cardboard when checkingfor a leak. Escaping air or fluid under pressure,even a pin-hole size leak, can penetrate body tis-sue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treatedimmediately by a doctor familiar with this type ofinjury.

Inspect all of the components in the air circuit forthe starting motor. Inspect all of the air lines andconnections for leaks.

If the teeth of the starting motor pinion and/or theflywheel ring gear are damaged, the air circuit forthe starting motor must be examined in order todetermine the cause of the problem.

Removal and Installation of theStarting Motor

Refer to the Service Manual, “Disassembly andAssembly” module for information on removing thestarting motor and installing the starting motor.


i01454354

Turbocharger - InspectSMCS Code: 1052-040

Periodic inspection and cleaning is recommendedfor the turbocharger. Fouling of the turbine wheelscan contribute to loss of engine power and overallloss of engine efficiency.

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage to theturbocharger compressor wheel could allow partsfrom the compressor wheel to enter an enginecylinder. This can cause additional damage to thepistons, the valves, and the cylinder head.


Valve Stem Projection - Measure/Record

NOTICETurbocharger bearing failures can cause large quan-tities of oil to enter the air inlet and exhaust systems.Loss of engine lubricant can result in serious enginedamage.

Minor leakage of a turbocharger housing under ex-tended low idle operation should not cause problemsas long as a turbocharger bearing failure has not oc-curred.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is repaired orreplaced.

An inspection of the turbocharger can minimizeunscheduled downtime. Also, the chance forpotential damage to other engine parts is reduced.

Note: Turbocharger components require clearancesthat are precise. The turbocharger cartridge mustbe balanced due to high rpm.

The following conditions can cause the turbochargerto be out-of-balance:

• The buildup of deposits

• Chipping and/or flaking of deposits

If the turbocharger must be removed for inspection,use caution. Do not break deposits from the turbinewheel. Do not attempt to clean the turbine wheel.For options regarding removal, installation, repairand replacement, see the Service Manual or consultyour Caterpillar dealer.

1. Remove the exhaust outlet piping and removethe air inlet piping from the turbocharger. Visuallyinspect the piping for the presence of oil.

2. Turn the compressor wheel and the turbinewheel by hand. The assembly should turn freely.Inspect the compressor wheel and the turbinewheel for contact with the turbocharger housing.There should not be any visible signs of contactbetween the turbine wheel or compressorwheel and the turbocharger housing. If there isany indication of contact between the rotatingturbine wheel or the compressor wheel and theturbocharger housing, the turbocharger shouldbe reconditioned.

3. Check the compressor wheel for cleanliness. Ifonly the inlet side of the wheel is dirty, dirt and/ormoisture is passing through the air filteringsystem. If oil is found only on the back sideof the wheel, there is a possibility of a failedturbocharger oil seal.

The presence of oil may be the result of extendedengine operation at low idle. The presence ofoil may also result from restriction of the inlet air(plugged air filters). This causes oil to leak pastthe seal for the turbocharger compressor.

If oil is found on the compressor wheel and/orat the air inlet, the source of the oil is the fuelcompressor or the PCV system.

Note: Deposits of ash and silicone can accumulateon the turbine wheel. Turbine wheel will becomeunbalanced when the deposits flake off. Theturbocharger cartridge must be replaced whenthis occurs. However, remove deposits from thehousing. This will prevent wear on the blades of thenew turbine wheel.

4. Inspect the turbine wheel and the nozzle fordeposits of ash and silicone. If deposits of1.6 mm (0.06 inch) thickness are found orif the turbine is in contact with the housing,the turbocharger must be disassembled andcleaned. Removal of the deposits can be difficult.

5. Inspect the bore of the turbine housing forcorrosion and deposits.

6. Clean the turbocharger compressor housing withstandard shop solvents and a soft bristle brush.

7. Fasten the air inlet piping and the exhaust outletpiping to the turbocharger housing.

i01492440

Valve Stem Projection -Measure/RecordSMCS Code: 1105-082

Valve Recession – The valves and the valve seatsare worn over time. This causes the valves torecede into the cylinder head. This condition iscalled “valve recession”.

The exhaust valves and valve seats show thegreatest wear. The top end overhaul is scheduledaccording to the recession of the exhaust valves.

It is difficult to measure the actual valve recessionin the cylinder head. A simpler method is used todetermine the valve recession:

106Maintenance SectionValve Stem Projection - Measure/Record

• Measure the projection of the valve rotatorabove the cylinder head. It is not necessary toremove the rocker arms in order to obtain thismeasurement.

Measure the projection of the exhaust valve rotatorswith the 155-1536 Valve Recession Tool Group.Follow the instructions that are provided with thetool group.

Record the measurements on the Operation andMaintenance Manual, “Valve Data Sheet” (ReferenceMaterials Section).

• Measure the projection of the exhaust valverotators after 100 to 200 service hours. Thismeasurement is the baseline. The baseline is areference for subsequent measurements.

• Measure the projection of the exhaust valverotators at the first 1000 service hours. Illustration84 shows schedules for determining subsequentintervals.


(A) Schedule(B) Schedule(C) Schedule(Y) Valve recession in millimeters (inches)

(X) Hours of operation(1) 0.254 mm (0.0100 inch)(2) 0.218 mm (0.0086 inch)(3) 0.152 mm (0.0060 inch)

To determine intervals, use the point on the graphin Illustration 84 that is closest to the measurementfor each cylinder.


Walk-Around Inspection

For example, suppose that the measurement thatwas obtained at the initial 1000 hours shows a valverecession of approximately 0.152 mm (0.0060 inch).According to Schedule (C), the next interval formeasuring that cylinder is at 5000 service hours.Another cylinder may have a valve recession ofapproximately 0.254 mm (0.0100 inch). Accordingto Schedule (A), the next interval for measuring thatcylinder is at 3000 service hours.

• After 70 percent of the maximum limit has beenreached, measure the projection of the exhaustvalve rotators at every 1000 hours of operation.The 70 percent is 1.60 mm (0.063 inch).

• Plan for the top end overhaul as the projection ofthe valve rotator approaches the maximum limit.Perform the top end overhaul when the projectionof the valve rotator has increased by a total of2.3 mm (0.09 inch). Do not allow the recessionof the exhaust valves to exceed this limit. Thevalve head can break. This will cause severedamage in the combustion chamber.


i01492446

Walk-Around InspectionSMCS Code: 1000-040

Inspect the Engine for Leaks andfor Loose Connections

A walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can beavoided.

For maximum engine service life, thoroughly inspectthe engine room before starting the engine. Look foritems such as leaks, loose bolts, loose connectionsand trash buildup. Make repairs, as needed.

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

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak, clean up the fluid. If leaking is ob-served, find the source and correct the leak. If leakingis suspected, check the fluid levels more often thanrecommended until the leak is found or fixed, or untilthe suspicion of a leak is proved to be unwarranted.

NOTICEAccumulated grease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaningor high pressure water.

• Ensure that cooling lines are properly clamped.Check for leaks. Check the condition of all pipes.

• Inspect the water pumps for coolant leaks.

Note: The water pump seal is lubricated by coolantin the cooling system. It is normal for a smallamount of leakage to occur when the engine coolsand the parts contract.

Excessive coolant leakage may indicate the needto replace the water pump seal. For instructionson removal and installation of water pumps and/orseals, refer to the Service Manual, “Disassemblyand Assembly” module for the engine or consultyour Caterpillar dealer.

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

NEVER use a flame to check for gas leaks. Use agas detector.

An open flame can ignite mixtures of air and fuel.This will cause explosion and/or fire which couldresult in severe personal injury or death.

• Check the fuel system for leaks. Look for loosefuel line clamps.

• Inspect the piping for the air inlet system and theelbows for cracks and for loose clamps.

• Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

• Inspect the ground straps for good connectionsand for good condition.

• Check the condition of the gauges. Replace anygauge that is damaged. Replace any gauge thatcan not be calibrated.

• Inspect the exhaust system for leaks. If a leakis found, make repairs.

108Maintenance SectionWater Pump - Inspect

i00524084

Water Pump - InspectSMCS Code: 1361-040

A failed water pump might cause severe engineoverheating problems that could result in cracks inthe cylinder head, a piston seizure or other potentialdamage to the engine.

Visually inspect the water pump for leaks. If leakingof the water pump seals is observed, replace all ofthe water pump seals. Refer to the Service Manualfor the disassembly and assembly procedure.

Inspect the water pump for wear, cracks, pin holesand proper operation. Refer to the Service Manualor consult your Caterpillar dealer if repair is neededor replacement is needed.

i01023425

Water Temperature Regulator -ReplaceSMCS Code: 1355-510

Replace the water temperature regulators beforethe water temperature regulators fail. This is arecommended preventive maintenance practice.Replacing the water temperature regulators reducesthe chances for unscheduled downtime.

A water temperature regulator that fails in apartially opened position can cause overheating orovercooling of the engine.

A water temperature regulator that fails in theclosed position can cause excessive overheating.Excessive overheating could result in cracking ofthe cylinder head or a seizure of the pistons.

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup insidethe cylinders. This excessive carbon buildup couldresult in an accelerated wear of the piston rings andwear of the cylinder liner. Also, a low temperaturecan allow moisture to condense in the oil. This canform damaging acids.

NOTICEFailure to replace the water temperature regulators ona regularly scheduled basis could cause severe en-gine damage.

Never operate the engine without the water tempera-ture regulators installed.

If the water temperature regulator is installed incor-rectly, the engine may overheat, causing cylinder headdamage. Ensure that the new water temperature reg-ulator is installed in the original position.

For the procedure to replace the water temperatureregulators, see the Service Manual, “Disassemblyand Assembly” module. Consult your Caterpillardealer for assistance.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling systemto a level that is below the water temperatureregulator housing.

109Reference Information Section

Customer Service

Reference InformationSection

Customer Service

i01452711

Customer AssistanceSMCS Code: 1000

USA and Canada

When a problem arises concerning the operation ofan engine or concerning the service of an engine,the problem will normally be managed by the dealerin your area.

Your satisfaction is a primary concern to Caterpillarand to Caterpillar dealers. If you have a problemthat has not been handled to your completesatisfaction, follow these steps:

1. Discuss your problem with a manager from thedealership.

2. If your problem cannot be resolved at the dealerlevel without additional assistance, use thephone number that is listed below to talk with aField Service Coordinator:

1-800-447-4986

The normal hours are from 8:00 to 4:30 Mondaythrough Friday Central Standard Time.

3. If your needs have not been met still, submit thematter in writing to the following address:

Caterpillar Inc.Manager, Customer Service, Engine DivisionMossville Bldg AP.O. Box 600Peoria, Illinois 61552-0600

Please keep in mind: probably, your problem willultimately be solved at the dealership, using thedealership’s facilities, equipment, and personnel.Therefore, follow the steps in sequence when aproblem is experienced.

Outside of the USA and of Canada

If a problem arises outside the USA and outsideCanada, and if the problem cannot be resolved atthe dealer level, consult the appropriate Caterpillaroffice.

Latin America, Mexico, CarribeanCaterpillar Americas Co.701 Waterford Way, Suite 200Miami, FL 33126USAPhone: 305-476-6876Fax: 305-476-6850

Europe, Africa, and Middle EastCaterpillar Overseas S.A.76 Route de FrontenexP.O. Box 60001211 Geneva 6SwitzerlandPhone: 22-849-4444Fax: 22-849-4544

Far EastCaterpillar Asia Pte. Ltd.7 Tractor RoadJurong, Singapore 627968Republic of SingaporePhone: 65-662-8333Fax: 65-662-8302

ChinaCaterpillar China Ltd.37/F, The Lee Gardens33 Hysan AvenueCauseway Bay, Hong KongChinaPhone: 852-2848-0333Fax: 852-2848-0440

JapanShin Caterpillar Mitsubishi Ltd.Setagaya Business Square Tower10-1, Yoga 4-chomeSetagaya, TokyoJapanPhone: 81-3-5717-1121Fax: 81-3-5717-1177

JapanCaterpillar Power Systems, Inc.Japan Branch Sanno Grand Bldg.2-14-2 NagatachoChiyoda-ku, Tokyo, 100JapanPhone: 81-335-93-3237Fax: 81-335-93-3238

Australia and New ZealandCaterpillar of Australia Ltd.1 Caterpillar DrivePrivate Mail Bag 4Tullamarine, Victoria 3043AustraliaPhone: 03-9339-9333Fax: 03-9335-3366

110Reference Information SectionCustomer Service

i01028392

Ordering Replacement PartsSMCS Code: 7567

When replacement parts are required for thisproduct Caterpillar recommends using Caterpillarreplacement parts or parts with equivalent spec-ifications including, but not limited to, physicaldimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

Quality Caterpillar replacement parts are availablefrom Caterpillar dealers throughout the world.Caterpillar dealers’ parts inventories are up-to-date.The parts stocks include all of the parts that arenormally needed to protect your Caterpillar engineinvestment.

When you order parts, please specify the followinginformation:

• Part number

• Part name

• Quantity

If there is a question concerning the part number,please provide your dealer with a completedescription of the needed item.

When a Caterpillar engine requires maintenanceand/or repair, provide the dealer with all theinformation that is stamped on the Information Plate.This information is described in this Operation andMaintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform thedealer about the conditions of the problem andthe nature of the problem. Inform the dealer aboutwhen the problem occurs. This will help the dealerin troubleshooting the problem and solving theproblem faster.


Reference Materials

Reference Materials

i00912149

Maintenance RecordsSMCS Code: 1000

Caterpillar Inc. recommends the retentionof accurate maintenance records. Accuratemaintenance records can be used for the followingpurposes:

• Determine operating costs.

• Establish maintenance schedules for otherengines that are operated in the sameenvironment.

• Show compliance with the required maintenancepractices and maintenance intervals.

Maintenance records can be used for a variety ofother business decisions that are related to enginemaintenance.

Maintenance records are a key element of amaintenance program that is well managed.Accurate maintenance records can help yourCaterpillar dealer to fine tune the recommendedmaintenance intervals in order to meet the specificoperating situation. This should result in a lowerengine operating cost.

Records should be kept for the following items:

Fuel Consumption – A record of fuel consumptionis essential in order to determine when the loadsensitive components should be inspected orrepaired. Fuel consumption also determinesoverhaul intervals.

Service Hours – A record of service hours isessential to determine when the speed sensitivecomponents should be inspected or repaired.

Documents – These items should be easy to obtain,and these items should be kept in the enginehistory file. All of the documents should show thisinformation: date, service hours, fuel consumption,unit number, and engine serial number. Thefollowing types of documents should be kept asproof of maintenance or repair for warranty:

Keep the following types of documents as proof ofmaintenance for warranty. Also, keep these types ofdocuments as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owner’s repair costs

• Owner’s receipts

• Maintenance log

112Reference Information SectionReference Materials

i01176304

Maintenance LogSMCS Code: 1000

Table 37

Engine Model Customer Identifier

Serial Number Arrangement Number

ServiceHours

QuantityOf Fuel Service Item Date Authorization


Reference Materials

i00769479

Valve Data SheetSMCS Code: 1000

Table 38

Engine Model Serial Number Service Hours Authorization

Cylinder CylinderPressure

Valve Location CurrentMeasure

StemBaseline

RotatorBaseline Wear

Pushrod Side1

Exhaust Manifold

Pushrod Side2

Exhaust Manifold

Pushrod Side3

Exhaust Manifold

Pushrod Side4

Exhaust Manifold

Pushrod Side5

Exhaust Manifold

Pushrod Side6

Exhaust Manifold

Pushrod Side7

Exhaust Manifold

Pushrod Side8

Exhaust Manifold

Pushrod Side9

Exhaust Manifold

Pushrod Side10

Exhaust Manifold

Pushrod Side11

Exhaust Manifold

Pushrod Side12

Exhaust Manifold

Pushrod Side13

Exhaust Manifold

Pushrod Side14

Exhaust Manifold

Pushrod Side15

Exhaust Manifold

Pushrod Side16

Exhaust Manifold

114Reference Information SectionReference Materials

i01454386

Reference MaterialSMCS Code: 1000

The following literature can be obtained through anyCaterpillar dealer.

Lubricants

• Data Sheet, PEHP0002, “Multipurpose LithiumComplex Grease with Molybdenum (MPGM)”

• Data Sheet, PEHP0003, “Multipurpose LithiumComplex Grease (MPG)”

• Data Sheet, PEHP0017, “Special Purpose Grease(SPG) Bearing Lubricant”

• Special Publication, PECP6028, “One SafeSource”

• Special Publication, PEDP7036, “S·O·S FluidAnalysis”

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

Fuels

• Application and Installation Guide, LEKQ7256,“Fuels, Fuel Systems”

• Application and Installation Guide, LEKQ7260,“Low Energy Fuels”

Coolants

• Data Sheet, PEHP7057, “Coolant Analysis”

• Special Publication, PECP6028, “One SafeSource”

• Special Publication, PEDP7036, “S·O·S FluidAnalysis”

• Special Publication, SEBD0518, “Know YourCooling System”

• Special Publication, SEBD0970, “Coolant andYour Engine”

Miscellaneous

• Application and Installation Guide, LEKQ7250,“Air Intake”

• Application and Installation Guide, LEKQ7260,“Low BTU Engines”

• Disassembly and Assembly, RENR2269, “G3516BEngines”

• Engine Performance, LEBQ6117, “G3500Industrial”

• Engine Performance, LEBQ6169, “G3500Generator Set”

• Maintenance Management Schedules,SEBU6127, “Schedules for Industrial and EPGSpark Ignited Gas Engines”

• Schematics, RENR2271, “G3516B Engines”

• Service Manual, REG1139F, “Service ManualContents Microfiche”

• Software Program, LEKQ6378, “Methane NumberProgram”

• Specifications, SENR3130, “Torque Specifications”

• Specifications, RENR2267, “G3516B Engines”

• Specifications, SENR6417, “G3500 EngineAttachments”

• Special Instruction, GMG00694, “AnalyzingCylinder Condition By Measuring Air Flow”

• Special Instruction, REHS0128, “Using the147-5482 Indicator Gauge For Valve Lash andValve Bridge Adjustment”

• Special Instruction, SEHS7332, “Do Not OperateTag”

• Special Instruction, SEHS7633, “Battery TestProcedure”

• Special Instruction, SEHS7768, “Use of the6V-2150 Starting/Chargineg Analyzer”

• Special Instruction, SEHS8712, “Using the8T-2700 Blowby/Airflow Indicator Group”

• Special Instruction, SEHS8984, “Using the1U-8860 Blowby Pickup Group”

• Special Instruction, SEHS9031, “StorageProcedure for Caterpillar Products”

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

• Special Instruction, REHS0531, “Installation andInitial Start-Up Procedure for G3516B Engines”

• Special Publication, NEHS0526, “ServiceTechnician Application Guide”


Reference Materials

• Special Publication, NENG2500, “Caterpillar Toolsand Shop Products Guide”

• Special Publication, SEBF8029, “Index toGuidelines for Reusable Parts and SalvageOperations”

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

• Systems Operation/Testing and Adjusting,RENR2268, “G3516B Engines”

• Troubleshooting, RENR2270, “G3516B Engines”

i01109461

Additional Reference MaterialSMCS Code: 1000

The “EMA Lubricating Oils Data Book” canbe obtained from the following locations: localtechnological society, local library, and local college.If necessary, consult EMA at the following address:

Engine Manufacturers Associaton401 N. Michigan Ave.Chicago, IL, USA 60611Telephone: (312) 644-6610 ext. 3626

The “Society of Automotive Engineers (SAE)Specifications” can be found in your SAE handbook.This publication can also be obtained from thefollowing locations: local technological society, locallibrary, and local college. If necessary, consult SAEat the following address:

SAE International400 Commonwealth DriveWarrendale, PA, USA 15096-0001Telephone: (724) 776-4841

The “American Petroleum Institute Publication No.1509” can be obtained from the following locations:local technological society, local library, and localcollege. If necessary, consult API at the followingaddress:

American Petroleum Institute1220 L St. N.W.Washington, DC, USA 20005Telephone: (202) 682-8000

The International Organization for Standardization(ISO) offers information and customer serviceregarding international standards and standardizingactivities. ISO can also supply information on thefollowing subjects that are not controlled by ISO:national standards, regional standards, regulations,certification, and related activities. Consult themember of ISO in your country.

International Organization for Standardization(ISO)1, rue de VarembéCase postale 56CH-1211 Genève 20SwitzerlandTelephone: +41 22 749 01 11Facsimile: +41 22 733 34 30E-mail: [email protected] site: http://www.iso.ch

European classifications are established by theCounseil International Des Machines a Combustion(CIMAC) (International Council on CombustionEngines).

CIMAC Central SecretariatLyoner Strasse 1860528 FrankfurtGermanyTelephone: +49 69 6603 1567Facsimile: +49 69 6603 1566

i00382622

Warranty InformationSMCS Code: 1000

Engine Protection Plans

Extended Warranties and ServiceContracts

A wide variety of protection plans are available forCaterpillar Engines. Consult your Caterpillar dealerfor detailed information on the specific programsand coverages that are available.

Consult your Caterpillar dealer for information on aplan that is tailored in order to fit your requirements.

116Index Section

Index

A

Additional Reference Material ............................. 115After Starting Engine ............................................. 36

Engaging the Driven Equipment ........................ 36After Stopping Engine............................................ 39Aftercooler Condensation - Drain .......................... 59Air Starting Motor Lubricator Bowl - Clean ............ 59Air Starting Motor Lubricator Oil Level - Check ..... 60

Adjust the Lubricator .......................................... 60Air Tank Moisture and Sediment - Drain................ 60Alarms and Shutoffs .............................................. 28

Prevention of Start-up ........................................ 29Setpoints for Alarms and Shutoffs ..................... 29Testing Alarms and Shutoffs .............................. 29

Alternator - Inspect ................................................ 61Alternator and Fan Belts - Inspect/Adjust/Replace................................................................ 61Alternator Belt Adjustment ................................. 61Fan Drive Belt Adjustment ................................. 61Inspection........................................................... 61Replacement...................................................... 61

B

Battery Electrolyte Level - Check .......................... 62Before Starting Engine .................................... 14, 32

Air Inlet System.................................................. 32Cooling System.................................................. 32Driven Equipment .............................................. 32Electrical System ............................................... 32Fuel System....................................................... 32Lubrication System ............................................ 33Starting System ................................................. 33Walk-Around Inspection..................................... 32

Burn Prevention..................................................... 11Batteries............................................................. 12Coolant............................................................... 11Oils..................................................................... 12

C

Cold Weather Starting ........................................... 33Commercial Heavy-Duty Coolant/Antifreeze andSCA ..................................................................... 51

Control Panel - Inspect .......................................... 62Record the Data and Review the Data............... 62

Conventional Coolant/Antifreeze Cooling SystemMaintenance ........................................................ 51Adding the SCA to Conventional Coolant/Antifreezeat the Initial Fill ................................................. 51

Adding the SCA to Conventional Coolant/AntifreezeFor Maintenance .............................................. 52

Cleaning the Cooling System of Heavy-DutyCoolant/Antifreeze............................................ 52

Coolant Recommendations ................................... 49

Cooling System Coolant (DEAC) - Change........... 62Clean the Cooling System ................................. 63Cleaning a Cooling System that has HeavyDeposits or Plugging........................................ 64

Draining the Cooling System ............................. 62Fill the Cooling System ...................................... 65

Cooling System Coolant Analysis (Level II) -Obtain .................................................................. 65

Cooling System Coolant Level - Check ................. 65Add Coolant ....................................................... 66

Cooling System Specifications .............................. 48Cooling System Supplemental Coolant Additive(SCA) - Test/Add.................................................. 66Add the SCA, If Necessary ................................ 67S·O·S Coolant Analysis (Level I)........................ 67Test the Concentration of the SCA..................... 66

Crankcase Blowby - Measure/Record ................... 67Crankcase Pressure - Measure (Engines with FumesDisposal Filters) ................................................... 68

Crankshaft Vibration Damper - Inspect ................. 68Removal and Installation.................................... 69

Crushing Prevention and Cutting Prevention......... 13Customer Assistance........................................... 109

Outside of the USA and of Canada.................. 109USA and Canada ............................................. 109

Customer Service................................................ 109Cylinder Pressure - Measure/Record .................... 69

D

Diesel Engine Antifreeze/Coolant (DEAC) ............ 50Driven Equipment - Check..................................... 70Driven Equipment - Inspect/Replace/Lubricate ..... 70

E

Electrical System................................................... 15Grounding Practices .......................................... 15

Electrohydraulic System - Inspect ......................... 70Check the Oil Level ............................................ 70Inspect the Filter Indicator.................................. 70Inspect the Lines, Connections, andComponents..................................................... 71

Electrohydraulic System Oil - Change................... 71Electrohydraulic System Oil Filter - Change.......... 71Emergency Stopping ............................................. 38

Emergency Stop Button ..................................... 38Unplanned Shutdowns....................................... 38

Engine Air Cleaner Element - Replace.................. 72Cleaning the Primary Air Cleaner Elements ...... 73Servicing the Air Cleaner Elements ................... 72

Engine Air Cleaner Service Indicator - Inspect...... 74Test the Service Indicator .................................. 75

Engine Crankcase Breather - Clean...................... 75Breather Assemblies.......................................... 76Canisters............................................................ 76

117Index Section

Engine Features and Controls............................... 23Engine Lifting......................................................... 22Engine Lifting and Storage .................................... 22Engine Mounts - Check ......................................... 77Engine Oil .............................................................. 43

Commercial Oils................................................. 43Lubricant Viscosity Recommendations.............. 44

Engine Oil - Change .............................................. 77Engine Oil Filter - Change ..................................... 79

Inspect the Used Oil Filter Elements.................. 80Replacing the Engine Oil Filters During EngineOperation ......................................................... 80

Replacing the Engine Oil Filters With the EngineStopped............................................................ 79

Engine Oil Level - Check ....................................... 80Engine Oil Sample - Obtain ................................... 81

Obtain the Sample and the Analysis.................. 81Engine Operation................................................... 37

Operating the Engine and the DrivenEquipment ........................................................ 37

Partial Load Operation....................................... 37Engine Protective Devices - Check ....................... 82

Visual Inspection................................................ 82Engine Speed/Timing Sensor - Clean/Inspect....... 82Engine Starting................................................ 14, 32Engine Stopping .............................................. 15, 38Engine Storage...................................................... 22

Generator Storage ............................................. 22Engine Valve Lash - Inspect/Adjust ....................... 83

Engine Valve Lash ............................................. 84Valve Bridge....................................................... 83

Exhaust Bypass - Inspect...................................... 84Exhaust Piping - Inspect........................................ 84

F

Fire Prevention and Explosion Prevention............. 12Fire Extinguisher ................................................ 13Lines, Tubes and Hoses..................................... 13

Foreword.................................................................. 5California Proposition 65 Warning ....................... 4Literature Information........................................... 4Maintenance ........................................................ 4Maintenance Intervals.......................................... 4Operation ............................................................. 4Overhaul .............................................................. 5Safety................................................................... 4

Fuel Metering Valve Screen - Check ..................... 84Fuel Recommendations......................................... 46

Dry Natural Gas ................................................. 46Gaseous Fuel Filters.......................................... 47General Fuel Information ................................... 46Propane ............................................................. 46

Fuel Specifications ................................................ 46Fuel System Fuel Filter Differential Pressure -Check................................................................... 85

Fumes Disposal Filter - Drain ................................ 85Fumes Disposal Filter Differential Pressure -Check................................................................... 85

Fumes Disposal Filter Element - Replace ............. 86

G

Gas Pressure Regulator Condensation - Drain ..... 86General Coolant Information ................................. 48

Additives ............................................................ 49Glycol ................................................................. 49Water ................................................................. 48

General Hazard Information .................................... 9Asbestos Information ......................................... 11Containing Fluid Spillage ................................... 10Dispose of Waste Properly ................................ 11Fluid Penetration................................................ 10Pressure Air and Water...................................... 10

General Torque Information................................... 40

H

Hoses and Clamps - Inspect/Replace ................... 87Replace the Hoses and the Clamps .................. 87

Hydraulic Oil .......................................................... 44

I

Ignition System Spark Plugs - Check/Adjust/Replace(Spark Plugs with Adjustable Electrode Gaps) .... 88Cleaning the Spark Plug .................................... 91Inspecting the Spark Plug.................................. 90Installing the Spark Plug .................................... 91Removing the Spark Plug .................................. 89

Ignition System Spark Plugs - Replace (Spark Plugsthat have Precombustion Chambers) .................. 92Cleaning the Spark Plug .................................... 94Inspecting the Spark Plug.................................. 94Installing the Spark Plug .................................... 94Removing the Spark Plug .................................. 92

Ignition System Timing - Check/Adjust.................. 95Ignition Systems .................................................... 14Important Safety Information ................................... 2Inlet Air System - Inspect....................................... 95

L

Lubricant Information............................................. 43Lubricant Specifications ........................................ 43

M

Maintenance Interval Schedule ............................. 57Maintenance Log................................................. 112Maintenance Records.......................................... 111Maintenance Section ............................................. 40Manual Stop Procedure......................................... 39Model View Illustrations......................................... 16Model Views and Specifications ............................ 16Mounting and Dismounting.................................... 14

118Index Section

O

Operation Section.................................................. 22Ordering Replacement Parts............................... 110Overhaul (In-Frame) .............................................. 96

In-Frame Overhaul Information .......................... 96Scheduling an In-Frame Overhaul ..................... 96

Overhaul (Major).................................................... 97Major Overhaul Information ............................... 98Scheduling a Major Overhaul............................. 97

Overhaul (Top End) ............................................... 99Scheduling a Top End Overhaul ........................ 99Top End Overhaul Information ........................... 99

Overhaul Considerations ..................................... 101Overhaul Information ....................................... 101

Oxygen Sensor - Calibrate .................................. 103

P

Performance Parameters....................................... 23Air/Fuel Ratio ..................................................... 23Oil Consumption ................................................ 23Setting of the Exhaust Bypass (Wastegate) ...... 23

Plate Locations and Film Locations....................... 20Engine Identification........................................... 20Information Plate................................................ 20Serial Number Plate........................................... 20

Product Description ............................................... 17Cooling System.................................................. 18Engine Service Life ............................................ 18Fuel System (Air/Fuel Ratio Control) ................. 17Ignition System .................................................. 18Lubrication System ............................................ 18

Product Identification Information .......................... 20Product Information Section .................................. 16

R

Radiator - Clean .................................................. 103Reference Information ........................................... 21Reference Information Section ............................ 109Reference Material .............................................. 114

Coolants........................................................... 114Fuels ................................................................ 114Lubricants ........................................................ 114Miscellaneous .................................................. 114

Reference Materials ............................................ 111Refill Capacities..................................................... 56

Cooling System.................................................. 56Lubrication System ............................................ 56

S

S·O·S Coolant Analysis ......................................... 54S·O·S Coolant Analysis (Level I)........................ 55S·O·S Coolant Analysis (Level II)....................... 55

S·O·S Oil Analysis ................................................. 44Condemning Limits of the Oil............................. 45

Safety Section ......................................................... 6Safety Signs and Labels.......................................... 6Sensors and Electrical Components ..................... 24

Electronic System .............................................. 24Sensors.............................................................. 25

Specifications ........................................................ 19Standard Torque for Constant Torque HoseClamps................................................................. 41

Standard Torque for Inch Fasteners ...................... 41Standard Torque for Metric Fasteners ................... 40Standard Torque for Worm Drive Band HoseClamps................................................................. 41

Starting Motor - Inspect ....................................... 104Air Starting Motor............................................. 104Electric Starting Motor ..................................... 104Removal and Installation of the StartingMotor .............................................................. 104

Starting the Engine................................................ 34Automatic Starting ............................................. 34Manual Starting.................................................. 35Parameters for the Start/Stop Control................ 34

Starting with Jump Start Cables ............................ 35Supplemental Coolant Additive (SCA)................... 51

T

Table of Contents..................................................... 3Torque Specifications ............................................ 40Turbocharger - Inspect......................................... 104

V

Valve Data Sheet................................................. 113Valve Stem Projection - Measure/Record............ 105

W

Walk-Around Inspection ...................................... 107Inspect the Engine for Leaks and for LooseConnections ................................................... 107

Warranty Information ........................................... 115Engine Protection Plans................................... 115

Water Pump - Inspect.......................................... 108Water Temperature Regulator - Replace............. 108Water/Supplemental Coolant Additive (SCA) ........ 53

Adding the SCA to Water at the Initial Fill .......... 53Adding the SCA to Water for Maintenance ........ 53

Product and Dealer InformationNote: For product identification plate locations, see the section “Product Identification Information” in theOperation and Maintenance Manual.

Delivery Date:

Product Information

Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information

Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:

©2001 CaterpillarAll Rights Reserved Printed in U.S.A.