Home

MAINTENANCE INTERVALS - Safety

1. 1 2 z Jo O o g Q SS 3 o O Illustration 61 900833473 1 Receptacle for the wiring harness 2 Solenoid 3 Bolt 4 Guards 84 Maintenance Section Electrohydraulic Actuator Recondition SEBU7563 09 1 Disconnect the wiring harness from receptacle 1 Inspect the connectors for damage and corrosion Make repairs if necessary 2 Inspect the joint between solenoid 2 and the housing for leaks If a leak is found between the solenoid and the housing replace the O ring seal for the solenoid For instructions refer to this Operation and Maintenance Manual Electrohydraulic Actuator Recondition 3 Check the solenoid s mounting bolts 3 for tightness 4 Remove guards 4 A O O o g O O g00833477 Illustration 62 5 Rod end 6 Clevis 7 Boot 5 Disconnect rod end 5 from clevis 6 6 Remove clevis 6 7 Remove rubber boot 7 Inspect the boot for damage If the boot is damaged obtain a new boot for assembly There may be a small amount of hydraulic fluid inside of the boot Wipe off the boot and reinstall the boot If an excessive amount of hydraulic fluid is found inside the boot the seal for the actuator s shaft is probably worn If this is the case replace the piston assembly For instructions refer to this Operation and Maintenance Manual Electr
2. 80 Engine Crankcase Breather Clean n se 91 Engine Mounts Check rarnnrrnnnronvrrnnnrrnnrrnnnrenenn 92 Engine Valve Lash Inspect Adjust 101 Engine Valve Rotators Inspect eee 102 Valve Stem Projection Measure Record 122 Every 5000 Service Hours Air Starting Motor Lines Screen Clean 67 Air Starting Motor Lubricator Bowl Clean 67 Combustion Sensor Clean Inspect Replace 72 Cooling System Level Switch Inspect wax 77 Crankcase Blowby Measure Record 55 80 Cylinder Pressure Measure Record 0 81 Driven Equipment Check nrnnrnnnrnnrrrrrrnrnnnnnnnnnn 82 Electrohydraulic System Check Adjust 85 Electrohydraulic System Oil Change 86 Electrohydraulic System Oil Filter Change 87 Engine Oil Change rrrnnnnnnvrrvnnrennrrrnnnrrrrrrennrerenr 92 Engine Oil Filter Change seeen 93 Engine Protective Device Connections Inspect 98 Engine Protective Devices Check s es 100 Exhaust Bypass Recondition eee 102 Gas Shutoff Valve Inspect ceeeeeeeeeees 105 Inlet Air System Inspect n 111 Inlet Gas Manifold and Piping Inspect Replace 111 SEBU7563 09 63 Maintenance Section Maintenance Interval Schedule Prechamber Check Valves Clean n 118 Starting Motor Inspect i e 119 Turbocharger Inspect
3. g00790542 Illustration 103 1 Air valve 2 Purge valve 3 Gate valve 4 Tube Note Use of a platform may be necessary in order to reach the cleaner tube 1 Stop the engine 2 Ensure that air valve 1 and gate valve 3 are closed 3 Open purge valve 2 in order to relieve any pressure from the container 4 Remove tube 4 Discard the used tube 5 Install a new tube 6 Close purge valve 2 100682053 Valve Stem Projection Measure Record SMCS Code 1105 082 Valve Recession The valves and the valve seats are worn over time This causes the valves to recede into the cylinder head This condition is called valve recession The exhaust valves and valve seats show the greatest wear due to high operating temperatures The top end overhaul interval is normally scheduled according to exhaust valve recession SEBU7563 09 123 Maintenance Section Walk Around Inspection The actual measurement of the valve recession inside of the cylinder head is difficult to obtain Two simpler methods are used to determine valve recession e Measure the projection of the valve stem above the cylinder head It is necessary to remove the rocker arms in order to obtain this measurement This method is more accurate than measuring the projection of the exhaust valve rotators Measure the projection of the exhaust valve stems with the 4C 2980 Cylinder Head Valve Projection Group Measure the pr
4. 0 5 81 Electrohydraulic System Oil Filter Change 87 Engine Crankcase Breather Clean naases 91 Engine Protective Device Connections Inspect 98 Engine Speed Timing Sensor Clean Inspect 100 Engine Valve Lash Inspect Adjust rrrnnrenn 101 Engine Valve Rotators Inspect mrrssrrnnnvrnn 102 Valve Stem Projection Measure Record 122 Every 1000 Service Hours Actuator Control Linkage Lubricate 0 0 66 Belts Inspect Adjust Replace mrrnrrrnrrnnrnnnnnn 71 Hoses and Clamps Inspect Replace 105 Ignition System Spark Plugs Check Adjust 108 Every 2000 Service Hours Aftercooler Condensation Drain s es 67 Cooling System Coolant Sample Level 2 OCIA 222 cass ten ade cog E E ET ea Savane ada ET 77 Crankshaft Vibration Damper Inspect 80 Engine Crankcase Breather Clean 00 91 Engine Mounts Check rrnnrrnnnnonvrrnnnvrnnrrnnnrenenr 92 Engine Valve Lash Inspect Adjust 0 0 101 Engine Valve Rotators Inspect eee 102 Valve Stem Projection Measure Record 122 Every 5000 Service Hours Air Starting Motor Lines Screen Clean 67 Air Starting Motor Lubricator Bowl Clean 67 Combustion Sensor Clean Inspect Replace 72 Cooling System Level Switch Inspect wax 77 Crankcase Blowby Measure Record 008 80 Cyli
5. Inspect the components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures New parts are not required if the existing parts can still be used reconditioned or repaired If the components are not in the reusability guidelines refer to the Service Manual Specifications module Rebuild The component can be reconditioned in order to comply with reusability guidelines 116 Maintenance Section Overhaul Considerations SEBU7563 09 Replace The service life of the part is exhausted The part may fail before the next maintenance interval The part must be replaced with a part that meets functional specifications The replacement part may be a new part a Cat remanufactured part a rebuilt part or a used part Some worn components may be exchanged with your Caterpillar dealer Consult your Caterpillar dealer about repair options for your engine Table 42 Top End Overhaul Procedure Component Inspect Replace Seals for the gas admission valve Precombustion chambers Drive coupling Rebuild Gas pressure regulator Starting motor Turbochargers Replace Connecting rod bearings Cylinder heads and gaskets Oil tempera
6. 7 After 60 to 90 seconds close air valve 1 Close gate valve 4 8 Open purge valve 2 in order to relieve any pressure from the container Close purge valve 2 i00908991 Turbocharger Inspect SMCS Code 1052 040 Periodic inspection and cleaning is recommended for the turbocharger Fouling of the turbine wheels can contribute to loss of engine power and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel could allow parts from the compressor wheel to enter an engine cylinder This can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential
7. 85 Maintenance Section Electrohydraulic System Check Adjust Illustration 64 900833594 3 Rod end 4 Clevis 5 Boot 6 Nut 4 Disconnect rod end 3 from clevis 4 5 Remove clevis 4 and rubber boot 5 Inspect the boot for damage If the boot is damaged obtain a new boot for assembly Note Handle the actuator carefully Use care not to damage the actuator s shaft Damage to the shaft can result in premature failure of the O ring seal This will cause hydraulic fluid to leak 6 Remove nut 6 in order to remove the actuator from the bracket Note Do not allow debris to enter the actuator Seal the openings with clean covers immediately after the solenoid and or the piston assembly is removed 7 up 900833595 Illustration 65 7 Housing 8 Piston assembly 9 O ring seal 10 Bolt 11 Solenoid 12 O ring seal Note The spring in the housing will be loose after the piston assembly is removed 7 Place housing 7 in a vise Remove piston assembly 8 Remove O ring seal 9 from the joint between the piston assembly and the housing Note O ring seal 9 is included with the piston assembly 8 Install a new O ring seal 9 and piston assembly 8 Make sure that the spring in the housing is properly aligned in the bore of the piston
8. 98 Engine Speed Timing Sensor Clean Inspect 100 Engine Valve Lash Inspect Adjust ee 101 Engine Valve Rotators Inspect eee 102 Valve Stem Projection Measure Record 122 Every 1000 Service Hours Actuator Control Linkage Lubricate 0 66 Belts Inspect Adjust Replace mrrrnrrnrrnnrnnnnnn 71 Combustion Sensor Clean Inspect Replace 72 Hoses and Clamps Inspect Replace 105 Ignition System Spark Plugs Replace 111 Prechamber Check Valves Clean 2 005 118 Every 2000 Service Hours Aftercooler Condensation Drain i 67 Cooling System Coolant Sample Level 2 Obtaln MESA tener ree creer ene ee er ree 77 Crankshaft Vibration Damper Inspect 80 Cylinders Inspect o oo eeeeeeeeeeeeeeeeeeeteeeeeeeeeeees 82 Engine Crankcase Breather Clean aasan 91 Engine Mounts Check arrnrrnnnronnrrrnnnnrnrrrennrerenr 92 Engine Valve Lash Inspect Adjust 0 0 0 101 Engine Valve Rotators Inspect mmrrrsrrnnnrrrn 102 Valve Stem Projection Measure Record 122 Every 5000 Service Hours Air Starting Motor Lines Screen Clean 67 Air Starting Motor Lubricator Bowl Clean 67 Cooling System Level Switch Inspect 77 Crankcase Blowby Measure Record 5 80 Cylinder Pressure Measure Record 05 81 Driven Equipm
9. 1 Shut off the engine 2 Shut off the fuel supply to the GSOV 1 2 I L 9 7 Z 1 Illustration 94 900834076 1 Receptacle 2 Gasket 3 Cap 4 Bolt 5 Cover 3 Disconnect the wiring harness from receptacle 1 Inspect the connectors for damage and corrosion Make repairs as needed 4 Inspect gasket 2 for damage and wear Replace the gasket if necessary 5 Remove cap 3 Remove the washer under the cap in order to inspect the solenoid 6 Inspect the solenoid for damage If the epoxy coating is cracked or damaged obtain a new solenoid for assembly 7 Inspect the cavity for the solenoid Look for moisture debris and abrasion of the wiring Make repairs if necessary Thoroughly clean the cavity 8 Remove bolts 4 and cover 5 in order to inspect the internal parts of the GSOV 9 Clean the internal parts Inspect the diaphragm the center pin for the diaphragm and the shaft for the solenoid If any of the parts are damaged replace the entire GSOV 10 Inspect the internal passages Remove any debris 11 Reassemble the diaphragm the center pin for the diaphragm and the shaft for the solenoid Install cover 5 with bolts 4 12 Install cap 3 Connect the wiring harness to
10. 2 Open both drain valves 2 Allow the oil to drain Note Some oil will remain in the housing after the oil has been drained This oil will pour out of the housing when cover 3 is removed Prepare to catch the oil in a suitable container Clean up any spilled oil with rags DO NOT use absorbent particles to clean up the oil Personal injury can result from parts and or cov ers under spring pressure Spring force will be released when covers are re moved Be prepared to hold spring loaded covers as the bolts are loosened 3 Be alert to the spring force The cover has a spring force up to 240 N 54 Ib Gradually loosen but do not remove the last two bolts or nuts that are located at opposite ends of covers 3 Before removing the last two bolts or nuts pry the covers loose or tap the covers with a rubber mallet in order to relieve any spring pressure GRS SRRRIRRI SR STI KR BREW SEKI SKIKKER PS32320 ORKER SR SSR PRS SSRS RSRK SRK RRK SEKIREI SEKI PS29229 RR PR92392 R PROSS RRS RRs KR RR RSS RRS eganetoneconaconnsecetecorerocanseanecacerea SRN G RRR RRR RN RR INN 23293232300000 SSK BEEK ER XO ox RRS g00789772 Illustration 81 5 Wire rack 6 O ring seal 7 Element 4 Elements 7 are mounted on wire racks 5 inside the housing Use a pan to catch the oil that drips when wire racks 5 ar
11. 90 Maintenance Section Engine Air Cleaner Service Indicator Inspect SEBU7563 09 Nr Illustration 73 900294189 1 Service indicator 2 Cover 1 Remove cover 2 2 Remove the used element and dispose of the element 3 Clean the inside of cover 2 and clean the inside of the body 4 Install a new element Install cover 2 5 Reset service indicator 1 if necessary i01520297 Engine Air Cleaner Service Indicator Inspect SMCS Code 7452 040 Some engines are equipped with an air cleaner for crankcase ventilation This air cleaner filters air that is drawn into the crankcase The air dilutes the harmful fumes that may accumulate in the crankcase The air and the fumes are drawn away from the crankcase Illustration 74 900789538 Service indicator Observe the service indicator Clean the air cleaner element or replace the air cleaner element when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position e The air filter restriction reaches 25 kPa 1 inch of H20 Inspect the service indicator daily for cracks holes or loose fittings If any of these conditions are present repair the service indicator or replace the service indicator Test the Service Indicator Service indicators are important instruments Check for ease
12. Clean the oil filler cap Install the oil filler cap 102169249 Engine Air Cleaner Element Single Element Clean Replace SMCS Code 1051 1054 037 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements Note Use of a platform may be necessary to reach the air cleaner element If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air cleaner element Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected The air cleaner element should be repla
13. condition of the engine Note Cylinder pressure is one of the three factors that help to determine the in frame overhaul interval For more information refer to this Operation and Maintenance manual Overhaul In Frame Maintenance Section Cylinder pressure can be measured during inspection of the spark plugs Use the following guidelines for checking the cylinder pressure e Remove all of the spark plugs e Verify that the choke is fully open Minimize the cranking time This will enable a maximum consistent cranking speed for the check Also the starting air or battery power will be conserved A loss of cylinder pressure or a change of pressure in one or more cylinders may indicate the following conditions These conditions may indicate a problem with lubrication e Excessive deposits e Guttering of valves e A broken valve e A piston ring that sticks e A broken piston ring e Worn piston rings e Worn cylinder liners If the cylinder pressure has risen by one or more compression ratios the engine needs a top end overhaul in order to remove deposits Failure to remove the deposits will increase the chance for detonation Severe guttering of the valves will occur To measure the cylinder pressure refer to Special Instruction GMG00694 Analyzing Cylinder Condition By Measuring Air Flow Also use the 146 2739 Cylinder Pressure Adapter Illustration 60 is a graph of typical cylinder pressures for engi
14. higher inlet manifold air pressure and a higher compression ratio Higher voltage reduces the service life of components such as spark plug wires and transformers Removing the Spark Plug 12 3 Illustration 95 g00823378 1 Harness connector 2 Bolt 3 Transformer 4 O ring seal 5 Extension 6 Spark plug 1 Ensure that the mode control switch is in the STOP or OFF RESET position NOTICE Pulling on the wiring harness may break the wires Do not pull on the wiring harness 2 Remove the lockwire Disconnect harness connector 1 Use pliers to turn the connector counterclockwise 3 Remove bolts 2 4 Remove transformer 3 Inspect O ring seal 4 If the O ring seal is worn or damaged discard the O ring seal and use a new O ring seal for assembly 5 Remove extension 5 Pressurized air can cause personal injury When pressurized air is used for cleaning wear a pro tective face shield protective clothing and pro tective shoes 6 Debris may have collected near the spark plug Thoroughly remove any debris Use compressed air The maximum air pressure for cleaning purposes must be below 207 kPa 30 psi Ensure that the area around the spark plug is clean and free of dirt and debris SEBU7563 09 109 Maintenance Section Ignition System Spark Plugs Check Adjust 7 Use a 40 4601 Spark Plug Socket and an extension to loosen spark plug 6 After the spark plu
15. pry the cover loose or tap the cover with a rubber mallet in order to relieve any spring pressure Illustration 83 900789772 5 Wire rack 6 O ring seal 7 Element 5 Elements 7 are mounted on wire rack 5 inside the housing Use a pan to catch the oil that drips when wire rack 5 is removed Remove wire rack 5 Remove used elements 7 Clean up any oil that is spilled 96 Maintenance Section Engine Oil Level Check SEBU7563 09 NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 6 Ensure that the new oil filter elements are in good condition Place the elements on wire rack 5 Install the wire rack and the elements 7 Ensure that the surfaces for O ring seal 6 are clean Inspect the O ring seal If the old O ring seal is damaged or deteriorated replace the old O ring seal with a new O ring seal Install the O ring seal 8 Install cover 3 Ensure that the spring is seated properly between element 8 and cover 3 Close drain valve 2 9 Rotate control valve 4 to the LOWER FILL position Observe pre
16. receptacle 1 13 Turn on the fuel supply to the GSOV Use a gas detector to check for gas leaks 103847809 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Hoses and clamps must be inspected periodically in order to ensure safe operation and continuous operation of the engine Take proper safety precautions before inspecting or replacing hoses and clamps Note Always use a board or cardboard when the engine components are checked for leaks Leaking fluid that is under pressure can cause serious injury or possible death This includes leaks that are the size of a pin hole Refer to Operation and Maintenance Manual General Hazard Information for more information Inspect the Hoses and the Clamps Inspect all hoses for leaks that are caused by the following conditions Replace any hose which exhibits any of the following conditions Failure to replace a hose which exhibits any of the following conditions may result in a hazardous situation e Hoses which are cracked e Hoses which are soft e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally 106 Maintenance Section Hoses and Clamps Inspect Replace SEBU7563 09 e Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering e Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps I
17. the gaskets of the cooling system filler cap are damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gaskets of the cooling system filler cap are not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 102062976 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Climbing equipment may be required to access this service point Refer to the Operation and Maintenance Manual Mounting and Dismount ing topic for safety information Engines That Are Equipped With a Sight Gauge Illustration 57 g00750429 1 Filler cap 2 Sight gauge If the engine is equipped with a sight gauge observe the position of the coolant in the sight gauge At normal operating temperature the proper coolant level is in the upper half of the sight gauge If the coolant level is low add the proper coolant mixture Engines That Are Not Equipped With a Sight Gauge Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system component
18. 1 Drain valve 2 Open drain valve 1 in order to drain used oil After the oil has drained close drain valve 1 SEBU7563 09 93 Maintenance Section Engine Oil Filter Change Note If a suction device is used in order to remove the oil from the oil pan ensure that the suction device is clean This will prevent dirt from entering the oil pan Be careful not to strike the engine oil suction tubes or the piston cooling jets 3 Clean the oil suction screen Note Approximately 1 L 1 qt of oil will remain in the housing after the sump has been completely drained This oil will pour out of the housing when the cover for the oil suction screen is removed Prepare to catch the oil in a suitable container Clean up any spilled oil with rags DO NOT use absorbent particles to clean up the oil Illustration 79 900789729 2 Screen assembly a Loosen the bolts of the cover for the oil suction screen Remove the cover and the gasket Discard the old gasket Slide screen assembly 2 from the tube b Wash the screen assembly in clean nonflammable solvent Allow the screen assembly to dry before installation c Install the screen assembly Install a new gasket Install the cover 4 Change the engine oil filters Refer to this Operation and Maintenance Manual Engine Oil Filter Change topic Maintenance Section NOTICE Only use oils that are recommended by Caterpillar For the proper oil to use refer t
19. Battery Electrolyte Level Check SMCS Code 1401 535 FLV When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water e A mixture of 0 1 L 0 11 qt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM 10
20. Code 7422 040 The low coolant level switch actuates an alarm or a shutoff if the coolant level is low A low coolant level could cause the engine to overheat This could result in damage to the engine 78 Maintenance Section SEBU7563 09 Cooling System Supplemental Coolant Additive SCA Test Add If the coolant level is low coolant must be added to the expansion tank or the heat exchanger A R nr FT Illustration 59 900789360 1 Switch 2 Lines For proper operation of the switch the lines and the switch must be clean 1 Drain the coolant to a level below lower line 2 Drain the coolant into a clean container so that the coolant can be reused 2 Remove switch 1 Inspect the openings of the inlet and the outlet for plugging If an opening is plugged clean the switch 3 Inspect lines 2 for plugging Clean the lines if necessary Pressure air or a flexible wire can be used to clean the lines 4 Install switch 1 5 Pour the coolant into the cooling system Verify that the low coolant level switch is operating properly A switch that is operating properly will activate an alarm until a sufficient amount of coolant is added 102017557 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and eyes Do not
21. This condition is not an indication of leakage between the shell and the insulator Inspect shell 3 for damage Cracks can be caused by overtightening the spark plug Overtightening can also loosen the shell Discard any spark plug that has a shell that is cracked or loose Inspect electrode 5 for excessive wear Flat surfaces with sharp edges provide the best conditions for creating a spark An electrode will become worn from use The surfaces erode A higher voltage is required in order to produce a spark Illustration 97 g00760569 6 Precious metal pads on the electrode and the ground strap Caterpillar spark plugs have precious metal pads 6 on the tips of the electrode and the ground strap This material will gradually erode Replace the spark plug if the precious metal is worn off Light brown deposits or beige deposits around the electrode are produced by normal operation White deposits or gray deposits may be caused by the following substances e Excessive oil e Use of the wrong oil e A substance that is introduced through the fuel system or the air system A spark plug can operate despite a buildup of ash However a buildup of ash can cover the electrode gap The buildup will cause misfire Large deposits may retain heat which can cause premature fuel ignition Premature fuel ignition can lead to uncontrollable detonation 110 Maintenance Section Ignition System Spark Plu
22. agent are gone 6 Flush the cooling system with clean water until the water that drains is clean Close the cooling system drain valves if equipped Clean the cooling system drain plugs and install the cooling system drain plugs Cleaning a Cooling System that has Heavy Deposits or Plugging Note For the following procedure to be effective there must be an active flow through the cooling system components 1 Flush the cooling system with clean water in order to remove any debris 2 Close the cooling system drain valves if equipped Clean the cooling system drain plugs and install the cooling system drain plugs 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the cooling system filler cap 4 Start the engine Operate the engine for a minimum of 90 minutes with a coolant temperature of at least 82 C 180 F 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the cooling system drain valves if equipped Remove the cooling system drain plugs Allow the water to drain NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make s
23. cooling airflow e Proper charging of the battery Observe battery voltage on the Advisor panel or Cat ET during engine operation to evaluate the performance of the alternator Make repairs if necessary See the Service Manual for service procedures Consult your Caterpillar dealer for assistance 102601741 Barring Device Lubricate SMCS Code 1235 086 NOTICE Do not use an impact wrench to operate the barring device The use of an impact wrench will cause gear tooth failure Guards must be in place prior to operating barring device motor Remove all hand tools prior to operating barring device motor Note Prelube of the engine is required before the crankshaft is rotated for normal maintenance The barring device provides a means for slowly turning the flywheel in order to service the engine When the barring device is in the engaged position the engine starting system is disabled When the barring device is not used the barring device must be fully disengaged from the flywheel and secured in the disengaged position Refer to the Service Manual for information on operation of the barring device 70 Maintenance Section Barring Device Lubricate SEBU7563 09 NOTICE Do not operate the engine starting motor until the bar ring group pinion gear is fully disengaged from the fly wheel ring gear Serious damage to the engine could result Electric Barring Device Note This type of barring devi
24. cylinder heads and turbochargers Also some other engine components are inspected Top end overhauls require more tools than preventive maintenance The following tools are needed for restoring the engine to factory specifications e Torque wrenches e Dial indicators e Accurate measurement tools e Cleaning equipment e Rebuilding equipment Caterpillar dealers are equipped with these tools Caterpillar dealers can provide a flat rate price for a top end overhaul Unexpected problems may be found during a top end overhaul Plan to correct these problems if necessary e Buildup in the cylinders from excessive oil consumption Plugging of the aftercooler from coolant that is poorly maintained e Degradation of the oil cooler from hydrogen sulfide in the fuel Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications If you elect to perform an overhaul without the services of a Caterpillar dealer be aware of the following recommendations The following definitions explain the terminology for the services that are performed during an overhaul Inspect
25. damage to other engine parts Note Turbocharger components require clearances that are precise The turbocharger cartridge must be balanced due to high rpm The following conditions can cause the turbocharger to be out of balance e The buildup of deposits e Chipping and or flaking of deposits If the turbocharger must be removed for inspection use caution Do not break deposits from the turbine wheel Do not attempt to clean the turbine wheel For options regarding removal installation repair and replacement see the Service Manual or consult your Caterpillar dealer 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 122 Maintenance Section Turbocharger Cleaner Tube Replace SEBU7563 09 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is fo
26. drain valve 3 is closed 8 For instructions on filling the lubricator see this Operation and Maintenance Manual Air Starting Motor Lubricator Oil Level Check topic 102654969 Air Starting Motor Lubricator Oil Level Check SMCS Code 1451 535 NOTICE Never allow the lubricator bowl to become empty The air starting motor will be damaged by a lack of lubrica tion Ensure that sufficient oil is in the lubricator bowl als Illustration 47 901333366 1 Observe the oil level in sight gauge 3 If the oil level is less than 1 2 add oil to the lubricator bowl A WARNING Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved 2 Ensure that the air supply to the lubricator is OFF Slowly loosen filler plug 4 in order to release pressure from the lubricator bowl SEBU7563 09 69 Maintenance Section Air Tank Moisture and Sediment Drain 3 Remove filler plug 4 Pour oil into the lubricator bowl Use nondetergent SAE 10W oil for temperatures that are greater than 0 C 32 F Use air tool oil for temperatures that are below 0 C 32 F 4 Install filler plug 4 Adjust the Lubricator Note Adjust the lubricator with a
27. drink cooling system coolant additive Note Caterpillar recommends an S O S coolant analysis Level 1 Test the Concentration of the SCA Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Follow the instructions that are provided in the kit Water and SCA NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Use the instructions that follow 1 Fill the syringe to the 1 0 ml mark with the coolant 2 Dispense the 1 0 mL coolant sample from the syringe into the empty mixing bottle 3 Add tap water to the mixing bottle in order to bring the level up to the 10 ml mark Place the cap on the bottle and shake the bottle 4 Add 2 to 3 drops of the NITRITE INDICATOR SOLUTION B to the mixing bottle Move the bottle in a circular motion in order to mix the solution 5 Add 1 drop of NITRITE TEST SOLUTION A to the mixing bottle Move the bottle in a circular motion in order to mix the solution 6 Repeat 5 until the solution changes color from red to light gray green or blue Record the number of drops of NITRITE TEST SOLUTION A that were required to cause the color change 7 Use Table 36 to interpret
28. environments h Illustration 76 900476231 1 Clip 2 Cup 1 Loosen clips 1 Remove cup 2 2 Clean the inside of the cup 3 Install the cup Fasten the clips i01765695 Engine Crankcase Breather Clean SMCS Code 1317 070 If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that can shut down the engine Leakage of the crankshaft seal can occur Note Use of a platform may be necessary to reach the engine crankcase breather Perform this maintenance when the engine is stopped N ete ch Tl g00789623 3 Illustration 77 2 Tee 3 Hose clamp 4 O ring seal 5 Retaining clamp 1 Loosen retaining clamps 5 Loosen hose clamps 3 Remove breather assemblies 1 and O ring seals 4 2 Wash the breather elements in clean nonflammable solvent Inspect tee 2 for cracks that can be caused by vibration Replace the old tee with a new tee if cracking is found 3 Install new O ring seals 4 92 Maintenance Section Engine Mounts Check SEBU7563 09 4 Allow the breather elements to dry before installation Install the breather assemblies in
29. hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved 1 Ensure that the air supply to the lubricator is OFF Illustration 46 g01333332 1 Filler plug 2 Bowl 3 Drain valve 2 Slowly loosen filler plug 1 in order to release the pressure from the lubricator NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 3 Place a suitable container under bowl 2 and open drain valve 3 in order to drain the oil from the bowl 4 Remove bowl 2 Clean the bowl with warm water 5 Dry the bowl Inspect the bowl for cracks If the bowl is cracked replace the damaged bowl with a new bowl Inspect the gasket If the gasket is damaged replace the gasket 6 Install the bowl 7 Make sure that
30. pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers For conventional heavy duty coolant antifreeze check the concentration of supplemental coolant additive SCA regularly The concentration of SCA can be checked with an S O S coolant analysis Level 1 Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Never collect samples from expansion bottles e Never collect samples from the drain for a system e Keep the unused sampling bottles stored in plastic bags Keep the lids on empty sampling bottles until you are ready to collect the sample Complete the information on the label for the sampling bottle before you begin to take the samples Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location e In order to avoid contamination immediately place the sample in the t
31. recommends using S O S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The fluid sampling bottle includes t
32. scheduled overhaul e A 300 percent increase in oil consumption e A 200 percent increase in crankcase blowby A 20 percent loss of cylinder compression Note These indications do not require an engine to be shut down for service These indications only mean that an engine should be scheduled for service in the near future If the engine operation is satisfactory an immediate overhaul is not a requirement An in frame overhaul does not typically require the engine to be removed Instead the service is performed with the engine in place Note The generator or the driven equipment may also require service when the engine overhaul is performed In Frame Overhaul Information An in frame overhaul includes all of the work that is done for a top end overhaul Additionally some other components that wear are replaced The condition of components is inspected Those components are replaced if necessary Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications If you elect to perform an overhaul without the services of a Caterpillar dealer be aware of the fol
33. the oil level is at the FULL mark on the LOW IDLE side of the oil level gauge 7 Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes 8 Remove the oil level gauge and check the oil level Maintain the oil level above the ADD mark 101520518 Engine Oil Filter Change SMCS Code 1308 510 1308 Replace the engine oil filters when the following conditions are met e Every oil change e The engine oil filter differential pressure reaches 100 kPa 15 psi 94 Maintenance Section Engine Oil Filter Change SEBU7563 09 Service tools are available to aid in the service of oil filters Consult your Caterpillar dealer for the part names and the part numbers Follow the instructions that are supplied with the service tools If the service tools are not used perform the following appropriate procedure Replacing the Engine Oil Filters With the Engine Stopped Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Perform the following procedure after the oil has been drained Note Use this procedure if the engine oil filters do not have a control valve LI g00789754 Illustration 80 1 Pressure gauge 2 Drain 3 Cover 4 Control valve 1 Connect a hose from each drain valve 2 to a suitable container in order to catch the oil
34. the sealing flange for damage and debris Replace any prechamber cup that has a damaged flange Replace any prechamber cup that has eroded holes Replace any prechamber cup that has cracks that are extending from the holes 4 Clean the prechamber gasket set in the cylinder head by using the 9U 5156 Cleaning Tool Group Wipe the surface with a clean cloth and solvent 5 Install new prechamber gaskets and O rings 6 Install the ignition body assembly in cylinder head Refer to the engine s Specifications manual for the proper torque procedure 102602093 Prechamber Check Valves Clean SMCS Code 1550 070 900789869 2 O ring seal 3 Check valve assembly 4 O ring seal 5 Gasket Note Use of a platform may be necessary to reach the prechamber check valves Note Refer to the engine s Disassembly and Assembly manual for instructions on removal and installation of the check valves 1 Remove check valve assembly 3 and gasket 5 2 Discard gasket 5 and O ring 4 Disassemble the check valve by unscrewing the end cap a Clean all parts with a non chlorinated solvent b Reassemble the check valve and torque the cap to 2 N m 1 5 Ib ft 3 Install a new gasket and a new O ring Install the clean dry check valve assembly and torque to 115 N m 85 Ib ft 4 Do NOT overtighten the plug for the check valve Tighten to 15 N m 11 Ib ft SEBU7563 09 119 Maintenance Section Prechamber Check Va
35. 0 000 service hours Check the Alignment The alignment between the engine and the driven equipment must be maintained properly Improper alignment will cause damage to the engine the coupling and the driven equipment Check the alignment according to the instructions that are provided by the following manufacturers e Caterpillar e OEM of the coupling e OEM of the driven equipment 100935098 Driven Equipment Inspect Replace Lubricate SMCS Code 3279 040 Observe the driven equipment during operation Look for the following items e Unusual noise and vibration e Loose connections e Damaged parts Perform any maintenance that is recommended by the OEM of the driven equipment Refer to the literature of the OEM of the driven equipment for the following service instructions e Inspection e Lubricating grease and lubricating oil requirements e Specifications for adjustment e Replacement of components e Requirements for ventilation 101610487 Electrohydraulic Actuator Inspect SMCS Code 1716 040 Inspect the actuators for the fuel control the wastegate and the air choke During operation the linkage of the electrohy draulic actuators can form pinch points which can cause personal injury Shut down the engine before you service the electrohydraulic actuators
36. 00792283 1 Sight gauge 2 Hose 3 Line Check the Oil Level 1 Check the oil level in sight gauge 1 The oil should be between the ADD and FULL marks on the tank Note For the proper oil to use refer to this Operation and Maintenance Manual Refill Capacities and Recommendatons topic Maintenance Section 2 If necessary remove the oil filler cap Pour the correct oil into the oil filler 3 Clean the oil filler cap Install the oil filler cap Inspect the Lines Connections and Components The linkage can move and form a pinch point which can cause personal injury Keep hands away from the linkage Inspect the hoses and lines for wear and leaks Ensure that the hoses and lines are properly clamped Inspect the connections for leaks Ensure that the connections are secure Inspect the following items for leaks and good condition e Actuators e Pressure relief valve e Pump Make repairs if necessary 102603161 Electrohydraulic System Oil Change SMCS Code 1716 510 OC Ensure that the engine cannot start during this procedure Illustration 67 900792335 1 Oil filler cap 2 Valve 1 Remove oil filler cap 1 Note Drain the oil into a suitable container Dispose of fluids according to local regulations 2 Place a suitable container under valve 2 Open the valve Allow the oil to drain After the
37. 070 1907 040 1907 070 The engine speed timing sensor is located at the right rear side of the engine oes I r IN g00901865 Illustration 89 1 Engine speed timing sensor 2 Bolt 1 Disconnect the wiring harness from engine speed timing sensor 1 2 Remove bolt 2 in order to remove engine speed timing sensor 1 3 Inspect the sensor for damage If the sensor is damaged obtain a new sensor for installation SEBU7563 09 101 Maintenance Section Engine Valve Lash Inspect Adjust 4 Inspect the O ring seal for the sensor If the O ring seal is damaged obtain a new O ring seal for installation 5 Clean the tip of the sensor Note The engine speed timing sensor does not require any special adjustments 6 Install the sensor Make sure that the sensor is properly seated Tighten bolt 2 7 Inspect the wiring harness Make sure that the connector is in good condition Attach the wiring harness to the sensor Make sure that the mating of the connectors is proper Engine Valve Lash Inspect Adjust SMCS Code 1102 025 For instructions on the following procedures refer to Systems Operation Testing and Adjusting Consult your Caterpillar dealer for assistance Note Use of a platform may
38. 1000 4450 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of all maintenance including the following procedures all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Actuator Control Linkage Replace 2008 66 Barring Device Lubricate 69 Cooling System Coolant Sample Level 2 Obtains fees auch eek heehee venetian 77 Engine Air Cleaner Element Single Element Clean Replace mmrrnnnnnnronnnnnrnrnnvnvnnnonnnnnnrnnnnnnnnn 87 Engine Air Precleaner Clean 00 ee 91 Engine Oil Change rrrrrnnnnnnnvrnnnnernrrrnnnnrrsrrnnnnenn 92 Engine Oil Filter Change n se 93 Overhau
39. 2601764 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspection Inspect the alternator belt and the fan drive belts for wear and for cracking Replace the belts if the belts are not in good condition Check the belt tension according to the information in the Service Manual Specifications Slippage of loose belts can reduce the efficiency of the driven components Vibration of loose belts can cause unnecessary wear on the following components e Belts e Pulleys e Bearings If the belts are too tight unnecessary stress is placed on the components This reduces the service life of the components Adjusting the Alternator Belt Illustration 52 g01092641 Typical alternator 1 Mounting bolt 2 Adjusting nuts 3 Mounting bolt 1 Remove the drive belt guard 72 Maintenance Section Combustion Sensor Clean Inspect Replace SEBU7563 09 2 Loosen mounting bolt 1 adjusting nuts 2 and mounting bolt 3 3 Turn adjusting nuts 2 in order to increase or decrease the drive belt tension 4 Tighten adjusting nuts 2 Tighten mounting bolt 3 Tighten mounting bolt 1 For the proper torque see the Service Manual Specifications module 5 Reinstall the drive belt guard If new drive belts are installed check the drive belt tension again after 30 minutes of engine operation at the rated rpm Adjusting the Fan Drive Belt Note Do not overtigh
40. 5711 Engine Valve Rotators Inspect SMCS Code 1109 040 NOTICE A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life If a damaged rotator is not replaced valve face guttering could result and cause pieces of the valve to fall into the cylinder This can cause piston and cylinder head damage Note Use of a platform may be necessary to reach the engine valve rotators Perform this procedure after the valve lash has been set 1 Mark the tops of the valve rotators with a permanent marker Note the position of the marks 2 Install the valve covers See the Service Manual for the procedure 3 Start the engine Operate the engine for 5 minutes Stop the engine 4 Remove the valve covers Observe the position of the marks that are on the valve rotators If a valve fails to rotate consult your Caterpillar dealer 101765718 Exhaust Bypass Recondition SMCS Code 1057 020 Illustration 90 g00799396 Typical example 1 Rod ends 2 Cover and seal 3 Shaft Note Use of a platform may be necessary in order to reach the components of the exhaust bypass Replace the following parts e Rod ends 1 e Cover and seal 2 e Shaft 3 For instructions on assembling the exhaust bypass refer to the Specifications 10045
41. 7458 Exhaust Shields Inspect SMCS Code 1067 040 Hot engine components can cause injury from burns Before performing maintenance on the engine allow the engine and the components to cool SEBU7563 09 103 Maintenance Section Fuel System Fuel Filter Differential Pressure Check NOTICE The exhaust shields can be damaged if work is per formed on the exhaust shields or around the exhaust shields Remove the exhaust shields or protect the exhaust shields before performing work on the exhaust shields or around the exhaust shields Handle the exhaust shields carefully Do not tear the foil that is inside of the exhaust shields Torn foil will allow the insulation to absorb flammable liquids and a fire can result from engine heat Ensure that the exhaust manifold is cool Inspect the exhaust shields Replace any exhaust shield that is damaged Refer to the Service Manual for the procedure to remove the exhaust shields and install the exhaust shields i02602064 Fuel System Fuel Filter Differential Pressure Check SMCS Code 1261 535 If the engine is equipped with a fuel filter a fuel filter differential pressure gauge must be installed The fuel filter differential pressure gauge is installed in order to determine when the fuel filter requires service This gauge and the fuel filter are supplied by the customer A fuel filter differential pressure gauge indicates the difference in fuel pressure betwee
42. Check Valves Replace 5 119 Prelube Pump Inspect eceeeeeeeeeteeeees 119 Water Pump Inspect rrrrnnnnrnrrrrrnnrnnrnnnnnnnnnn 124 Every 20 000 Service Hours or 3 Years Cooling System Coolant NGEC Change 74 Every 25 000 Service Hours Gas Admission Valve Seals Inspect Replace 104 Overhaul Top End erervnvrvnnvnrorvvrnvnrvvnnrrnvnrennnnne 114 Prechamber Clean Inspect rrnnnnnnnrnnrnrnnnnnnn 118 Every 50 000 Service Hours Electrohydraulic Actuator Recondition 84 Gas Admission Valve Recondition 0 103 Overhaul In Frame rarrrnnnnnnnvvrrrnnnnnrnnrrnvnrnnnnnne 112 Every 100 000 Service Hours Overhaul Major eeerernrrvrnnnnnvrvrrnnvnnnrnnrrnnnrennnnne 113 62 Maintenance Section Maintenance Interval Schedule SEBU7563 09 i03915106 Maintenance Interval Schedule G3600 Engines That Use Natural Gas and Have a Compression Ratio of 10 5 1 or 11 1 SMCS Code 1000 4450 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of all maintenance including the following procedures all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be d
43. Consult your Caterpillar dealer for information on available borescopes When possible insert the borescope through the opening in the cylinder head for the prechamber assembly and the ignition body This location will provide the best possible view of the entire combustion chamber This requires draining the coolant to a level below the cylinder head If this is not possible insert the borescope through the opening for the combustion sensor Look for the following conditions e Valve wear e Deposits on the valve seat e Deposits on the valve face Polishing of the cylinder walls Scratching of the cylinder walls e Deposits on the cylinder walls that are above the upper limit of the piston stroke Deposits that are on the valve face and the valve seat can cause guttering of the valve Inspect the valve seat and the valve face for excessive deposits If excessive deposits are found replace the valve and the valve seat Determine whether the exhaust valve face has erosion from pitting This requires the exhaust valve to be in the open position To obtain as much detail as possible obtain a close up view of the valve face Erosion of the exhaust valve face can lead to guttering of the valve If erosion is found on the exhaust valve face recondition the cylinder head as soon as possible Note Operation at loads that are less than 50 percent of the rated load can result in an excessive buildup of carbon deposits in the combusti
44. La pe ay Illustration 87 g01302112 Inside of control panel front 2 e ICE nm Illustration 88 901201607 Inside of control panel rear 1 Terminal strips 3 Check the wiring for secure connections at these points of the junction box and the control panel e Connectors e Relays e Switches e Terminal strips Perform a pull test for each wire This test will ensure that the wiring is properly attached Test each wire individually a Pull each wire with approximately 45 N 10 Ib of force Pull the wire firmly If a wire is loose repair the connection For instructions on connecting wires see the Service Manual Troubleshooting module Inspect the wiring at the relays and terminal strips for these conditions e Corrosion e Fraying a If corrosion is found scrape large deposits Use cotton swabs with isopropyl alcohol to clean any corrosion that remains Investigate the source of the corrosion Correct the condition If damage is found replace the part b Remove frayed strands of wire or tin the wire c Perform Steps 6 and 7 for the connectors of the control panel and the junction bo
45. Lubricant Fuel and Coolant Recommendations Note The exhaust heat shields must be in place and snug around the shaft of the wastegate in order to provide maximum life of rod ends Hydraulic Actuators Illustration 41 g01120800 Typical locations of grease fittings 102236400 Actuator Control Linkage Replace SMCS Code 1265 510 Inspect the rod ends of the following components for wear Note Use of a platform may be necessary to reach the linkages e Air choke actuator e Exhaust bypass actuator e Fuel control actuator e Linkages If necessary replace the rod ends Removal and Installation Illustration 42 g00799207 Typical example of rod ends on an actuator and on the linkage for an actuator For instructions on removal and installation of the control linkage for the actuators see the Disassembly and Assembly Manual See the Specifications Manual for instructions on adjusting the actuators Consult your Caterpillar dealer for assistance SEBU7563 09 67 Maintenance Section Aftercooler Condensation Drain i01762572 Aftercooler Condensation Drain SMCS Code 1063 The aftercooler is similar to a radiator Coolant passes through the tubes in the aftercooler core Inlet air that is warmed by the turbocharger compressor is directed through the aftercooler core The air is cooled in the aftercooler Condensation
46. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR kon 2010 Operation and Maintenance Manual G3600 Engines 60 Maintenance Section Maintenance Interval Schedule SEBU7563 09 i03915129 Maintenance Interval Schedule G3600 Engines That Use Wellhead or Natural Gas and Have a Compression Ratio of 9 2 1 SMCS Code 1000 4450 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of all maintenance including the following procedures all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Actuator Control Linkage Rep
47. Service Manual Systems Operation Testing and Adjusting For assistance consult your Caterpillar dealer 102062446 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 The crankshaft vibration damper limits the torsional vibration of the crankshaft The visconic damper has a weight that is located inside a fluid filled case Damage to the crankshaft vibration damper or failure of the damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive gear train noise at variable points in the speed range A damper that is hot is due to excessive torsional vibration Monitor the temperature of the damper during operation The 8T 2821 Temperature Indicator or the 8T 2822 Temperature Indicator are recommended for monitoring the temperature of the damper Evenly space four of the adhesive indicators around the outer diameter of the damper Note If you use an infrared thermometer to monitor the temperature of the damper use the thermometer during operation with similar loads and speeds Keep a record of the data If the temperature begins to rise reduce the interval for inspecting the damper It is important to regularly monitor the temperature of the damper It is important to document the temperature of the damper when it increases and decreases This will verify that damper service is necessary If the temperature of th
48. Tighten the piston assembly according to the engine s Specifications 9 Remove bolts 10 in order to remove solenoid 11 Remove O ring seal 12 from the joint between the solenoid and the housing 10 Install a new O ring seal 12 and solenoid 11 Install bolts 10 Tighten the bolts according to the engine s Specifications 11 Install the actuator in the bracket with nut 6 12 Install boot 5 Make sure that the outer end of the boot folds inward when the actuator s shaft moves from the fully open position to the fully closed position 13 Install clevis 4 Connect rod end 3 to the clevis 14 Install guards 2 15 Connect the supply line and the return line for the hydraulic oil 16 Connect the wiring harness to receptacle 1 101525261 Electrohydraulic System Check Adjust SMCS Code 1716 025 1716 535 Check the Pressure Relief Valve Check the pressure relief valve for the hydraulic system according to the procedure that is in Systems Operation Testing and Adjusting Adjust the pressure according to the instructions 86 Maintenance Section Electrohydraulic System Inspect SEBU7563 09 102214104 Electrohydraulic System Inspect SMCS Code 1716 040 Inspect the conditions of these items for the electrohydraulic system e Oil level e Hoses lines connections and components Illustration 66 g
49. aired If the components are not in the reusability guidelines refer to the Service Manual Specifications module Rebuild The component can be reconditioned in order to comply with reusability guidelines Replace The service life of the part is exhausted The part may fail before the next maintenance interval The part must be replaced with a part that meets functional specifications The replacement part may be a new part a CAT remanufactured part a rebuilt part or a used part Some worn components may be exchanged with your Caterpillar dealer Consult your Caterpillar dealer about repair options for your engine Table 40 Major Overhaul Procedure Component Inspect Camshafts Replace Connecting rods Crankshaft Rebuild Inlet air piping Replace Aftercooler Camshaft lifters Exhaust manifolds Gear train bearings Oil cooler 1 In addition to these procedures perform the procedures for both the top end overhaul and the in frame overhaul 103247357 Overhaul Top End SMCS Code 7595 020 TE Scheduling a Top End Overhaul Table 41 lists the approximate number of service hours before a top end overhaul for different G3600 Engine applications SEBU7563 09 115 Maintenance Section Overhaul Top End Table 41 Estimated Service Hours Before a Top End Overhaul Fuel Compression Ratio Service Hours Wellhead gas or 9 2 1 25000 natural gas Natura
50. al for a small amount of leakage to occur when the engine cools and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For instructions on removal and installation of water pumps and or seals refer to the Service Manual Disassembly and Assembly module for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve covers 124 Maintenance Section Water Pump Inspect SEBU7563 09 NEVER use a flame to check for gas leaks Use a gas detector An open flame can ignite mixtures of air and fuel This will cause explosion and or fire which could result in severe personal injury or death e Check the fuel system for leaks Look for loose fuel line clamps Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground straps for good connections and for good condition e Check the condition of the gauges Replace any gauge that is damaged Replace any gauge that can not be calibrated Inspect the exhaust system for leaks If a leak is found make repairs 102624237 Water Pump Inspect SMCS Code 1361 040 A failed water pump might cause severe engine overheating problems that coul
51. also include all of the work that is done for an in frame overhaul A major overhaul includes additional parts and labor Additional parts and labor may be required in order to completely rebuild the engine In some cases the engine is relocated for disassembly For the major overhaul bearings seals gaskets and components that wear are disassembled The parts are cleaned and inspected If necessary the parts are replaced The crankshaft is measured for wear The crankshaft may require regrinding Alternatively the crankshaft may be replaced with a Caterpillar replacement part Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications If you elect to perform an overhaul without the services of a Caterpillar dealer be aware of the following recommendations The following definitions explain the terminology for the services that are performed during an overhaul Inspect Inspect the components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures New parts are not required if the existing parts can still be used reconditioned or rep
52. be necessary for these procedures Check the Timing of the Crankshaft and Camshaft The timing of the crankshaft and camshaft must be checked and the valve bridge must be adjusted before the valve lash is adjusted NOTICE If the camshaft is rotated with the timing pin installed the timing pin will break This can result in further dam age Make sure to remove the timing pin before the camshaft is rotated NOTICE DO NOT use the starting motor to rotate the crank shaft The lubrication oil can drain out from between the crankshaft and the engine bearings if the engine has not been operated for a period of time Damage can result if the crankshaft is rotated on dry bearing surfaces To prevent damage to the crankshaft bearings DO NOT crank the engine before prelube especially after this maintenance procedure NOTICE The prelube pump should not be operated continu ously for extended periods of time If during repairs the prelube pump has run continuously for a period of three hours or more it will be necessary to remove any oil that may have collected in the cylinders and or above the valves Prelube of the engine is required before the crankshaft is rotated for normal maintenance Activate the prelube pump for rotating the engine crankshaft NOTICE Do not use an impact wrench to operate the barring device The use of an impact wrench will cause gear tooth failure The barring device provides a m
53. can form in the passages of the aftercooler system Drain plugs are provided for draining the condensation Illustration 43 g00788934 A drain plug is located on the right side near the rear of the engine 1 Plug Illustration 44 g00788946 A drain plug is located on the left side near the front of the engine 2 Plug 1 Ensure that the engine is not running 2 Remove plugs 1 and 2 3 Drain the moisture into suitable containers 4 Install the plugs 101762654 Air Starting Motor Lines Screen Clean SMCS Code 1451 070 LI Illustration 45 900789123 1 Plug 2 Screen If the engine is equipped with an air starting motor use the following procedure 1 Ensure that the air supply to the air lines is OFF 2 Remove plug 1 3 Carefully remove screen 2 Clean the screen with nonflammable solvent Inspect the screen for damage If the screen is damaged replace the damaged screen with a new screen 4 Install clean dry screen 2 Clean plug 1 Install the plug 102654935 Air Starting Motor Lubricator Bowl Clean SMCS Code 1451 070 If the engine is equipped with an air starting motor use the following procedure 68 Maintenance Section Air Starting Motor Lubricator Oil Level Check SEBU7563 09 Personal injury can result from removing
54. cause severe damage in the combustion chamber and the turbocharger Consult your Caterpillar dealer for assistance 101492446 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life thoroughly inspect the engine room before starting the engine Look for items such as leaks loose bolts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak clean up the fluid If leaking is ob served find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water e Ensure that cooling lines are properly clamped Check for leaks Check the condition of all pipes e Inspect the water pumps for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is norm
55. ce may be electrically driven or manually driven Lubricating the Reducer an Illustration 48 900334420 Rear view of an electrically driven barring device Lubricating the Pinion Illustration 49 901098831 Section view of a barring device without the electric motor 1 Grease fitting 2 Vent 1 Ensure that the barring device is locked in the disengaged position 2 Lubricate grease fitting 1 with Cat Advanced 3Moly Grease until the grease is visible at vent 2 Illustration 50 900991445 1 Ensure that the barring device is locked in the disengaged position 2 Remove level plugs 2 and check the lubricant level 3 If necessary remove cap 1 and add Caterpillar 4C 6767 Synthetic Oil until the oil is visible at the level plugs 4 Reinstall the level plugs and reinstall the cap Manual Barring Device Q O O Illustration 51 901098833 1 Grease fitting 2 Gear end 1 Ensure that the barring device is locked in the disengaged position 2 Lubricate grease fitting 1 with Cat Advanced 3Moly Grease until the grease is visible at gear end 2 SEBU7563 09 71 Maintenance Section Battery Electrolyte Level Check i02601752
56. ced at least one time per year This replacement should be performed regardless of the number of cleanings 88 Maintenance Section SEBU7563 09 Engine Air Cleaner Element Single Element Clean Replace Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes 1 Remove the air cleaner cover Remove the air cleaner element Note Refer to Cleaning the Air Cleaner Elements 2 Cover the air inlet with tape in order to keep dirt out 3 Clean the inside of the air cleaner cover and body with a clean dry cloth 4 Remove the tape for the air inlet Install an air cleaner element that is new or cleaned 5 Install the air cleaner cover 6 Reset the air cleaner service indicator Cleaning the Air Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pre
57. components are examples of the remanufactured parts e Alternators e Connecting rods e Crankshafts e Cylinder heads Oil Pumps e Starting motors e Turbochargers e Water pumps Consult your Caterpillar dealer for details and for a list of the remanufactured parts that are available Your Caterpillar dealer may be offering a variety of overhaul options A Flat Rate Overhaul guarantees the maximum price that you will pay for an overhaul Flat rate prices on preventive maintenance programs or major repair options are available from many servicing dealers for all Caterpillar Engines Consult your Caterpillar dealer in order to schedule a before failure overhaul Overhaul Recommendation Caterpillar recommends a scheduled overhaul in order to minimize downtime A scheduled overhaul will provide the lowest cost and the greatest value Schedule an overhaul with your Caterpillar dealer Overhaul programs vary between dealers To obtain specific information about the types of overhaul programs and services consult your Caterpillar dealer 118 Maintenance Section Prechamber Clean Inspect SEBU7563 09 i02602727 Prechamber Clean Inspect SMCS Code 1106 57 1 Illustration 99 901302648 1 Remove the ignition body assembly Remove prechamber cup 1 from the ignition body Refer to the engine s Disassembly and Assembly manual for instructions 2 Clean the deposits from the prechamber cup 3 Inspect
58. constant rate of air flow After the adjustment the lubricator will release oil in proportion to variations of the air flow 1 Ensure that the fuel supply to the engine is OFF NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 2 Operate the air starting motor Observe the drops of oil that are released in dome 1 Note Some lubricators have an adjustment screw rather than a knob 3 If necessary adjust the lubricator in order to release from one to three drops of oil per second To increase the rate turn knob 2 counterclockwise To decrease the rate turn the knob clockwise 100351324 Air Tank Moisture and Sediment Drain SMCS Code 1466 543 M amp S Moisture and sediment in the air starting system can cause the following conditions e Freezing e Corrosion of internal parts e Malfunction of the air starting system When opening the drain valve wear protective gloves a protective face shield protective cloth ing and protective shoes Pressurized air could cause debris to be blown and result in personal injury 1 Open the drain valve that is on the bottom of the air tank Allow the moisture and sediment to drain 2 Close the drain valve 102601719 Alternator Inspect SMCS Code 1405 040 Inspect the alternator for the following conditions e Proper connections e Clean ports for
59. d the front idler gear bearing Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter element If an excessive amount of debris is found in the oil filter element consult your Caterpillar dealer in order to arrange for further oil analysis 102602034 Engine Oil Level Check SMCS Code 1348 535 FLV The most accurate check of the oil level is performed when the engine is stopped Perform this maintenance on a surface that is as level as possible A ae P g00789822 oO Illustration 84 1 Oil level gauge 2 Oil filler Illustration 85 g01140702 3 ADD mark 4 RUNNING FULL mark 5 STOPPED FULL OIL COLD NO PRELUBE mark Note For engines with powered crankcase ventilation remove the oil filler cap Allow the crankcase pressure to stabilize before checking the engine oil level SEBU7563 09 97 Maintenance Section Engine Oil Sample Obtain 1 Ensure that oil level gauge 1 is seated 2 Remove the oil level gauge and observe the oil level Add engine oil if the level is in the ADD zone If the engine is running maintain the level in the RUNNING FULL zone NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can cause the crankshaft to dip into the oil This will reduce the power that is devel oped an
60. d also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling oil blowing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber De posits in the combustion chamber lead to the following problems guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately 3 If necessary remove oil filler cap 2 and add oil For the correct oil to use see this Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section Wipe off the oil level gauge and reinstall the oil level gauge Clean the oil filler cap and reinstall the oil filler cap 4 Record the amount of oil that is added For the next oil sample and analysis include the total amount of oil that has been added since the previous sample This will help to provide the most accurate oil analysis Note Some engines are equipped with an automatic oil level controller The oil level should still be checked on a daily basis with the oil level gauge 103542996 Engine Oil Sample Obtain SMCS Code 1348 554 SM In addition to a good preventive maintenance program Caterpillar
61. d or loose Inspect electrode 10 for excessive wear Light brown deposits or beige deposits around the electrode is produced by normal operation White deposits or gray deposits may be caused by the following substances e Excessive oil e Use of the wrong oil e A substance that is introduced through the fuel system or the air system A buildup of ash on the electrode reduces the efficiency of the sensor 8 Measure the resistance between terminal post 6 and electrode 10 The sensor must pass a low voltage check for continuity between the terminal post and the electrode The resistance must not exceed five ohms 9 Thoroughly clean the sensor Clean the shell and the electrode that is inside of the shell Do not use a wire brush Glass beads are the preferred method for cleaning Follow these guidelines for the use of glass beads e Always use clean glass beads e Use care in order to clean only the electrode and the insulator near the electrode e Do not use glass beads on the outside of the shell or on the upper part of the insulator Ensure that the sensor is clean and free of dirt and oil Note Do not use anti seize compound on the sensor Most of the heat is transferred through the threads and the seat area of the sensor The surfaces must be in contact in order to provide the heat transfer that is required 10 Place a new 108 3515 Plug Gasket on the sensor Install the sensor by hand until the sens
62. d result in cracks in the cylinder head a piston seizure or other potential damage to the engine Visually inspect the water pump for leaks If leaking of the water pump seals is observed replace all of the water pump seals Refer to two articles in the Disassembly and Assembly Manual Water Pump Disassemble and Water Pump Assemble for the disassembly and assembly procedure If it is necessary to remove the water pump refer to two articles in the Disassembly and Assembly Manual Water Pump Remove and Water Pump Install Inspect the water pump for wear cracks pin holes and proper operation Refer to the Parts Manual for the correct part numbers for your engine or consult your Caterpillar dealer if repair is needed or replacement is needed
63. da 1 800 523 TOOL SEBU7563 09 75 Maintenance Section Cooling System Coolant NGEC Change Clean the Cooling System 1 Flush the cooling system with clean water in order to remove any debris 2 Close the cooling system drain valves if equipped Clean the cooling system drain plugs and install the cooling system drain plugs NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute in order to avoid air locks Proper venting of the cooling system is essential to fill at this rate 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the cooling system filler cap 4 Start the engine Operate the engine for a minimum of 30 minutes with a coolant temperature of at least 82 C 180 F 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the cooling system drain valves if equipped Remove the cooling system drain plugs Allow the water to drain NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning
64. e damper reaches 110 C 230 F consult your Caterpillar dealer Inspect the damper for evidence of dents cracks and leaks of the fluid SEBU7563 09 81 Maintenance Section Cylinder Pressure Measure Record If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous smooth and sticky If leaking silicone is found repair the damper or replace the damper If the fluid leak is oil inspect the crankshaft seal for leaks If a leak is observed replace the seal Inspect the damper and repair or replace the damper for any of the following reasons e The damper is dented cracked or leaking e The paint on the damper is discolored from heat e The engine has had a failure because of a broken crankshaft e An analysis of the oil has revealed that the front bearing of the crankshaft is badly worn e There is a large amount of gear train wear that is not caused by a lack of oil Removal and Installation Refer to the Service Manual Disassembly and Assembly or consult your Caterpillar dealer for information about damper replacement 102602007 Cylinder Pressure Measure Record SMCS Code 1223 082 CC 1223 7450 082 Measure the cylinder pressure of new engines Record the data Continue to periodically measure the cylinder pressure Comparing the recorded data to the new data provides information about the
65. e expelled through the exhaust stack The particles that are expelled will be burned The materials that are listed in Table 43 are recommended for use with this cleaning procedure Table 43 Materials for Cleaning 3600 Engine Turbochargers Material Particle Size Nut shell 1 7 mm 1 16 inch Formed carbon 1 mm 1 32 inch Granulated carbon 70 hardness 1 2 to 2 mm 3 64 to 5 64 inch Granulated dry rice 1 7 mm 1 16 inch g00833073 Illustration 102 1 Air valve 2 Purge valve 3 Cap 4 Gate valve Note During normal engine operation air valve 1 purge valve 2 and gate valve 4 are closed 1 Ensure that purge valve 2 is closed Ensure that cap 3 is secure Open gate valve 4 SEBU7563 09 121 Maintenance Section Turbocharger Inspect 2 Open air valve 1 in order to remove deposits that may be in the connecting pipe After three minutes close air valve 1 Close gate valve 4 3 Open purge valve 2 in order to relieve any pressure from the container Close purge valve 2 4 Remove cap 3 Pour 0 5 L 0 5 qt of the particles into the container Tighten cap 3 5 Ensure that purge valve 2 is closed Reduce the output of the engine so that the exhaust temperature before the turbine is less than 577 C 1070 F 6 Open gate valve 4 Open air valve 1
66. e recommended amount of supple mental coolant additive concentration 3 Add the proper amount of SCA The concentration of the SCA depends on the type of coolant that is used To determine the proper amount see this Operation and Maintenance Manual Refill Capacities and Recommendations topic 4 Clean the cooling system filler cap Install the cooling system filler cap Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulators for these systems e Jacket water e Oil cooler e Aftercooler Replace the water temperature regulators before the water temperature regulators fail This is a recommended preventive maintenance practice Replacing the water temperature regulators reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or a seizure of the pistons A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of
67. e removed Remove wire racks 5 Remove used elements 7 Clean up any oil that is spilled NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 5 Ensure that the new oil filter elements are in good condition Place the elements on wire rack 5 Install the wire rack and the elements SEBU7563 09 95 Maintenance Section Engine Oil Filter Change 6 Ensure that the surfaces for O ring seals 6 are clean Inspect the O ring seals If the old O ring seals are damaged or deteriorated replace the old O ring seals with new O ring seals Install the O ring seals 7 Install covers 3 Ensure that the spring is seated properly between elements 7 and covers 3 Close drain valves 2 8 Ensure that the crankcase is filled with oil Operate the prelube pump and rotate the control valve if equipped to the FILL position for each housing After both of the housings are full of oil turn the control valve if equipped to the RUN position 9 Start the engine Check for oil leaks Replacing the Engine Oil Filters During Engine Operation Filter contains hot pressurized fluid when engine is running Follo
68. ean Inspect Replace Pressurized air can cause personal injury When pressurized air is used for cleaning wear a pro tective face shield protective clothing and pro tective shoes Note The maximum air pressure for cleaning purposes must be below 207 kPa 30 psi 4 The area around sensor 4 may have debris Thoroughly remove any debris Use compressed air Ensure that the area around the sensor is clean and free of debris 5 Loosen sensor 4 with a 15 9 mm 5 8 inch spark plug socket and an extension After the sensor has been loosened remove the sensor by hand in order to detect problems with the threads If the sensor resists removal by hand apply penetrating oil to the threads Use the wrench and apply steady pressure to the sensor until the sensor is loose 6 7 Peay J Illustration 54 9 10 900789274 Combustion sensor 6 Terminal post 7 Insulator 8 Shell 9 Gasket 10 Electrode 6 After the sensor is removed discard gasket 9 7 Inspect the sensor closely for damage Terminal post 6 must not move If the terminal post can be moved by hand discard the sensor Inspect insulator 7 for cracks If a crack is found discard the sensor Inspect shell 8 for damage Cracks can be caused by overtightening the sensor Overtightening can also loosen the shell Discard any sensor that has a shell that is cracke
69. eans for slowly turning the flywheel in order to service the engine The barring device can also be used to prevent rotation of the crankshaft Valve Bridge NOTICE Do NOT attempt to adjust the valves if the crankshaft and camshaft are not synchronized Disregard for this can result in engine damage such as bent valves Check the valve bridges Perform the procedure for both valve bridges for each cylinder After the valve bridge is checked for each cylinder check the valve lash for the exhaust valves the inlet valves and the gas admission valves Engine Valve Lash If the valve lash is within the tolerance an adjustment of the valve lash is NOT necessary The crankshaft and camshaft timing must be checked and valve bridge adjustment must be performed before making a valve lash adjustment Perform the valve lash setting when the engine is cold After the engine has been shut down and the valve covers are removed the engine is considered cold Before performing maintenance prevent the entry of foreign matter into the top of the cylinder head and the valve mechanism Thoroughly clean the area around the valve mechanism covers 102 Maintenance Section Engine Valve Rotators Inspect SEBU7563 09 Gas Admission Valve Check the valve lash for the gas admission valve when the valve lash for the inlet valves and exhaust valves are checked Adjust the valve lash for the gas admission valves if necessary i0176
70. ent Check mrnnrnnnnnnrnrrnrrrnnnnnnnnnn 82 Electrohydraulic System Check Adjust 85 Electrohydraulic System Oil Change 05 86 Electrohydraulic System Oil Filter Change 87 Engine Protective Device Connections Inspect 98 Engine Protective Devices Check seses 100 Exhaust Bypass Recondition cee 102 Gas Shutoff Valve Inspect rnrrnnrnnrnnrrrrrrrnrnn 105 SEBU7563 09 65 Maintenance Section Maintenance Interval Schedule Inlet Air System Inspect i is 111 Inlet Gas Manifold and Piping Inspect Replace 111 Prechamber Check Valves Replace 5 119 Starting Motor Inspect rnaansnnvrnnnnnrnnrrrnnnnn narr 119 Turbocharger Inspect n se 121 Turbocharger Cleaner Tube Replace 122 Between 10 000 and 14 000 Service Hours Gas Admission Valve Seals Inspect Replace 104 Overhaul Top End asiingie aiken 114 Prechamber Clean Inspect rernrnnnnrnnrnrrnnnnnn 118 Every 10 000 Service Hours Alternator Inspect eeeeeeeeeeeceeceeeeeeeeeeeteeeeees 69 Cooling System Water Temperature Regulator Replace Lunvik acta etd tached nani abuse 79 Electrohydraulic Actuator Inspect 0 cere 83 Engine Oil Temperature Regulator Replace 98 Engine Speed Timing Sensor Clean Inspect 100 Exhaust Shields Inspect ecceeeeeeeeeees 102 Gas Pressure Regulator Inspect R
71. eplace 104 Prelube Pump Inspect eceeeeeeeeeeeeeees 119 Water Pump Inspect cceceeeeeeeeeeeeeeereeeees 124 Every 20 000 Service Hours or 3 Years Cooling System Coolant NGEC Change 74 Between 27 000 and 33 000 Service Hours Electrohydraulic Actuator Recondition 84 Gas Admission Valve Recondition 0 103 Overhaul In Frame rrrrrrnnnnnnvvrrnnnnvnrnnrrnnnrnnnnnne 112 Between 36 000 and 44 000 Service Hours Gas Admission Valve Seals Inspect Replace 104 Overhaul Top End j asr rae anaa nE 114 Between 52 000 and 54 000 Service Hours Overhaul Major eerrrrnrrvrnnnnnnnvrnnnvnnnrnnrrnnnsnnnnnne 113 66 Maintenance Section Actuator Control Linkage Lubricate SEBU7563 09 Actuator Control Linkage Lubricate If applicable SMCS Code 1265 086 The linkage can move and form a pinch point which can cause personal injury Keep hands away from the linkage Before performing this procedure ensure that the linkage is meant to be lubricated If the linkage is meant to be lubricated this article applies to the following air choke actuator fuel control actuator and exhaust bypass actuator Apply Dow Corning 41 Extreme High Temperature Bearing Grease to the rod ends bearings of the control linkage for the actuator For more information on grease see the Special Publication SEBU6400 Caterpillar Gas Engine
72. g has been loosened remove the spark plug by hand in order to detect problems with the threads After the spark plug has been removed discard the used gasket NOTICE The use of a thread tap will remove metal unnecessar ily This will also reduce the heat transfer for the spark plug This can result in a reduction of the spark plug service life and a reduction of the detonation margin If the spark plug resists removal by hand apply penetrating oil to the threads Use the wrench and apply steady pressure to the spark plug until the spark plug is loose If the spark plug cannot be removed by hand clean the threads with 9U 7511 Spark Plug Seat Cleaner This tool scrapes debris from the seat and from the threads Inspecting the Spark Plug Illustration 96 900838300 1 Terminal post 2 Insulator 3 Shell 4 Gasket 5 Electrode Inspect the spark plug closely for damage The condition of the spark plug can indicate the operating condition of the engine Terminal post 1 must not move If the terminal post can be moved by hand 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 the insulator The marks may be a result of corona that forms at the top of the shell The corona develops when a high voltage potential ionizes the air that surrounds a conductor which is a normal condition
73. g is installed If a used spark plug is installed place a new 9Y 6792 Gasket on the spark plug Orient the tabs of the gasket toward the electrode Otherwise the gasket may not seat properly If a gasket for a spark plug is installed incorrectly do not increase the torque on the spark plug in order to improve the seal Do not reuse the gasket Install a new gasket NOTICE Do not overtighten the spark plug The shell can be cracked and the gasket can be deformed The met al can deform and the gasket can be damaged The shell can be stretched This will loosen the seal that is between the shell and the insulator allowing combus tion pressure to blow past the seal Serious damage to the engine can occur Use the proper torque 4 Install the spark plug by hand until the spark plug bottoms out For the 301 6663 Spark Plug tighten the spark plug to 48 5 N m 35 4 lb ft For the 243 4291 Spark Plug tighten the spark plug to 45 5 N m 33 3 Ib ft 5 Inspect the extension and clean the extension Illustration 98 g00823413 1 O ring seal 2 Connection of the extension and the transformer 3 Connection of the extension and the spark plug a Inspect O ring seal 1 If the O ring seal is hard cracked or melted use a new O ring seal for assembly b Use a mild abrasive cleaner to clean deposits and or corrosion from the extension at connection points 2 and 3 c Appl
74. gs Check Adjust SEBU7563 09 Cleaning the Spark Plug Thoroughly clean the spark plug Do not use a wire brush Glass beads are the preferred method for cleaning Follow these guidelines for using glass beads e Always use clean glass beads e Use care in order to clean only the electrode and the insulator near the electrode e Do not use glass beads on the outside of the shell or on the upper part of the insulator Installing the Spark Plug Note Use the 9U 7516 Spark Plug Gauge to measure the electrode gap Do not use a flat feeler gauge for measuring the electrode gap of used spark plugs A feeler gauge will produce a false measurement because the used precious metal surfaces will be curved 1 Before installing the spark plug set the electrode gap to 0 29 0 03 mm 011 0 001 inch Adjust the electrode gap by bending the ground electrode at the existing bend Then bend the strap near the weld in order to achieve proper alignment and even spacing between the two precious metal surfaces Measure the electrode gap after the alignment Correct the electrode gap if necessary Note Do not use anti seize compound on spark plugs Most of the heat is transferred through the threads and the seat area of the spark plug The surfaces must be in contact in order to provide the heat transfer that is required 2 Ensure that the spark plug is clean and free of dirt and oil 3 Always use a new gasket when a spark plu
75. he parts that are needed for obtaining oil samples Instructions are also provided NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump 98 Maintenance Section Engine Oil Temperature Regulator Replace SEBU7563 09 For instructions see Special Publication PEgj0047 How To Take A Good S O S Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine 100839584 Engine Oil Temperature Regulator Replace SMCS Code 1330 510 The oil temperature regulators divert the engine oil to the oil cooler in order to maintain engine oil temperature For instructions on replacing the oil temperature regulators see the Service Manual Disassembly and Assembly module 102601497 Engine Protective Device Connections Inspect SMCS Code 7400 040 Inspect the wiring and the electrical connections for these components e Connectors e Control pa
76. iminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Actuator Control Linkage Replace 208 66 Barring Device Lubricate rrnnnnnnvvrrvnnnnnvvrrnnnnnnr 69 Cooling System Coolant Sample Level 2 Obtain 4 saan an ee eee 77 Engine Air Cleaner Element Single Element Clean Replace sirine ia a ea 87 Engine Air Precleaner Clean eeen 91 Overhaul Considerations rrrsrrvrrrnnvvnnrrrnnvonnnnn 116 Valve Stem Projection Measure Record 122 Daily Air Starting Motor Lubricator Oil Level Check 68 Air Tank Moisture and Sediment Drain 69 Control Panel Inspect eseseeeeeeeeeeeeeeeeees 74 Cooling System Coolant Level Check 76 Driven Equipment Inspect Replace Lubricate 83 Electrohydraulic System Inspect 0 eee 86 Engine Oil Level Check rrrsrrnnnnnnnrrrnnnnnnnrrnnnnnnr 96 Fuel System Fuel Filter Differential Pressure CHECK
77. ions only mean that an engine should be scheduled for service in the near future If the engine operation is satisfactory an immediate overhaul is not a requirement The engine does not require an overhaul if the engine is operating within acceptable limits for oil consumption crankcase blowby and cylinder compression Other factors must also be considered for determining a major overhaul 114 Maintenance Section Overhaul Top End SEBU7563 09 e The service hours of the engine e The wear metal analysis of the lube oil e An increase in the levels of noise and vibration An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced An increase in the levels of noise and vibration indicates that rotating parts require service Note It is possible for oil analysis to indicate a decrease of wear metals in the lube oil The cylinder liners may be worn so that polishing of the bore occurs Also the increased use of lube oil will dilute the wear metals Monitor the engine as the engine accumulates service hours Consult your Caterpillar dealer about scheduling a major overhaul Note The driven equipment may also require service when the engine is overhauled Refer to the literature that is provided by the OEM of the driven equipment Major Overhaul Information A major overhaul includes all of the work that is done for a top end overhaul A major overhaul can
78. ith a new hose 5 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 108 Maintenance Section Ignition System Spark Plugs Check Adjust SEBU7563 09 6 Refill the lubrication system Refer to this Operation and Maintenance Manual Engine Oil Level Check in order to ensure that the lubrication system is filled with the proper amount of engine oil 7 Start the engine Inspect the lubrication system for leaks Air System 1 Remove the hose clamps 2 Disconnect the old hose 3 Replace the old hose with a new hose 4 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 5 Start the engine Inspect the air lines for leaks Ignition System Spark Plugs Check Adjust SMCS Code 1555 535 Maintenance of the spark plugs is required in order to obtain the following benefits e Normal fuel consumption e Normal levels of emissions e Maximum service life of the spark plugs The service life of the spark plugs is affected by fouling due to deposits from the oil and by peak voltage Maintenance of the ignition system is also affected by voltage Higher voltage is required by
79. ixs3e teristics ns eae nea aeri 103 Walk Around Inspection rrrrrrnrrnnrnnnnnrnnnnnnnnnn 123 Every 250 Service Hours Battery Electrolyte Level Check n 71 Cooling System Coolant Sample Level 1 Obtain varerlen ieee end ances ens 77 Cooling System Supplemental Coolant Additive SGA gt TESHAdd sist iz teense inten sais 78 Engine Oil Sample Obtain a se 97 Initial 1000 Service Hours Air Starting Motor Lines Screen Clean 67 Air Starting Motor Lubricator Bowl Clean 67 Crankcase Blowby Measure Record 008 80 Cylinder Pressure Measure Record 05 81 Electrohydraulic System Oil Filter Change 87 Engine Crankcase Breather Clean a a 91 Engine Protective Device Connections Inspect 98 Engine Speed Timing Sensor Clean Inspect 100 Engine Valve Lash Inspect Adjust ee 101 Engine Valve Rotators Inspect eeeee 102 Valve Stem Projection Measure Record 122 Every 1000 Service Hours Actuator Control Linkage Lubricate 0 0 66 Belts Inspect Adjust Replace rrrrnnnnnnnrrnnnrrnenr 71 Hoses and Clamps Inspect Replace 105 Ignition System Spark Plugs Replace 111 Every 2000 Service Hours Aftercooler Condensation Drain s es 67 Cooling System Coolant Sample Level 2 Obtaln v re EEEE E reddet 77 Crankshaft Vibration Damper Inspect
80. l Considerations arrsnrvrrnnnnrnvrrrnnronnnnne 116 Valve Stem Projection Measure Record 122 Daily Air Starting Motor Lubricator Oil Level Check 68 Air Tank Moisture and Sediment Drain 69 Control Panel Inspect ceeeeeeeeeeceeeeeeeeeees 74 Cooling System Coolant Level Check 76 Driven Equipment Inspect Replace Lubricate 83 Electrohydraulic System Inspect eee 86 Engine Air Cleaner Service Indicator Inspect 90 Engine Oil Level Check rrrsrrnnnnnnnvrrnnnnnnvrrnnnnnnr 96 Fuel System Fuel Filter Differential Pressure CHECK EPEE EE E 103 Turbocharger Clean eeens 120 Walk Around Inspection rrnrrrnnrrnrnnnnnrrnnnnnnnnn 123 Every 125 Service Hours Engine Oil Sample Obtain a se 97 Every 250 Service Hours Battery Electrolyte Level Check n se 71 Cooling System Coolant Sample Level 1 OBbtaln ei eaaa aa a aa dares 77 Cooling System Supplemental Coolant Additive SCAJ TeStAdd orenian ienai me arna 78 Initial 1000 Service Hours Air Starting Motor Lines Screen Clean 67 Air Starting Motor Lubricator Bowl Clean 67 Crankcase Blowby Measure Record 5 80 Cylinder Pressure Measure Record 0 81 Electrohydraulic System Oil Filter Change 87 Engine Crankcase Breather Clean 055 91 Engine Protective Device Connections Inspect
81. l gas 10 5 1 15000 Bio gas 9 2 1 10000 to 14000 Top end overhauls are normally scheduled according to the projection of exhaust valve stems This measurement provides an accurate indication of the rate of valve wear This measurement can be used to predict when a cylinder head requires replacement Measure the projection of the exhaust valve stems at the first 1000 service hours This measurement is the baseline The baseline is a reference for subsequent measurements Continue to periodically measure the projection Plan for the top end overhaul as the valve stem projection approaches the maximum limit Perform the top end overhaul when the valve stem projection has increased by a total of 2 3 mm 09 inch Do not allow the projection of the exhaust valve stems to exceed this limit Note Generally cylinder heads wear out at different rates In some cases servicing the cylinder heads at different times may be the most economic decision This depends on the valve stem projection of the individual cylinders However this decision must include the costs of additional downtime that is caused by this procedure Perform an economic analysis in order to determine if cylinder heads should be serviced as a group or divided into smaller groups Note The generator or the driven equipment may also require service when the engine overhaul is performed Top End Overhaul Information A top end overhaul involves servicing the
82. lace 008 66 Barring Device Lubricate 69 Cooling System Coolant Sample Level 2 Obtaif bere nee ei Ae vee ios 71 Engine Air Cleaner Element Single Element Clean Replace sirine ia a ea 87 Engine Air Precleaner Clean eeen 91 Overhaul Considerations rrrsrrvrrrnnvvnnrrrnnvonnnnn 116 Valve Stem Projection Measure Record 122 Daily Air Starting Motor Lubricator Oil Level Check 68 Air Tank Moisture and Sediment Drain 69 Control Panel Inspect eseseeeeeeeeeeeeeeeeees 74 Cooling System Coolant Level Check 76 Driven Equipment Inspect Replace Lubricate 83 Electrohydraulic System Inspect 0 eee 86 Engine Oil Level Check rrrsrrnnnnnnnrrrnnnnnnnrrnnnnnnr 96 Fuel System Fuel Filter Differential Pressure Check ooreen ra stinn aetirad erate 103 Walk Around Inspection rrrrrrnrrnnrnnnnnrnnnnnnnnnn 123 Every 250 Service Hours Battery Electrolyte Level Check n se 71 Cooling System Coolant Sample Level 1 OBTAIN iiiar ii raain air ar AA 77 Cooling System Supplemental Coolant Additive SGA TES AIG aan ctr initio tein 78 Engine Oil Sample Obtain asasen 97 Initial 1000 Service Hours Air Starting Motor Lines Screen Clean 67 Air Starting Motor Lubricator Bowl Clean 67 Crankcase Blowby Measure Record 5 80 Cylinder Pressure Measure Record
83. lication An established S O S oil analysis program enables used oil to be evaluated The evaluation can be used to determine if this oil change interval is suitable for your specific engine Engines That Use Bio Gas The oil change interval is determined by the results of oil analysis Change the lubrication oil when oil analysis determines that the oil has reached the condemning limit Also change the engine oil filters Change the Engine Oil Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Ensure that the engine is stopped before performing this procedure Attach a DO NOT OPERATE tag to the starting controls Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed when the cold oil is drained Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will allow the waste particles to be recirculated through the engine lubrication system with the new oil 1 After the engine has been operated at normal operating temperature STOP the engine Note Drain the oil into a suitable container Dispose of fluids according to local regulations Illustration 78 900789667
84. lowing recommendations The following definitions explain the terminology for the services that are performed during an overhaul Inspect Inspect the components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures New parts are not required if the existing parts can still be used reconditioned or repaired If the components are not in the reusability guidelines refer to the Service Manual Specifications module Rebuild The component can be reconditioned in order to comply with reusability guidelines SEBU7563 09 113 Maintenance Section Overhaul Major Replace The service life of the part is exhausted The part may fail before the next maintenance interval The part must be replaced with a part that meets functional specifications The replacement part may be a new part a CAT remanufactured part a rebuilt part or a used part Various worn components may be exchanged with your Caterpillar dealer Consult your Caterpillar dealer about repair options for your engine Table 38 In Frame Overhaul Procedure Component Inspect Aftercooler pepe Cylinder liners Oil cooler Pistons Rebuild Gas admis
85. lves Replace i02602222 Prechamber Check Valves Replace SMCS Code 1550 510 3 NG 5 Illustration 101 900789869 1 Plug 2 O ring seal 3 Check valve assembly 4 O ring seal 5 Gasket Note Use of a platform may be necessary to reach the prechamber check valves Note Refer to the engine s Disassembly and Assembly manual for instructions on removal and installation of the check valves 1 Remove check valve assembly 3 and gasket 5 2 Keep plug 1 for reassembly Discard the other parts Obtain new parts for reassembly 3 Install a new gasket and a new O ring Install the clean dry check valve assembly and torque to 115 N m 85 Ib ft 4 Do NOT overtighten the plug for the check valve Tighten to 15 N m 11 Ib ft i01612991 Prelube Pump Inspect SMCS Code 1319 040 Inspect the prelube pump for the following conditions e Cracks e Pin holes e Proper operation e Wear Inspect the prelube pump for leaks Replace all of the seals if a leak is observed Inspect the wiring for the following conditions e Damage e Fraying Ensure that the wiring is in good condition Inspect the electrical connections Ensure that the electrical connections are secure If repair or replacement is necessary refer to the engine s Disassembly and Assembly manual Consult your Caterpillar dealer for assistance Air Prelube Pump Inspect all of the components in the air circuit for the p
86. mation about selecting and installing the proper hose clamps 10 Refill the cooling system 11 Clean the filler cap for the cooling system Inspect the gaskets on the filler cap Replace the filler cap if the gaskets are damaged Install the filler cap 12 Start the engine Inspect the cooling system for leaks Fuel System Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components Note High pressure fuel lines may be installed between the high pressure fuel pump and the fuel injectors High pres
87. n cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 70 g00281692 Note When the air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Air Cleaner Elements SEBU7563 09 89 Maintenance Section Engine Air Cleaner Element Single Element Clean Replace Vacuum Cleaning Vacuum cleaning is a good method for cleaning air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Air Cleaner Elements Inspecting the Air Cleaner Elements Illustration 71 900281693 Inspect the clean dry air cleaner element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the air cleaner element Rotate the air cleaner element Inspect the air cleaner element for tears and or holes Inspect the air cleaner elemen
88. n the inlet side and the outlet side of the fuel filter The differential pressure increases as the fuel filter becomes plugged Operate the engine with a full load at the rated rom and at the normal operating temperature Check the fuel filter differential pressure at full load Service the fuel filter when the fuel filter differential pressure reaches 1 7 kPa 0 25 psi For instructions refer to Special Instruction SEHS9298 Installation and Maintenance of Gaseous Fuel Filters Consult your Caterpillar dealer for assistance 101765725 Gas Admission Valve Recondition SMCS Code 1105 020 GS Note Use of a platform may be necessary to reach the gas admission valves For the procedure to remove the gas admission valve refer to the engine s Disassembly and Assembly When you disassemble the gas admission valve inspect the seals Replace the seals if necessary Refer to this Operation and Maintenance Manual Gas Admission Valve Seals Inspect Replace ee a LE Illustration 91 900833978 Exploded view and section view of the parts for the gas admission valve 1 Retainer locks 2 Valve rotator 3 Outer valve spring 4 Inner valve spring 5 Valve guide 6 Support assembly 7 Valve To recondition the gas admission valve replace retainer locks 1 valve rotator 2 outer valve spring 3 inner valve spring 4 and valve 7 104 Maintenance Sec
89. nder Pressure Measure Record 0008 81 Driven Equipment Check nrnnrnnnrnnrrrrrrnrnnnnnnnnnn 82 Electrohydraulic System Check Adjust 85 Electrohydraulic System Oil Change 05 86 Electrohydraulic System Oil Filter Change 87 Engine Oil Change rrrnnnnnnvrrvnnrennrrrnnnrrrrrrennrerenr 92 Engine Oil Filter Change seeen 93 Engine Protective Device Connections Inspect 98 Engine Protective Devices Check aeee 100 Exhaust Bypass Recondition rrrrvvnnnnrvrvrnnnnnn 102 Gas Shutoff Valve Inspect ceeeeeeeeees 105 Ignition System Spark Plugs Replace 111 Inlet Air System Inspect n se 111 SEBU7563 09 61 Maintenance Section Maintenance Interval Schedule Inlet Gas Manifold and Piping Inspect Replace 111 Prechamber Check Valves Clean n 118 Starting Motor Inspect i e 119 Turbocharger Inspect n se 121 Every 10 000 Service Hours Alternator Inspect cececeeeeeeceeeeeeeeeeeeeeteeeeees 69 Cooling System Water Temperature Regulator Replace rrrnnnnnronnnvnnnnnnnnrnnnnvnnronnnnnnrnnnnnrnnnnnnnnn 79 Electrohydraulic Actuator Inspect srrrrrrnnrern 83 Engine Oil Temperature Regulator Replace 98 Engine Speed Timing Sensor Clean Inspect 100 Exhaust Shields Inspect cceeeeeeeeeees 102 Gas Pressure Regulator Inspect Replace 104 Prechamber
90. nel e Junction box e Sensors tet H C ne eo e 2 Illustration 86 900449867 Typical examples of electrical connectors A Military Standard connector 1 Plug 2 Receptacle B Deutsch HD connector C Phoenix terminal strip Note Military Standard MS Caterpillar Environmental CE and Vehicle Environmental VE connectors are similar in design However the wiring is soldered to the pins and sockets of Military Standard connectors In CE and VE connectors the wiring is crimped into the pins and sockets The wiring is crimped into the pins and sockets of Deutsch HD connectors also 1 Turn the mode control switch to the OFF RESET position Open the circuit breaker of the main power supply 2 Inspect all of the wiring for the following conditions e Fraying e Damaged insulation e Corrosion Make repairs as needed SEBU7563 09 99 Maintenance Section Engine Protective Device Connections Inspect
91. nes with different compression ratios 82 Maintenance Section Cylinders Inspect SEBU7563 09 2136 310 2067 300 1998 290 1929 280 1860 270 1791 260 1723 250 1654 240 1585 230 1516 220 1447 210 1378 200 1309 190 1240 180 1171 7 1 8 1 9 1 10 1 1 1 121 Illustration 60 900789376 Y Cylinder pressure in kPa psi X Compression ratio 1 Normal range for cylinder pressure Record the pressure for each cylinder Use Operation and Maintenance Manual Valve Data Sheet Reference Materials Section Cylinders Inspect Inspect the Combustion Chamber SMCS Code 1223 040 1223 Excessive deposits can accumulate in the combustion chambers of engines that use gas with a low BTU such as bio gas fuel landfill gas etc The deposits can affect the characteristics of combustion Erratic operation can result The rate of recession of the exhaust valves can increase The risk of guttering of the exhaust valves can increase Note Use of a platform may be necessary to inspect the combustion chamber Use a borescope to inspect the combustion chamber The inspection will provide information about the internal condition of the engine A borescope with a lens that can be rotated is recommended This type of borescope provides a clear view of the combustion chamber and of the bottom deck of the cylinder head Photographic documentation or video documentation is also recommended
92. nspect all clamps for the following conditions Replace any clamp which exhibits signs of any of the following conditions e Cracking e Looseness e Damage Inspect all couplings for leaks Replace any coupling which exhibits signs of leaks Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Replace hoses that are cracked or soft Replace hoses that show signs of leakage Replace hoses that show signs of damage Replace hose clamps that are cracked or damaged Tighten or replace hose clamps which are loose Replace the Hoses and the Clamps NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJ0003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies s
93. o this Operation and Maintenance Manual Engine Oil topic Maintenance Section NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can cause the crankshaft to dip into the oil This will reduce the power that is devel oped and also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling oil blowing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber De posits in the combustion chamber lead to the following problems guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately Note For the amount of oil to use refer to this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section 5 Remove the oil filler cap Fill the crankcase through the oil filler tube only Clean the oil filler cap Install the oil filler cap 6 Follow this Operation and Maintenance Manual Starting The Engine procedure Operation Section Operate the engine at low idle for two minutes Inspect the engine for oil leaks Ensure that
94. of resetting The service indicator should reset in less than three pushes Check the movement of the yellow core when the engine is accelerated to the engine rated rpm The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum replace the service indicator If the new service indicator will not reset the fitting for the service indicator may be plugged SEBU7563 09 91 Maintenance Section Engine Air Precleaner Clean Illustration 75 900351792 Porous filter A porous filter is part of a fitting that is used for mounting of the service indicator Inspect the filter for cleanliness Clean the filter if necessary Use compressed air or a clean nonflammable solvent The service indicator may need to be replaced frequently in environments that are severely dusty Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 100935352 Engine Air Precleaner Clean SMCS Code 1055 070 Note More frequent cleaning may be required in dusty
95. ohydraulic Actuator Recondition 8 Install boot 7 Make sure that the outer end of the boot folds inward when the actuator s shaft moves from the fully open position to the fully closed position 9 Install clevis 6 Connect rod end 5 to the clevis 10 Install guards 4 11 Connect the wiring harness to receptacle 1 101610640 Electrohydraulic Actuator Recondition SMCS Code 1716 020 Recondition the actuators for the fuel control the wastegate and the air choke The main components of each actuator include the housing a piston assembly and a solenoid which actuates the piston The piston assembly and the solenoid can be serviced separately Note New parts or remanufactured parts may be used for reconditioning the actuators During operation the linkage of the electrohy draulic actuators can form pinch points which can cause personal injury Shut down the engine before you service the electrohydraulic actuators Jo Illustration 63 900833592 1 Receptacle for the wiring harness 2 Guards 1 Disconnect the wiring harness from receptacle 1 Inspect the connectors for damage and corrosion Make repairs if necessary 2 Remove guards 2 3 Disconnect the supply line not shown and the return line not shown for the hydraulic oil SEBU7563 09
96. oil has drained close the valve Note For the proper oil to use refer to the Special Publication SEBU6400 Caterpillar Gas Engine Lubricant Fuel and Coolant Recommendations 3 Pour the proper oil into the oil filler Clean the oil filler cap Install the oil filler cap 4 Clean up any oil that may have spilled SEBU7563 09 87 Maintenance Section Electrohydraulic System Oil Filter Change 102246458 Electrohydraulic System Oil Filter Change SMCS Code 1716 510 FI Illustration 68 900792302 1 Filter 2 Sight gauge 3 Filler cap 1 Remove filter 1 with a 1U 8760 Chain Wrench 2 Clean the sealing surface of the filter mounting base Ensure that all of the old filter gasket is removed Illustration 69 g00103713 Typical filter mounting base and gasket Note For the proper oil to use refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section 3 Apply clean hydraulic oil to the new filter gasket 4 Install the filter by hand Tighten the filter until the gasket contacts the mounting base Tighten the filter according to the instructions that are shown on the filter Do not overtighten the filter 5 Start the engine Check the oil level in sight gauge 2 The oil should be between the ADD and FULL marks on the tank If necessary remove oil filler cap 4 Pour the correct oil into the oil filler
97. oil has entered the cooling system and the coolant is contaminated NOTICE Use of commercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines Drain the Cooling System 1 Stop the engine and allow the engine to cool Ensure that the engine will not start when the cooling system is drained 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Illustration 55 900792409 Location of cooling system drain valves or drain plugs on the water pumps 1 Jacket water pump 2 Aftercooler and oil cooler pump Illustration 56 g00901833 Location of drain plug for the jacket water system 3 Open the cooling system drain valves if equipped Remove the cooling system drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Cana
98. ojection of the valve rotator above the cylinder head It is not necessary to remove the rocker arms in order to obtain this measurement Measure the projection of the exhaust valve rotators with the 148 2997 Valve Recession Tool Group Make several copies of this Operation and Maintenance Manual Valve Data Sheet Reference Materials Section Record the measurements on the sheets e Measure the projection of the inlet and exhaust valve stems and the exhaust valve rotators at the first 1000 service hours This measurement is the baseline The baseline is a reference for subsequent measurements e Measure the projection of the inlet and exhaust valve rotators when the engine valve lash is checked Continue this periodic measurement until the projection of the valve rotator has increased by a total of 1 6 mm 063 inch This is 70 percent of the maximum limit Measure the projection of the valve stems when this occurs This measurement will determine the actual wear of both the valves and the valve seats e After 70 percent of the maximum limit has been reached measure the projection of the exhaust valve stems at every 500 hours of operation Plan for the top end overhaul as the valve stem projection approaches the maximum limit Perform the top end overhaul when the valve stem projection has increased by a total of 2 3 mm 09 inch Do not allow the valve recession to exceed this limit The valve head can break This will
99. on chamber The deposits can lead to detonation and premature ignition This condition is more obvious at certain engine speeds and loads 102602013 Driven Equipment Check SMCS Code 3279 535 Every 5000 Service Hours Engines That Are Not Attached To the Base with a Dowel If some engines are too rigidly mounted excessive stress may affect the internal support of the cylinder block This could cause the following problems SEBU7563 09 83 Maintenance Section Driven Equipment Inspect Replace Lubricate e Distortion of the bores of the main bearing e Distortion of the alignment of the bore Severe damage to the engine could result The service life of the engine could be severely reduced For engines that are not attached to the base with a dowel check the following e Check the alignment after every 5000 service hours e Inspect the drive coupling according to the specifications of the OEM Every 10 000 Service Hours Engines That Are Attached To the Base with a Dowel Some engines must be more rigidly mounted Due to thermal expansion a cold engine will expand after the engine achieves operating temperature Some engines are attached to the base with a dowel in the rear mounting support This installation forces the thermal growth forward The driven equipment is also attached with a dowel in order to maintain alignment with the engine For this type of installation check the alignment after every 1
100. or bottoms out Tighten the sensor to 38 2 Nem 28 2 Ib ft 11 Install extension 3 Make sure that discs 5 are positioned in order to align the extension s connectors with sensor 4 and connector 2 12 Make sure that the O ring seal on connector 2 is in good condition Install the connector 13 Attach harness connector 1 to connector 2 74 Maintenance Section Control Panel Inspect SEBU7563 09 i01762721 Control Panel Inspect SMCS Code 4490 040 7451 040 Inspect the condition of the panel If a component is damaged ensure that the component is repaired or that the component is replaced If equipped ensure that the electronic displays are operating properly Inspect the wiring for good condition Ensure that the wiring connections are secure Record the Data and Review the Data If equipped check the gauges and check the indicators frequently during normal operation Record the data in a log Compare the new data to the data that was previously recorded Comparing the new data to the recorded data will establish the normal gauge readings for the engine gauge reading that is abnormal may indicate a problem with operation or with the gauge 102601979 Cooling System Coolant NGEC Change SMCS Code 1350 044 Clean the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The
101. or a short time the crankcase blowby can decrease as the piston rings are seated The crankcase blowby will gradually increase as the following components show wear e piston rings e cylinder liners Note A problem with the piston rings causes the oil to deteriorate rapidly Information regarding the condition of the piston rings can be obtained from the measurement of the crankcase blowby and the results of oil analysis The crankcase blowby of a worn engine may exceed the crankcase blowby of a new engine by two times or more A sudden increase in crankcase blowby could indicate a broken piston ring The following conditions are other potential sources of crankcase blowby e Worn valve guides e A turbocharger seal that leaks A rebuilt engine can have a high crankcase blowby due to the following factors e The piston rings are not seated properly e Worn parts such as valve guides were not replaced Excessive crankcase blowby may indicate the need for an overhaul By keeping a record of the results a gradual increase in the amount of the crankcase blowby will be noted until the amount of crankcase blowby has become excessive Use the 1U 8860 Large Engine Blowby Pickup Group to measure the blowby Refer to Special Instruction SEHS8984 1U 8860 Large Engine Blowby Pickup Group that is provided with the tool Record the crankcase blowby for the engine Keep a record of the results For more information see the
102. r assistance 112 Maintenance Section Overhaul In Frame SEBU7563 09 i02252012 Overhaul In Frame SMCS Code 1000 020 Scheduling an In Frame Overhaul Table 37 lists the approximate number of service hours before an in frame overhaul for different G3600 Engine applications Table 37 Estimated Service Hours Before An In Frame Overhaul Fuel Compression Ratio FG ours Wellhead gas or 9 2 1 50000 natural gas 45000 to Natural gas 10 5 1 48000 27000 to Bio gas 9 2 1 33000 Scheduling an in frame overhaul normally depends on the following three conditions e An increase of oil consumption e An increase of crankcase blowby e A decrease and a variation of cylinder compression Each individual condition may not indicate a need for an overhaul However evaluating the three conditions together is the most accurate method of determining when an overhaul is necessary The engine may not require an overhaul if the engine is operating within acceptable limits for oil consumption crankcase blowby and cylinder compression Periodically measure each of the three conditions The first measurement should occur during the first scheduled maintenance This establishes a baseline for future measurements Additional measurements are scheduled at regular intervals in order to determine a schedule for the next in frame overhaul The following changes in the three conditions normally require a
103. relube pump Inspect all of the air lines and connections for leaks Ensure that the components in the air circuit are in good condition Electric Prelube Pump Inspect the brushes Replace the brushes if necessary 101113939 Starting Motor Inspect SMCS Code 1451 040 1453 040 If the starting motor fails the engine may not start in an emergency situation A scheduled inspection of the starting motor is recommended The starting motor pinion and the flywheel ring gear must be in good condition in order for the engine to start properly The engine will not start if the starting motor pinion does not engage the flywheel ring gear The teeth of the starting motor pinion and the flywheel ring gear can be damaged because of irregular engagement Inspect the starting motor for proper operation Listen for grinding when the engine is started Inspect the teeth of the starting motor pinion and the flywheel ring gear Look for patterns of wear on the teeth Look for teeth that are broken or chipped If damaged teeth are found the starting motor pinion and the flywheel ring gear must be replaced 120 Maintenance Section Turbocharger Clean SEBU7563 09 Electric Starting Motor Note Problems with the electric starting motor can be caused by the following conditions malfunction of the solenoid and malfunction of the electric starting system Inspect the electrical system for the following conditions e Loose connection
104. s e Corrosion e Wires that are worn or frayed e Cleanliness Make repairs if necessary Air Starting Motor Personal injury or death can result from improp erly checking for a leak Always use a board or cardboard when checking for a leak Escaping air or fluid under pressure even a pin hole size leak can penetrate body tis sue causing serious injury and possible death If fluid is injected into your skin it must be treated immediately by a doctor familiar with this type of injury Inspect all of the components in the air circuit for the starting motor Inspect all of the air lines and connections for leaks If the teeth of the starting motor pinion and or the flywheel ring gear are damaged the air circuit for the starting motor must be examined in order to determine the cause of the problem Removal and Installation of the Starting Motor Refer to the Service Manual Disassembly and Assembly module for information on removing the starting motor and installing the starting motor Consult your Caterpillar dealer for assistance 101765784 Turbocharger Clean Cleaning with Dry Particles SMCS Code 1052 070 Note Use of a platform may be necessary to reach the turbocharger If the engine has more than one turbocharger each turbocharger requires cleaning Note The drain openings in the exhaust housing of the turbocharger are closed during the cleaning procedure Some of the particles will b
105. s are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure Check the coolant level when the engine is stopped and cool Check the coolant level only after the engine has been stopped and the cooling system filler cap is cool enough to touch with your bare hand Remove the cooling system filler cap slowly in order to relieve any pressure Maintain the coolant within 13 mm 0 5 inch below the bottom of the filler pipe Add Coolant Note For the proper coolant mixture to use see this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section 1 Stop the engine Allow the engine to cool 2 Remove the cooling system filler cap slowly in order to relieve any pressure Pour the proper coolant mixture into the filler pipe Illustration 58 g00103639 Gaskets SEBU7563 09 77 Maintenance Section Cooling System Coolant Sample Level 1 Obtain 3 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets are damaged replace the old cooling system filler cap with a new cooling system filler cap Install the cooling system filler cap 4 Start the engine Inspect the cooling system for leaks 102064894 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated
106. s es 121 Every 10 000 Service Hours Alternator Inspect eeeeeeeeeeeceeceeeeeeeeeeeeeeeeees 69 Cooling System Water Temperature Regulator Replace tie oot cinta tae nende 79 Electrohydraulic Actuator Inspect eee 83 Engine Oil Temperature Regulator Replace 98 Engine Speed Timing Sensor Clean Inspect 100 Exhaust Shields Inspect ecceeeeeeeeeees 102 Gas Pressure Regulator Inspect Replace 104 Prechamber Check Valves Replace 5 119 Prelube Pump Inspect eeceeeeeeeeteeeees 119 Water Pump Inspect rrrrnnnnrnrrrrrnnrrnrrnnnnnrnnn 124 Every 15 000 Service Hours Gas Admission Valve Seals Inspect Replace 104 Overhaul Top End Jesss aere en Anr sanea ERREKEN ERS 114 Prechamber Clean Inspect rrnnrnnnnrnnrrrrnnnnnn 118 Every 20 000 Service Hours or 3 Years Cooling System Coolant NGEC Change 74 Between 45 000 and 48 000 Service Hours Electrohydraulic Actuator Recondition 84 Gas Admission Valve Recondition 05 103 Overhaul In Frame rrrrrrnnnnnnnvrnnnnnnnrnnrrnnnsennnnne 112 Between 75 000 and 80 000 Service Hours Overhaul Major eeerernrrvrnnnnnnnvrrnnnnnnnnnrnnnnrnnnnnne 113 64 Maintenance Section Maintenance Interval Schedule SEBU7563 09 i03915101 Maintenance Interval Schedule G3600 Engines That use Bio Gas SMCS Code
107. sion valve Electrohydraulic actuators Vibration damper Replace Camshaft bearings Camshaft followers Connecting rod bearings Crankshaft seals Engine oil pump Exhaust shields Gaskets and seals Electrohydraulic system s oil pump Main bearings Oil temperature regulators Piston rings Prechamber assemblies Water pumps Water temperature regulators 1 In addition to these procedures perform the procedures for the top end overhaul 102252260 Overhaul Major SMCS Code 7595 020 MJ Scheduling a Major Overhaul Table 39 lists the approximate number of service hours before a major overhaul for different G3600 Engine applications Table 39 Estimated Service Hours Before a Major Overhaul Fuel Compression Ratio dg ours Wellhead gas or 9 2 1 100000 natural gas i 75000 to Natural gas 10 5 1 80000 F 52000 to Bio gas 9 2 1 54000 The need for a major overhaul is determined by several factors e An increase of oil consumption e An increase of crankcase blowby e A decrease and variation of cylinder compression The following changes in the three conditions normally require a scheduled overhaul e A 300 percent increase in oil consumption e A 200 percent increase in crankcase blowby e A 20 percent loss of cylinder compression Note These indications do not require an engine to be shut down for service These indicat
108. ssure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The air cleaner element can be used up to six times if the element is properly cleaned and inspected When the air cleaner element is cleaned check for rips or tears in the filter material The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean air cleaner elements e Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean air cleaner elements that have not bee
109. ssure gauge 1 Check cover 3 for leaks Note A hydraulic stop will limit the rotation of the control valve until the oil filter housing is full of oil 10 After the pressure of the lower oil filter and the upper oil filter is equal rotate control valve 4 to the UPPER SERVICE position Repeat Step 1 through Step 9 for the upper oil filter 11 After the oil filters have been serviced and after the pressure of the lower oil filter and the upper oil filter is equal rotate control valve 4 to the RUN position Inspect the Used Oil Filter Elements Cut the used oil filter element open with a utility knife Remove the metal wrap Cut the filter element free from the end caps Spread apart the pleats and inspect the element for metal debris An excessive amount of debris in the element may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the element Ferrous metals may indicate wear on the steel and the cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts the brass parts or the bronze parts of the engine Parts that may be affected include the following components main bearings rod bearings turbocharger bearings and cylinder heads Aluminum debris may indicate problems with the bearings of the front gears If aluminum is found in the filter inspect the crankshaft vibration damper an
110. sure fuel lines are constantly charged with high pressure Do not check the high pressure fuel lines with the engine or the starting motor in operation Wait for 10 minutes after the engine stops before you perform any service or repair on high pressure fuel lines in order to allow pressure to be purged 1 Drain the fuel from the fuel system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose with a new hose 5 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 6 Carefully inspect the engine for any spilled fuel Make sure that no fuel remains on or close to the engine Note Fuel must be added to the fuel system ahead of the fuel filter 7 Refill the fuel system Refer to this Operation and Maintenance Manual Fuel System Prime for information about priming the engine with fuel 8 Start the engine Inspect the fuel system for leaks Lubrication System Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin 1 Drain the oil from the lubrication system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose w
111. t for light that may show through the filter material If it is necessary in order to confirm the result compare the air cleaner element to a new air cleaner element that has the same part number Do not use an air cleaner element that has any tears and or holes in the filter material Do not use an air cleaner element with damaged pleats gaskets or seals Discard damaged air cleaner elements Storing Air Cleaner Elements If an air cleaner element that passes inspection will not be used the air cleaner element can be stored for future use Illustration 72 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the air cleaner elements in Volatile Corrosion Inhibited VCI paper Place the air cleaner element into a box for storage For identification mark the outside of the box and mark the air cleaner element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location Crankcase Air Cleaner Engines that are equipped with positive crankcase ventilation have an air cleaner for crankcase ventilation Clean the air cleaner element or replace the air cleaner element when the following conditions occur The yellow diaphragm enters the red zone e The red piston locks in a visible position e The air restriction reaches 0 25 kPa 1 inch of H20
112. ten the drive belts Overtightening can result in failure of the drive shaft Replacement For applications that require multiple drive belts replace the drive belts in matched sets Replacing one drive belt of a matched set will cause the new drive belt to carry more load because the older drive belts are stretched The additional load on the new drive belt could cause the new drive belt to fail 102601781 Combustion Sensor Clean Inspect Replace SMCS Code 1900 1905 To provide a signal without interference to the engine control module the sensor must be in good condition The connections must be clean 2 av ae SN 4 5 gt ie Illustration 53 900789241 Section view of a cylinder head with a combustion sensor 1 Harness connector 2 Connector 3 Extension 4 Sensor 5 6 Note Use of a platform may be necessary to reach the combustion sensor Note Clean the connections and polish the connections with a clean dry cloth Always install a new O ring seal in connector 1 when the combustion sensor is serviced 1 Disconnect harness connector 1 from connector 2 Remove the O ring seal from the harness connector Clean the end of the harness connector Install a new O ring seal 2 Remove connector 2 Clean the inside of the connector s adapters 3 Remove extension 3 Clean both ends of the extension SEBU7563 09 73 Maintenance Section Combustion Sensor Cl
113. terpillar dealer for assistance To determine the reusability publications that are needed to inspect the engine refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts The Guidelines For Reusable Parts and Salvage Operations is part of an established Caterpillar parts reusability program These guidelines were developed in order to assist Caterpillar dealers and customers reduce costs by avoiding unnecessary expenditures for new parts If the engine parts comply with the established inspection specifications the parts can be reused New parts are not necessary if the old parts can be reused repaired or salvaged If the parts are not within the inspection specifications the parts should be salvaged repaired replaced or exchanged The use of out of spec parts could result in unscheduled downtime and or costly repairs The use of out of spec parts can also contribute to increased fuel consumption and reduction of engine efficiency Your Caterpillar dealer can provide the parts that are needed to rebuild the engine at the least possible cost Overhaul Programs An economical way to obtain most of the parts that are needed for overhauls is to use Caterpillar remanufactured parts Caterpillar remanufactured parts are available at a fraction of the cost of new parts These parts have been rebuilt by Caterpillar and certified for use The following
114. the original position Coat the rubber parts with clean engine oil or petroleum jelly in order to make installation easier Tighten the retaining clamps and the hose clamps according to the engine s Specifications manual i01612978 Engine Mounts Check SMCS Code 1152 535 Check the torque of the bolts for the mounting plates For the proper torque refer to Gas Engines Application and Installation Guide LEKQ7252 G3600 Mounting Alignment Engine vibration can be caused by the following conditions e Improper mounting of the engine e Deterioration of the isolators Settling of the isolators will result in misalignment between the engine and the driven equipment Inspect the condition of isolators if necessary Keep the isolators clean and dry Ensure that the isolators are free of oil and contamination Inspect the isolators for deterioration Replace any isolator that shows deterioration For more information refer to the literature that is provided by the OEM of the isolators Also refer to the following publications e Gas Engines Application and Installation Guide LEKQ7252 G3600 Mounting Alignment e Special Instruction SEHS9162 Spring Isolator Group Installation and Adjustment Procedure Consult your Caterpillar dealer for assistance Engine Oil Change SMCS Code 1348 044 1348 Oil Change Interval Considerations for the oil change interval include the type of fuel and the engine app
115. the piston rings and wear of the cylinder liner Also a low temperature can allow moisture to condense in the oil This can form damaging acids NOTICE Failure to replace the water temperature regulator on a regularly scheduled basis could cause severe en gine damage Never operate an engine without the water tempera ture regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position 80 Maintenance Section Crankcase Blowby Measure Record SEBU7563 09 Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing i02602965 Crankcase Blowby Measure Record SMCS Code 1317 Note The typical crankcase blowby on a new engine is approximately 0 02 m bkW h 50 ft bhp h Measure the crankcase blowby of new engines Record the data Continue to periodically measure the crankcase blowby Comparing the recorded data to the new data provides information about the condition of the engine Note Crankcase blowby is one of the three factors that help to determine the in frame overhaul interval For more information see the Operation and Maintenance manual Overhaul In Frame topic in the Maintenance Section After a new engine is used f
116. the results SEBU7563 09 79 Maintenance Section Cooling System Water Temperature Regulator Replace Table 36 Number of Concentration Maintenance Drops of SCA Required Less than 25 Less than the Add SCA recommended Retest the concentration of coolant SCA 25 to 30 The None recommended concentration of SCA More than 30 More than the Remove the recommended coolant concentration of Replace with SCA water only Retest the coolant Add the SCA If Necessary Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly Note Always dispose of fluids according to local regulations 2 If necessary drain some coolant in order to allow space for the addition of the SCA NOTICE Excessive supplemental coolant additive concentra tion can form deposits on the higher temperature sur faces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temperature components Excessive supplemental coolant additive concentra tion could also result in blockage of the heat exchang er overheating and or accelerated wear of the water pump seal Do not exceed th
117. tion Gas Admission Valve Seals Inspect Replace SEBU7563 09 Valve guide 5 will probably have very little wear However measure the inner diameter of the valve guide at both ends and the middle The maximum allowable inner diameter of the valve guide at both ends and the middle is 9 538 mm 0 3755 inch If any measurement exceeds this specification replace the valve guide If this is not possible replace support assembly 6 and the valve guide It is unlikely for support assembly 6 to require replacement However inspect the valve seat in the support assembly Gauge diameter s maximum depth 2 0 mm 0 079 in L N o Gauge diameter 44 75 39 75 mm 1 565 in Illustration 92 900833994 Angle and dimensions for the valve seat in the support assembly If the valve seat is worn the valve seat can be slightly ground according to these specifications e The angle for the valve seat is 44 75 0 5 degrees e The gauge diameter of the valve seat within a maximum depth of 2 0 mm 0 079 inch from the end of the support assembly is 39 75 mm 1 565 inch Use some Prussian blue to verify complete contact of the valve in the valve seat 101765734 Gas Admission Valve Seals Inspect Replace SMCS Code 1105 040 GS 1105 510 GS The camshaft operates the mechanism for the gas admission valve in order to allow fuel to enter the inlet port of the cylinder Note Use of a platform ma
118. ture regulators Spark plug extenders Water temperature regulators 102250409 Overhaul Considerations SMCS Code 7595 043 Overhaul Information An overhaul is replacing the major worn components of the engine An overhaul is a maintenance interval that is planned The engine is rebuilt with certain rebuilt parts or new parts that replace the worn parts An overhaul also includes the following maintenance e Inspection of all the parts that are visible during the disassembly e Replacement of the seals and gaskets that are removed Cleaning of the internal passages of the engine and the engine block Most owners will save money by overhauling the engine at the intervals that are recommended in the Operation and Maintenance Manual It is not practical to wait until the engine exhibits symptoms of excessive wear or failure It is not less costly to wait A planned overhaul before failure may be the best value for the following reasons Costly unplanned downtime can be avoided Many original parts can be reused according to the guidelines for reusable parts The service life of the engine can be extended without the risk of a major catastrophe due to engine failure Achieve the best cost value relationship per hour of extended service life Overhaul Intervals Top end overhauls are determined by the projection of exhaust valve stems In frame overhauls are determined by cylinder compression crankcase blo
119. ube that is provided for mailing Submit the sample for Level 1 analysis Note Level 1 results may indicate a need for Level 2 Analysis For additional information about coolant analysis see the Special Publication SEBU6400 Caterpillar Gas Engine Lubricant Fuel and Coolant Recommendations or consult your Caterpillar dealer 102168823 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to this Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain Maintenance Section for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see the Special Publication SEBU6400 Caterpillar Gas Engine Lubricant Fuel and Coolant Recommendations or consult your Caterpillar dealer 101519993 Cooling System Level Switch Inspect SMCS
120. uitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Cooling System Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved _ Stop the engine N Allow the engine to cool Q Before servicing a coolant hose slowly loosen the filler cap for the cooling system in order to relieve any pressure DA Remove the filler cap for the cooling system a Drain the coolant from the cooling system to a level that is below the hose that is being replaced Drain the coolant into a suitable clean container The coolant can be reused er Remove the hose clamps SEBU7563 09 107 Maintenance Section Hoses and Clamps Inspect Replace N Disconnect the old hose Replace the old hose with a new hose Oo Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for infor
121. um e Connection of the air plenum to the cylinder head Inspect the components for the following conditions e Cracks e Leaks e Loose connections e Debris Ensure that all of the connections are secure Ensure that the components are in good condition and free of debris Make repairs if necessary For information regarding removal and installation of the components refer to Service Manual Disassembly and Assembly Consult your Caterpillar dealer for assistance 100683392 Inlet Gas Manifold and Piping Inspect Replace SMCS Code 1550 040 1550 510 Inspect the components of the fuel inlet system for the following conditions e Cracks e Deterioration e Leaks e Loose connections e Wear Inspect the following components e Fuel lines from the source to the gas regulator Fuel lines from the gas regulator to the fuel inlet Fuel inlet Control valve e Fuel manifold e Connections of the fuel manifold and the fuel lines e Connections of the fuel lines to the orifice e Connections of the fuel lines to the cylinder head e Connections of the fuel lines to the precombustion chamber e Fuel pressure sensor e Fuel temperature sensor Ensure that all of the connections are secure Ensure that the components of the fuel system are in good condition Make repairs if necessary For information regarding removal and installation of the components see the Service Manual Consult your Caterpillar dealer fo
122. und only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber Note Deposits of ash and silicon can accumulate on the turbine wheel Turbine wheel will become unbalanced when the deposits flake off The turbocharger cartridge must be replaced when this occurs However remove deposits from the housing This will prevent wear on the blades of the turbine wheel 4 Inspect the turbine wheel and the nozzle for deposits of ash and silicon If deposits of 1 mm 1 32 inch thickness are found the turbocharger must be disassembled and cleaned at an ABBrepair facility 5 Inspect the bore of the turbine housing for corrosion 6 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 7 Check the clearances of the turbocharger bearing Compare the clearances to the Service Manual Specifications If the clearances are not within the specifications the turbocharger must be repaired 8 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 101765785 Turbocharger Cleaner Tube Replace SMCS Code 1052 510
123. ure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 6 Flush the cooling system with clean water until the water that drains is clean Close the cooling system drain valves if equipped Clean the cooling system drain plugs and install the cooling system drain plugs Fill the Cooling System NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute in order to avoid air locks Proper venting of the cooling system is essential to fill at this rate Note For information about the proper coolant to use and the capacity of the cooling system see this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section 1 Fill the cooling system with coolant antifreeze Do not install the cooling system filler cap 2 Start the engine Operate the engine in order to purge the air from the cavities of the engine block Allow the coolant to warm and allow the coolant level to stabilize Stop the engine 76 Maintenance Section Cooling System Coolant Level Check SEBU7563 09 3 Check the coolant level Maintain the coolant to the proper level on the sight gauge if equipped If a sight gauge is not equipped maintain the coolant to the level that is specified by the OEM of the cooling system 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If
124. utsch HD connectors ensure the following conditions e The index markings of the plug and the receptacle are aligned e The connection is turned fully e The plug and the receptacle are securely connected 8 Close the circuit breaker of the main power supply Engine Protective Devices Check SMCS Code 7400 535 Alarms and shutoffs must function properly Alarms provide timely warning to the operator Shutoffs help to prevent damage to the engine It is impossible to determine if the engine protective devices are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints Ensure that the engine protective devices are functioning properly NOTICE During testing abnormal operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately 101762818 Engine Speed Timing Sensor Clean Inspect SMCS Code 1905 040 1905
125. w instructions on control valve to avoid per sonal injury If rapid air movement exists to blow fluid Stop the engine to avoid fire If it is necessary to replace the oil filters during engine operation perform the following procedure OL FILTER CHANGE VALVE Illustration 82 g00789754 1 Pressure gauge 4 Control valve 1 Connect a hose from drain valve 2 to a suitable container in order to catch the oil 2 Rotate control valve 4 to the LOWER SERVICE position 3 Open drain valve 2 and drain the lower oil filter housing Observe pressure gauge 1 until the pressure is 0 Note Some oil will remain in the housing after the oil has been drained This oil will pour out of the housing when cover 3 is removed Prepare to catch the oil in a suitable container Clean up any spilled oil with rags DO NOT use absorbent particles to clean up the oil Personal injury can result from parts and or cov ers under spring pressure Spring force will be released when covers are re moved Be prepared to hold spring loaded covers as the bolts are loosened 4 After zero pressure has been reached remove cover 3 Be alert to the spring force The cover has a spring force up to 240 N 54 Ib Gradually loosen but do not remove the last two bolts or nuts that are located at opposite ends of cover 3 Before removing the last two bolts or nuts
126. wby and oil consumption Major overhauls are determined by the in frame tests and by results of S O S oil analysis Some other factors that are important for determining the overhaul intervals include the following considerations e Performance of preventive maintenance e Use of recommended lubricants e Use of recommended coolants e Use of recommended fuels Proper installation Operating conditions e Operation within acceptable limits Engine load e Engine speed Note To avoid oil problems engines that are turbocharged and aftercooled must be operated at a minimum of 60 percent of rated load Generally engines that are operated at a reduced load and or speed achieve more service life before an overhaul However this is for engines that are properly operated and maintained SEBU7563 09 117 Maintenance Section Overhaul Considerations Bio Gas The overhaul intervals for engines that use bio gas depend on the concentration of contaminants in the fuel Although silicon is the primary contaminant in bio gas other contaminants may cause further reductions in the overhaul intervals For more information refer to Gas Engines Application and Installation Guide LEKQ7260 G3600 G3300 Low Energy Fuels Overhaul Inspection Refer to the Service Manual for the disassembly and assembly procedures that are necessary in order to perform the required maintenance on the items that are listed Consult your Ca
127. x Check the wiring for secure connections at these points e Connectors e Sensors Perform a pull test for each wire This test will ensure that the wiring is properly attached Test each wire individually a For wiring that is attached to a connector hold the body of the connector with one hand Pull each wire with approximately 45 N 10 Ib of force Pull the wire firmly b Before testing the wiring of the sensors ensure that the sensors are securely installed Then pull each wire with approximately 45 N 10 Ib of force If a wire is loose repair the connection For instructions on connecting wires see the Service Manual Troubleshooting module Disconnect the connectors at the following locations Inspect the connectors e Engine sensors 100 Maintenance Section Engine Protective Devices Check SEBU7563 09 e Junction box e Modules of the control panel a Inspect each pin and each socket for corrosion and damage If corrosion is found scrape large deposits Use cotton swabs with isopropyl alcohol to clean any corrosion that remains Investigate the source of the corrosion Correct the condition If damage is found replace the part 7 Reconnect the connectors a For Military Standard CE and VE connectors ensure the following conditions e The connection is threaded properly e The connection is threaded completely Very little thread or no thread is visible b For De
128. y be necessary to reach the gas admission valves For the procedure to remove the gas admission valve refer to the engine s Disassembly and Assembly Illustration 93 900833829 Exploded view and section view of the parts for the gas admission valve 1 Upper valve stem seal 2 Lower valve stem seal 3 4 and 5 O ring seals for the support assembly Note The portion of the valve stem in lower valve stem seal 2 may be slightly worn This shallow wear does not affect the performance of the gas admission valve Inspect valve stem seals 1 and 2 Inspect O ring seals 3 4 and 5 Replace the seals if necessary i00679524 Gas Pressure Regulator Inspect Replace SMCS Code 1550 040 1550 510 Inspect the gas pressure regulator for the following conditions e Wear e Cracks e Pin holes e Improper operation SEBU7563 09 105 Maintenance Section Gas Shutoff Valve Inspect If any of those conditions are found the gas pressure regulator must be repaired or replaced For information on replacing the gas pressure regulator see the Service Manual Consult your Caterpillar dealer for assistance i01611465 Gas Shutoff Valve Inspect SMCS Code 1329 040 The gas shutoff valve GSOV has a solenoid that is operated with 24 VDC When power is supplied to the solenoid fuel flows through the GSOV to the engine When the power is interrupted the gas is shut off
129. y one of the following lubricants to O ring seal 1 and to the extension at connection points 2 and 3 e 4C 9504 Dielectric Grease e 8T 9020 Dielectric Grease This lubricant will help to protect the connection points of the extension from corrosion 6 Ensure that the internal spring exerts force on the connection points Install the extension onto the spark plug SEBU7563 09 111 Maintenance Section Ignition System Spark Plugs Replace 7 Ensure that the transformer assembly is clean and free of dirt and oil Assemble the extension into the transformer Install the transformer 8 Connect the wiring harness Tighten the connector clockwise with pliers until the connector cannot be loosened by hand Replace the lockwire Ignition System Spark Plugs Replace SMCS Code 1555 510 Remove the used spark plugs Install new spark plugs For instructions on removing and installing spark plugs refer to this Operation and Maintenance Manual Ignition System Spark Plugs Check Adjust topic Maintenance Section 101935380 Inlet Air System Inspect SMCS Code 1058 040 1071 040 1087 040 Use of a platform may be necessary to inspect the following components of the air inlet system e Piping between the air cleaner and the turbocharger e Rubber hoses in the air lines Turbocharger Piping between the turbocharger and the aftercooler e Aftercooler e Connection of the aftercooler to the air plen

MAINTENANCE INTERVALS - Safety

Contents

Download Pdf Manuals

Related Search

Related Contents