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3600 Heavy Fuel Engines-Maintenance Intervals - Safety

1. Illustration 122 g00543927 Example of a graph of engine oil pressure Y Pressure in kPa X Calendar days 1 Baseline 2 Operating pressure 3 3 Setpoint alarm 132 Maintenance Section Trend Data Record SEBU6966 06 3 Average the data for each day Use a computer or graph paper in order to produce a graph of the data Compare the new data to the baseline This will help to reveal the trends of the engine performance Illustration 122 shows that the engine oil pressure was near baseline 1 Later the operating pressure was approaching setpoint 3 The trend of operating pressure 2 indicated that the condition required investigation before activation of the alarm 4 Compare the new data to the data from previous months This comparison will be useful for scheduling reconditioning for the engine Monitoring the Trends of Fuel Consumption Fuel consumption depends on the following factors e Engine load e The fuel efficiency of the engine e The service hours of the engine Use these two methods in order to obtain accurate data on fuel consumption e Calculate the Specific Fuel Consumption For this calculation the weight of the fuel that was burned is divided by the electrical energy that was produced Calculate the Heat Rate This calculation compensates for the fue
2. N Illustration 102 g00296711 1 Pressure gauge 2 Drain 3 Cover 4 Control valve 1 Connect a hose from drain valve 2 to a suitable container in order to catch the oil 2 Rotate control valve 4 to the LOWER SERVICE position 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 pry the cover loose or tap the cover with a rubber mallet in order to relieve any spring pressure 5 RR w st ZVIR sane 2RR R x 3 ss x 3 eee x ters s
3. Illustration 73 g00130652 Location of the cooling system drain valves or drain plugs on the water pumps 1 Jacket water pump 2 Aftercooler and oil cooler pump biai ee ae oO rf l G Illustration 74 g00475784 Location of the drain plug jacket water for 3606 and 3608 Engines Illustration 75 g00475850 Location of the drain plugs jacket water for 3612 and 3616 Engines 3 Open the cooling system drain valves if equipped Remove the cooling system drain plugs Allow the coolant to drain SEBU6966 06 83 Maintenance Section Cooling System Coolant DEAC Change 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 U S A 309 675 6277 Inside U S A 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL CSTG COSA Geneva Switzerland 41 22 849 40 56 Clean th
4. Keep the lids on empty sampling bottles until you are ready to collect the sample Complete the information on the label for the sampling bottle before you begin to take the samples Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location In order to avoid contamination immediately place the sample in the tube that is provided for mailing Submit the sample for Level 1 analysis Note Level 1 results may indicate a need for Level 2 Analysis 88 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SEBU6966 06 For additional information about coolant analysis see this Operation and Maintenance Manual Refill Capacities and Recommendations or consult your Caterpillar dealer 102354695 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 Operation and Mainten
5. Replace the components if necessary e Aftercooler core e Alarm and shutoff controls e Camshafts 124 Maintenance Section Overhaul Major SEBU6966 06 e Camshaft bearings e Connecting rod bearings Crankshaft Cylinder liners Cylinder sleeves e Exhaust manifolds e Front gear group Fuel transfer pump seals e Main bearings e Oil cooler seals e Oil pump bushings and seals e O Ring seals and plugs Pistons and piston rings Priority valve e Rear gear group e Rear gear train bearings and seals e Rocker arm bearings e Thermocouples e Thrust bearings Turbocharger bearings bushings and seals e Valve lubricator pump gaskets and seals e Valve mechanism group e Water pump bearing and seals Inspect the camshaft for damage to the journals and the lobes Inspect the following components for signs of wear and or for signs of scuffing e camshaft bearings e camshaft followers Inspect the crankshaft for any of the following conditions e deflection e damage to the journals e bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the following components e rod bearing e main bearings Note If the crankshaft or the camshaft are removed for any reason use the magnetic particle inspection process to check for cracks Replace the crankshaft vibration damper if any
6. 4 Change the fuel selector switch on the control box for the fuel booster module from heavy fuel oil to distillate fuel 5 Monitor fuel temperature and fuel viscosity during the changeover Adjust the bypass valve in the fuel lines in order to balance the fuel supply pressure to each engine at 550 to 620 kPa 80 to 90 psi 6 When the fuel viscosity is reduced to ten cSt slowly open the valve which allows fuel flow through the fuel cooler until there is a maximum flow of fuel to the fuel cooler SEBU6966 06 113 Maintenance Section Fuel Analysis Obtain When the fuel viscosity reaches eight cSt slowly close the supply of steam to the Vokes filter When the full fuel flow is directed through the fuel cooler the fuel viscosity will continue to decrease to a final level of four to five cSt After four to five cSt is reached operate the engine at constant load for 15 minutes This step will ensure that all of the heavy fuel has been cleared from the engine prior to reducing the load or increasing the load If you are reducing the load in order to stop the engine remove the load and allow an appropriate cooldown period before you shut down the engine 10 After the engine has stopped close the fuel supply and fuel return lines at the engine Close the supply lines and the return lines for injector tip cooling Changeover from Distillate Fuel to Heavy Fuel Oil During Engine Operation NOTICE To
7. Engine Air Precleaner Clean 96 Engine Oil Centrifuge Check seese 101 Engine Oil Level Check ecceeeeeeeeeeeeeneees 104 Fuel Oil Conditioning Module Check 114 Fuel Oil Separator Check ceeceeeeeeeeeees 115 Fuel System Fuel Injector Tip Cooling Module CREEK niona o aE A A 115 Fuel System Primary Filter Water Separator BA S rr EE A OTEA 116 Fuel Tank Water and Sediment Drain 119 Governor Actuator Oil Level Check 120 Instrument Panel Inspect ceeeeeeeeeeee 121 Walk Around Inspection cccceeeeeeeeeereeeees 135 Every Week Fuel Oil Conditioning Module Check 4 114 Every 50 Service Hours or Weekly Zinc Rods Inspect Replace 2 00cseee 136 Every 100 Service Hours or 2 Weeks Turbocharger Water Wash eeen 134 Every 250 Service Hours Cooling System Supplemental Coolant Additive SCA TeSt Add ceccceccccccceceeeeeeeeeesenseeeeees 88 Every 250 Service Hours or 6 Weeks Air Shutoff gt TeSt irran ni T77 Air Starting Motor Lines Screen Clean 78 Engine Oil Sample Obtain asasinen 105 Governor Actuator Linkage Check e 119 Oil Mist Detector Check 122 Every 250 Service Hours or Monthly Cooling System Coolant Sample Level 1 ODIAIN a EE AA TEA TEE eee 87 Every 500 Service Hours or 3 Months Engine Mounts Inspect iier 98 Engine Pro
8. e Achieve the best cost value relationship per hour of extended service life Overhaul Intervals Some factors that are important for determining the overhaul intervals include the following considerations Performance of preventive maintenance Use of recommended lubricants Use of recommended coolants e Use of recommended fuels Proper installation Operating conditions e Operation within acceptable limits Engine load e Engine speed 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 Other factors must also be considered for determining a major overhaul e The total amount of fuel consumption e The service hours of the engine e An increase of oil consumption e An increase of crankcase blowby 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 128 Maintenance Section Overhaul Considerations
9. CSTG COSA Geneva Switzerland 41 22 849 40 56 Clean the Cooling System 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the cooling system drain valves if equipped Clean the drain plugs and install the drain plugs NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with clean water Install the cooling system filler cap Install the vent plug 4 Operate the engine until the temperature reaches 49 C 120 F to 66 C 150 F 4 Stop the engine and allow the engine to cool Ensure that the engine will not start when the cooling system is drained Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 5 Open the cooling system drain valves if equipped Remove the drain plugs See Illustration 77 Allow the coolant to drain Flush the cooling system with clean water Close the cooling system drain valves if equipped Install the drain plugs 6 Repeat Steps 3 3 4 and 5 Fill the Cooling System NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks L Illustration 80 g00546449 1 Fill the cooling system with Extended Life Coolant ELC 86 Maintenance Section Cooling System Coolant Extender ELC Add
10. SEBU6966 06 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 Using Fuel Consumption For Calculating the Overhaul Intervals The total fuel consumption is the most important factor for estimating the overhaul interval Fuel consumption compensates for the application and for the engine load If the total fuel consumption has not been recorded use the equation in Table 23 in order to estimate the hours until the overhaul The equation may also be used to estimate overhaul intervals for new engines Table 23 Equation For Calculating Overhaul Intervals H F R H is the number of estimated hours until the overhaul interval F is the estimated total amount of fuel consumption of the engine R is the rate of fuel consumption in liters per hour or gallons per hour Use the actual records of fuel consumption when possible If the actual records are not available use the following procedure in order to estimate the fuel consumption 1 Estimate the average percent of the load for the operation of the engine 2 Refer to the engine s Caterpillar Engine Specifications spec sheet This will determine the fuel consumption for the percent of t
11. 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 101980670 Trend Data Record SMCS Code 1000 043 Records of engine performance are an important element of a maintenance program The data on engine performance can help to predict problems with operation Also the data can provide information that is useful for achieving optimum operation Traditionally data on engine performance might be recorded regularly However the data might not be reviewed until the occurrence of a problem This method of monitoring engine operation has several disadvantages e The engine may not be providing optimum performance This may not be noticed because the engine does not exhibit excessive changes in performance e Because a problem occurs the engine may be in an alarm condition that requires a quick response e Repairs may cause more downtime e The cost of downtime is compounded by the cost of parts and labor f
12. 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 A major overhaul includes all of the work that is done for top end overhauls A major overhaul includes additional parts and labor Additional parts and labor are required in order to completely rebuild the engine For the major overhaul all of the 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 Fuel Consumption Before A Major Overhaul The overhaul interval that is listed in this Operation and Maintenance Manual Maintenance Interval Schedule is expressed in service hours A more accurate figure to use is fuel consumption Fuel consumption corresponds more accurately to the engine load Table 21 lists an average range of fuel consumption for a reasona
13. Install the clean dry grid 122 Maintenance Section Oil Mist Detector Check SEBU6966 06 101979490 Oil Mist Detector Check SMCS Code 1336 535 7400 535 Drain the Condensation Note More frequent draining may be required in humid environments Illustration 119 g00541353 Oil mist detector 1 Vent line 2 Drain Inspect vent line 1 for proper ventilation Open drain 2 in order to drain the condensation trap Drain the condensation into a suitable container Close the drain Check the Vacuum in the Measuring Track Check the vacuum in the measuring track according to the service instructions that are provided by the OEM of the oil mist detector Adjust the driving air pressure if necessary Refer to the Testing and Adjusting RENR2225 for additional information about the oil mist detector or the literature that is provided by the OEM of the oil mist detector 101979802 Oil Mist Detector Clean Replace SMCS Code 7400 070 Note For all maintenance and service procedures for the oil mist detector refer to the Testing and Adjusting RENR2225 for additional information about the oil mist detector or refer to the service instructions that are provided by the OEM of the oil mist detector Every Three Months Perform the following maintenance items according to the instructions tha
14. 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 SEBU6966 06 79 Maintenance Section Air Starting Motor Lubricator Oil Level Check 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 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 102213914 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 Illustration 67 g00745561 1 Observe the oil level in sight gauge 3 If the oil level is less than 1 2 add oil to the lubricator bowl Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve
15. SEBU6966 06 The water lines for the turbochargers must be vented when the cooling system is filled Remove plug 1 Press a small screwdriver into the check valve in order to vent the line After filling the cooling system 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 ELC to warm and allow the coolant level to stabilize Stop the engine 3 Check the coolant level Maintain the coolant to the proper level on the sight gauge if equipped If a sight gauge is not equipped maintain the coolant within 13 mm 5 inch below the bottom of the filler pipe 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets of the cooling system filler cap are damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gaskets of the cooling system filler cap are not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure is stamped on the face of the cooling system filler cap If the cooling system filler cap does not maintain 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 102285855 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Cat
16. for any of the following reasons e The damper is dented cracked or leaking The paint on the damper is discolored from heat The engine has had a failure because of a broken crankshaft The crankshaft bearings are showing excessive wear There is a large amount of gear train wear that is not caused by a lack of oil Dampers With Sampling Ports Illustration 83 g00819045 Some dampers have ports for fluid samples If the damper has no external damage collect a 2 to 5 mL sample of the damper fluid The fluid should be analyzed in order to check for a loss of viscosity Use the results of the analysis to determine if the damper should be rebuilt or replaced Kits for fluid samples are available from the address that follows Return the kits to the same address for analysis Hasse amp Wrede GmbH Mohriner Allee 30 42 D 12347 Berlin Germany Phone 49 30 70 181 195 Fax 49 30 70 09 08 11 Dampers Without Sampling Ports Some dampers do not have a port for a fluid sample These dampers must be rebuilt or the dampers must be replaced when one of the following criteria has been met e the damper has reached 20 000 hours of operation SEBU6966 06 91 Maintenance Section Cylinders Inspect e the engine is undergoing a major overhaul Removal and Installation Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement 101217266 Cylinders Inspe
17. occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the day tank This causes water to accumulate in the day tank Draining the day tank regularly and obtaining fuel from reliable sources can help to eliminate water from the fuel Day tanks should have a provision for draining water and sediment Open the drain valve on the bottom of the day tank in order to drain the water and the sediment Close the drain valve Drain the water and sediment from the day tank daily The quality of the fuel and or the operating conditions may require more frequent draining of the water and sediment Fill the day tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some day tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some day tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Settling Tank Drain the water and the sediment from the settling tank daily Ensure that the temperature of the settling tank is proper for the viscosity of the fuel oil Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank daily Ensu
18. 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 100957883 Exhaust Manifold Inspect SMCS Code 1059 040 Inspect the exhaust manifold for buildup of deposits A thin layer of buildup can increase the operating temperature of the engine To inspect the exhaust manifold gain access to the manifold according to the instructions in the Service Manual Disassembly and Assembly module Use the following procedure to clean the exhaust manifold if necessary 1 Remove the exhaust manifold according to the instructions in the Service Manual Disassembly and Assembly module 2 Soak the exhaust manifold in water 3 Use a steel scraper to remove most of the deposits Remove the remainder of the deposits with a steel brush Remove any remaining debris with a nylon brush 4 Install the exhaust
19. 101 Maintenance Section Engine Oil Centrifuge Check NOTICE Only use oils that are recommended by Caterpillar For the proper oil to use refer to this Operation and Maintenance Manual Refill Capacities and Recom mendations 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 8 Remove the oil filler cap Fill the crankcase through the oil filler tube only Clean the oil filler cap Install the oil filler cap 9 Start the engine according to this Operation and Maintenance Manual Engine Starting topic Operation Section a Operate the engine at low idle for tw
20. Install the core For more information on cleaning the core consult your Caterpillar dealer 101052568 Air Shutoff Test SMCS Code 1078 081 The air shutoff must operate properly in case an emergency shutdown is needed Test the operation of the air shutoff It is not necessary for the engine to be operating in order to test the shutoff Illustration 63 g00545921 Air shutoff for in line engines 1 Knob 2 Reset lever Illustration 64 g00545922 Air shutoff for vee engines 1 Knob 2 Reset lever 1 To activate the air shutoff pull knob 1 78 Maintenance Section Air Starting Motor Lines Screen Clean SEBU6966 06 A plate that is inside of the apparatus will cover the air inlet This prevents air from entering the inlet manifold Reset lever 2 should move to the CLOSED position If this fails to occur investigate the problem See the Service Manual Disassembly and Assembly topic DO NOT operate the engine if the air shutoff will not activate Note The air shutoff must be reset before the engine can be started 2 To reset the air shutoff move reset lever 2 to the OPEN position 101762654 Air Starting Motor Lines Screen Clean SMCS Code 1451 070 LI 1 moth Illustration 65 g00789123 1 Plug 2 Screen
21. Perform a Static Test Inspect the components of the alarm and shutoff systems for good condition Test the operation of the alarms and shutoffs A static test of the engine protective devices will ensure that the alarms and shutoffs are functioning properly To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests Consult your Caterpillar dealer or refer to the Service Manual for more information SEBU6966 06 107 Maintenance Section Engine Protective Devices Check Inspect the Connections of the Engine Protective Devices Inspect the wiring and the electrical connections for these components Connectors Control panel Junction box Sensors Turn the engine control switch to the OFF RESET position Open the circuit breaker or circuit breakers of the main power supply Inspect all of the wiring for the following conditions e Fraying e Damaged insulation e Corrosion Make repairs as needed 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
22. a new O ring seal Install the O ring seal 8 Install cover 3 Ensure that the spring is seated properly between element 8 and cover 3 Close drain valve 2 9 Rotate control valve 4 to the LOWER FILL position Observe pressure gauge 1 Check cover 3 for leaks Note A hydraulic stop will limit the rotation of the control valve until the oil filter housing is full of oil 10 After the pressure of the lower oil filter and the upper oil filter is equal rotate control valve 4 to the UPPER SERVICE position Repeat Step 1 through Step 9 for the upper oil filter 11 After the oil filters have been serviced and after the pressure of the lower oil filter and the upper oil filter is equal rotate control valve 4 to the RUN position Inspect the Used Oil Filter Elements Cut the used oil filter element open with a utility knife Remove the metal wrap Cut the filter element free from the end caps Spread apart the pleats and inspect the element for metal debris An excessive amount of debris in the element may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the element Ferrous metals may indicate wear on the steel and the cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts the brass parts or the bronze parts of the engine Parts that may be affected include the follo
23. and adjust the valve bridge if necessary Perform the procedure for both valve bridges for each cylinder If the valve bridges for the inlet valves require frequent adjustment the lubricator for the inlet valve may not be operating The lubricator may not be adjusted properly After the valve bridge is checked for each cylinder proceed with the valve lash adjustment if necessary Engine Valve Lash Note The specification for the valve lash is listed in this Operation and Maintenance Manual Engine Description topic Product Information Section 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 110 Maintenance Section Engine Valve Rotators Inspect SEBU6966 06 i01765711 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
24. and unit injectors e The engine is shut down for an undetermined period of time without circulation of the fuel through the engine The following definitions will assist operators in determining the circumstances for changing the fuel General recommendation Flush the engine fuel system with distillate fuel prior to performing any maintenance on the fuel system Flush the fuel system with distillate fuel if the engine is shut down for more than 12 hours If the jacket water heaters are not functional flush the fuel system with distillate fuel after every engine shut down Temporary shutdown The engine is shut down for 12 hours or less It is not necessary to change the fuel The engine can be stopped and started with heavy fuel Jacket water heaters must be operated in order to maintain the temperature of the jacket water at a minimum of 65 C 149 F Continue to circulate heavy fuel through the engine in order to maintain the temperatures of fuel system components for start up The fuel must have the correct viscosity and temperature at all times Extended shutdown The engine is shut down for more than 12 hours or for an unknown length of time Flush the engine fuel system with distillate fuel Unless cold ambient conditions make the use of jacket water heaters necessary use of jacket water heaters is not required Shut off the circulation through the fuel system and the module for cooling the unit injector tips
25. 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 Ensure that cooling lines are properly clamped and tight 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 normal 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 the removal of water pumps and the installation of water pumps and or seals refer to the Service Manual 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 cover Inspect 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 e Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good con
26. clean diesel fuel on the seals to make installation easier Tighten nut 4 Close drain valve 3 8 Lift lock 1 and move lever 2 to the BOTH RUN position for one minute 9 To service FILTER 1 lift lock 1 and turn lever 2 to the FILTER 2 RUN position Release the lock 10 Repeat Steps 2 through 8 for FILTER 1 Servicing the Primary Filters With the Engine Stopped 1 Ensure that the fuel to the engine is OFF 2 Refer to Servicing the Primary Filters During Engine Operation Perform Steps 2 through 7 for both filters It may be necessary to prime the fuel system before the engine will start See this Operation and Maintenance Manual Fuel System Prime topic Maintenance Section Water Separator Replace the water separator element according to the instructions that are provided by the OEM of the water separator 100938540 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Replace the secondary fuel filter elements when either of the following conditions occurs e The fuel filter differential pressure reaches 105 kPa 15 psi e The elements have been used for a maximum of 1500 hours of operation Operation of the Vokes Fuel Filter The filter may be operated with the fuel flow through one side of the filter or through both sides of the filter Either practice is acceptable provided that the maximum fuel filter differential pressure is not excee
27. damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 84 Maintenance Section Cooling System Coolant ELC Change SEBU6966 06 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 to avoid air locks Note For information about the proper coolant to use see this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section For the capacity of the cooling system see this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section Illustration 76 g00546449 1 Plug 1 Fill the cooling system with coolant antifreeze The water lines for the turbochargers must be vented when the cooling system is filled Remove plug 1 Press a small screwdriver into the check valve in order to vent the line After filling the cooling system 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
28. 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 element Dirt could be forced into the pleats Note Refer to Inspecting the Air Cleaner Elements 94 Maintenance Section Engine Air Cleaner Element Replace SEBU6966 06 Vacuum Cleaning Vacuum cleaning is a good method for cleaning 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 Washing the Air Cleaner Elements with Nonsudsing Detergent Do not wash air cleaner elements in any flammable solution such as diesel fuel or gaso line Doing so can cause fire or an engine runaway and can result in personal injury Washing with nonsudsing detergent is effective for cleaning elements that have deposits of carbon or oil Use a cleaning agent that is specifically manufactured for cleaning air cleaner elements Cleaning with pressurized water pressurized air or a vacuum cleaner is recommended prior to washing with nonsudsing detergent 1 Place the element into a wash tank so that the gasket is up The wash tank should be equipped with a rack so that the element does not rest on the bottom of the wash t
29. firmly If a wire is loose repair the connection 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 denatured alcohol to clean any corrosion that remains Investigate the source of the corrosion Correct the condition If damage is found replace the part b Remove frayed strands of wire or tin the wire c Perform Steps 6 and 7 for the connectors of the control panel and the junction box Illustration 108 Illustration 107 g00748501 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 g00495500 Jaeger connector 108 Maintenance Section SEBU6966 06 Engine Timing Synchronization and Valve Lash Inspect Adjust Illustration 109 g00495342 Deutsch DT connectors Note The wiring is soldered to the pins and sockets of Military Standard and Jaegerconnectors The wiring is crimped into the pins and sockets of Deutsch DT connectors 5 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 w
30. 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 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 After the cooling system has been drained 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
31. 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 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 connections e Corrosion e Wires that are worn or frayed e Cleanliness Make repairs if necessary 130 Maintenance Section Trend Data Record SEBU6966 06 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
32. 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 SEBU6966 06 87 Maintenance Section Cooling System Coolant Sample Level 1 Obtain Engines That Are Not Equipped With a Sight Gauge Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 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 82 g00103639 Gaskets 3 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets are
33. manifold according to the instructions in the Service Manual Disassembly and Assembly module 101003546 Exhaust Piping Inspect SMCS Code 1061 040 Hot engine components can cause injury from burns Before performing maintenance on the engine allow the engine and the components to cool Inspect the components of the exhaust system Repair the components or replace the components for any of the following conditions e Damage e Cracks e Leaks e Loose connections For information on removal and installation see the Service Manual Disassembly and Assembly module Consult your Caterpillar dealer for assistance 100457458 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 SEBU6966 06 111 Maintenance Section Fuel Changeover 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
34. not removed when the cold oil is drained Drain the crankcase with the oil warm This method allows the waste particles that are suspended in the oil to properly drain 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 100 Maintenance Section Engine Oil Change SEBU6966 06 NOTICE Ensure that the engine is stopped before performing this procedure Attach aDO NOT OPERATE tag to the starting controls Note Drain the oil into a suitable container Dispose of fluids according to local regulations q Loo Illustration 98 g00130760 1 Drain valve 2 Open drain valve 1 in order to drain used oil After the oil has drained close drain valve 1 Note If a suction device is used in order to remove the oil from the oil pan ensure that the suction device is clean This will prevent dirt from entering the oil pan Be careful not to strike the engine oil suction tubes or the piston cooling jets 3 Clean the oil suction screen Note Approximately 1 L 1 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
35. of the following conditions occur e Engine failure due to a broken crankshaft e Excessive wear of the front bearing for the crankshaft e Excessive wear of the gear train that is not caused by a lack of lubrication Inspect the gears of the gear train and inspect the gear train bushings for the following conditions e Worn gear teeth e Unusual fit e Unusual wear Cleaning and Inspection of Components Clean the following components Inspect the components for good condition Replace the components if necessary Replace the gaskets and seals for the components Air inlet lines Camshaft front covers Camshaft drive gear covers Central structure covers Crankcase side covers Crankshaft Crankshaft vibration damper Front housing group Fuel lines SEBU6966 06 125 Maintenance Section Overhaul Top End Fuel transfer pump e Gear inspection group e Oil cooler core e Oil lines Oil suction screen e Piston under crown e Power take off covers Priority valve group e Rear housing group Rear structure covers e Valve covers e Water lines 101216631 Overhaul Top End SMCS Code 7595 020 TE A top end overhaul involves the removal the inspection and the rework of the cylinder head components Some additional components are replaced and serviced Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating w
36. oil has reached the condemning limit In the absence of oil analysis change the engine oil according to the interval that is listed in Table 20 Table 20 Oil Change Intervals For 3600 Engines Heavy Fuel Oil Engine Lube Oil Oil Change Capacity Interval Industrial Engines and Generator Set Engines 3606 880 L 700 Service 229 US gal Hours 3608 1112 L 650 Service 289 US gal Hours 3612 1302 L 500 Service 339 US gal Hours 3616 1677 L 500 Service 443 US gal Hours Marine Engines Zero Degree Tilt 3606 731 L 500 Service 190 US gal Hours 3608 795 L 450 Service 207 US gal Hours 3612 943 L 400 Service 245 US gal Hours 3616 1091 L 300 Service 284 US gal Hours 1 The capacity includes the oil sump plus oil filters that are installed at the factory Engines with auxiliary oil filters will require additional oil The capacity is approximate The actual capacity may vary by five percent Caterpillar recommends using the capacity that is listed and then adjusting the oil level according to the oil level gauge dipstick 2 Use this oil change interval in the absence of oil analysis Change the Engine Oil Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin 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
37. 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 3 Remove filler plug 4 Pour oil into the lubricator bowl Use nondetergent SAE 10W oil for temperatures that are greater than 0 C 32 F Use air tool oil for temperatures that are below 0 C 32 F 4 Install filler plug 4 Adjust the Lubricator Note Adjust the lubricator with a constant rate of air flow After the adjustment the lubricator will release oil in proportion to variations of the air flow 1 Ensure that the fuel supply to the engine is OFF NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 2 Operate the air starting motor Observe the drops of oil that are released in dome 1 Note Some lubricators have an adjustment screw rather than a knob 3 If necessary adjust the lubricator in order to release from one to three drops of oil per second To increase the rate turn knob 2 counterclockwise To decrease the rate turn the knob clockwise 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 condi
38. psi to any operating engine Changing the Fuel The method that is used for changing the fuel depends on the equipment that is used Different sites may have different equipment The following methods are possible The fuel system can be flushed through the use of auxiliary fuel pump a separate fuel tank and fuel lines The fuel supply can be switched through the use of a dual source of fuel at the fuel oil conditioning module A motorized three way valve with a clock timer is recommended for changing the fuel This valve can be used with a single engine and with sites that have more than one engine sharing one fuel oil conditioning module The fuel can be changed during engine operation or after stopping Changeover From Heavy Fuel Oil To Distillate Fuel During Engine Operation NOTICE The preheat temperature for pure distillate fuel must not exceed 60 C 140 F At temperatures above 60 C 140 F distillate fuel loses the lubricating prop erties Operating an engine on fuel with insufficient lu bricity can damage the unit injectors NOTICE To prevent excessive injection pressures when the fu el is changed to heavy fuel oil the engine must not be operated at more than 75 percent of rated load 1 Operate the engine at reduced load 2 Set the timer for the three way valve to 45 to 50 minutes 3 Make sure that all of the valves from the distillate fuel line to the fuel booster module are OPEN
39. reduce the height of the engine support assembly remove shims 2 Maintain a record of all of the shims that are added from the time of the engine commissioning When the combined total of the shims that are added to any isolator exceeds 5 mm 2 inch the isolator must be repaired or replaced 101421709 Engine Mounts Inspect SMCS Code 1152 040 1152 Inspect the condition of the isolators The isolators must be kept clean and dry Ensure that the isolators are free of oil and contamination Resilient Isolators Illustration 96 g00745665 1 Rubber element Each isolator has four rubber elements The most usual cause for failure of the isolator is oil contamination of the rubber elements Inspect the rubber elements of each isolator for the following conditions e Swelling e Blistering e Cracking Perform the following procedures when deterioration of the rubber elements is initially observed e Record the observation in a log e Check the alignment of the driven equipment After deterioration of the rubber elements is initially observed the rubber elements must be carefully inspected Any further deterioration of the rubber elements must be recorded The isolator must be repaired or replaced if rapid deterioration of the rubber elements is observed Deterioration of the rubber elements is usually accompanied by settl
40. service activities that are described in the literature 100936346 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 e The oil filters have been used for 1000 service hours or six months Note Do not attempt to clean the used oil filters Used oil filters will retain waste particles The used oil filters would not filter the oil properly 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 102 Maintenance Section Engine Oil Filter Change SEBU6966 06 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 N Illustration 100 g00296711 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 ca
41. the engine block Allow the coolant to warm and allow the coolant level to stabilize Stop the engine 3 Check the coolant level Maintain the coolant to the proper level on the sight gauge if equipped If a sight gauge is not equipped maintain the coolant to the level that is specified by the OEM of the cooling system 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets of the cooling system filler cap are damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gaskets of the cooling system filler cap are not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure is stamped on the face of the cooling system filler cap If the cooling system filler cap does not maintain 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 102305948 Cooling System Coolant ELC Change SMCS Code 1350 044 NL Use only clean water to flush the cooling system when Extended Life Coolant ELC is drained and replaced 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
42. 3600 HEAVY FUEL ENGINES Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU6966 06 01 2007 Caterpillar CATERPILLAR All Rights Reserved 74 Maintenance Section Maintenance Interval Schedule SEBU6966 06 102304354 Maintenance Interval Schedule SMCS Code 1000 4450 7500 When Required Centrifugal Oil Filter Inspect 00 0 eee 81 Cooling System Coolant Sample Level 2 ODA steve ce icets A tice tet ee hee nie 88 Engine Air Cleaner Element Replace 92 Engine Crankcase Breather Clean a an 96 Engine Oil Change c cccecceeeceeeeeeeeeeeeeeeenneeees 99 Engine Oil Filter Change cesses 101 Fuel Changeover 0 0 eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaees 111 Fuel Analysis Obtain 0 0 0 0 eee 113 Fuel System Primary Filter Water Separator Element Replace 2 scccececeeeeeeeeeeeeneeees 116 Fuel System Secondary Filter Replace 117 Metal Particle Detector Inspect 121 Zinc Rods Inspect Replace 00eeeee 136 Every Service Hour Trend Data Record cccccceeeeceeeeeeeeeeeeteeeees 130 Daily Air Starting Motor Lubricator Oil Level Check 79 Air Tank Moisture and Sediment Drain 79 Cooling System Coolant Level Check 86 Driven Equipment Inspect Replace Lubricate 92 Engine Air Cleaner Service Indicator Inspect 95
43. Alignment To minimize bearing problems and vibration of the engine crankshaft and the driven equipment the alignment between the engine and driven equipment must be properly maintained Check the alignment according to the instructions that are provided by the following manufacturers e Caterpillar e OEM of the drive coupling e OEM of the driven equipment Torque all of the fasteners to the proper specifications Inspect the Drive Coupling Inspect the drive coupling according to the instructions that are provided by the OEM of the coupling For the following service information see the literature that is provided by the OEM of the coupling e Lubrication requirements e Specifications for the end play e Reusability Guidelines e Replacement instructions Inspect the Rear Gear Train Inspect the crankshaft gear If excessive wear is found replace the crankshaft gear and the large cluster idler If any gear causes damage to other gears through failure replace the entire rear gear train For the correct parts see the Parts Manual for the engine For removal and replacement instructions see the Service Manual Disassembly and Assembly module Consult your Caterpillar dealer for assistance 92 Maintenance Section Driven Equipment Inspect Replace Lubricate SEBU6966 06 100935098 Driven Equipment Inspect Replace Lubricate SMCS Code 3279 040 Observe the driven equipment during operation Lo
44. C Add 86 Between 16 000 and 24 000 Service Hours Overhaul Major ccccceeeeeeeeeeeeeneeeeeeeeneeeeeeeeaas 122 Overhaul Considerations 126 Every 16 000 Service Hours or 6 Years Cooling System Coolant ELC Change 84 76 Maintenance Section Aftercooler Condensation Drain SEBU6966 06 102348942 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 can form in the passages of the aftercooler system Drain plugs are provided for draining the moisture 6 and 8 Cylinder Engines 6 and 8 cylinder engines have one drain plug for draining moisture from the aftercooling system A EN AO N g00475925 Illustration 60 For 6 and 8 cylinder engines one drain plug is located on the left side near the rear of the engine 1 Plug Note Prepare a suitable container for the moisture 1 Remove plug 1 2 Drain the moisture into a suitable container 3 Install the plug 12 and 16 Cylinder Engines 12 and 16 cylinder engines have two drain plugs for draining moisture from the aftercooling system Illustrat
45. ELC Extended Life Coolant does not require the frequent Supplemental Coolant Additive SCA additions which are associated with the present conventional coolants The Extender only needs to be added once Check the cooling system only when the engine is stopped and cool 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Extender 3 Add Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations in the Maintenance Section for more information concerning the Cat ELC Extender additions 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 102158408 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 A Illustration 81 g00750429 1 Filler cap 2 Sight gauge If the engine is equipped with a sight gauge observe the position of the coolant
46. IDLE WITH WARM OIL side 4 The oil level should be between ADD mark 5 and FULL mark 6 SEBU6966 06 105 Maintenance Section Engine Oil Sample Obtain 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 2 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 Do not fill the crankcase above FULL mark 6 Clean the oil filler cap Install the oil filler cap 3 Record the amount of oil that is added For the next oil sample and analysis includ
47. 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 102344769 Air Starting Motor Lubricator Bowl Clean SMCS Code 1451 070 If the engine is equipped with an air starting motor use the following procedure 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 1 Ensure that the air supply to the lubricator is OFF LO Illustration 66 g00745554 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
48. Purge the pressurized air from the air lines and from the starting motor Lock the air valves to the starting motor in the OFF position Space heaters for the generator must be operational Recommendations for Shutdown and Start up The use of proper operating practices is important The following guidelines are recommended 112 Maintenance Section Fuel Changeover SEBU6966 06 e For generator sets operate the space heaters when the generator is not operating This will help to prevent moisture damage to windings The space heaters can be controlled with a thermostat or a relay e A lack of proper temperature control can lead to problems with the unit injectors or other fuel system components Operate the jacket water heaters when the engine is shut down This will help to maintain proper temperatures for start up in the cylinder heads cylinder liners and fuel system components Maintain the jacket water temperature to a minimum of 65 C 149 F e Follow the recommended procedures before starting any engine Incomplete procedures can lead to system malfunctions that do not allow engine operation See this Operation and Maintenance Manual Engine Starting topic Operation Section Prior to starting any engine after an overhaul or after servicing the fuel system ensure that all of the engine protective devices will function Prepare to use the emergency stop button if necessary e Test the engine with distil
49. Specific Oil Consumption Table 30 Equation For Calculating the Specific Oil Consumption OxD ekW hr SOC O is the liters of oil that have been consumed D is the density of the oil The density is expressed in grams per liter ekW hr is the electrical kilowatt hours that have been produced during consumption of the oil SOC is the specific oil consumption Table 31 is an example for using the equation that is in Table 30 The data in the example assumes the following conditions e The engine consumed 66 liters of oil during the operation e The operation generated 88 800 ekW Table 31 Example of the Equation for Calculating the Specific Oil Consumption 66 L 910g 1 0 676 g x x 1 L 88 800 ekW hr ekW hr 101261768 Turbocharger Inspect SMCS Code 1052 040 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Fouling of the compressor can contribute to loss of engine power increased black smoke 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 qua
50. ablish a program for calibrating the instruments periodically Avoid using infrared thermometers for obtaining data Be sure to read the gauges properly Accurate recording of the data is also important Use the following Steps to establish a program SEBU6966 06 131 Maintenance Section Trend Data Record 1 Establish a baseline for the engine parameters The baseline is necessary in order to know the normal gauge readings The new data will be compared to the baseline e Use the data from the engine commissioning The data is recorded for various loads The data is recorded before any wear or deterioration takes place e f there is no data from the engine commissioning use data from the engine test cell Understand that the data will not be specific to the site e If data is not available from the engine commissioning or the engine test cell calculate an average of the existing data e Establish a new baseline after an overhaul 2 Frequently record the new data during engine operation For an example of a log to use see this Operation and Maintenance Manual Hourly Performance Log Reference Information Section Be aware that the readings of some parameters depend on the engine load Record the data when the engine is operating at a high load This increases the accuracy of the data Also any reduction in performance will be revealed sooner A load of 75 to 100 percent is recommended e For operation
51. ance Manual Cooling System Coolant Sample Level 1 Obtain 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 SEBU7003 3600 and C280 Diesel Engine Fluids Recommendations or consult your Caterpillar dealer 102354713 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 This maintenance procedure is required for conventional coolants such as DEAC and for mixtures of water and SCA This maintenance is NOT required for cooling systems that are filled with Extended Life Coolant Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and eyes Do not drink cooling system coolant additive Note Caterpillar recommends an S O S coolant analysis Level 1 Test the Concentration of the SCA Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit 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 coo
52. aner Clean SEBU6966 06 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 100935352 Engine Air Precleaner Clean SMCS Code 1055 070 Note More frequent cleaning may be required in dusty environments Illustration 90 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 101421692 Engine Crankcase Breather Clean SMCS Code 1317 070 Clean the crankcase breather elements and replace the O ring seals at every oil change Perform this maintenance when the engine is stopped 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 may cause crankshaft seal leakage Tl g00745657 Illustration 91 1 Breather assembly 2 Tee 3 Hose clamp 4 O ring seal 5 Retaining clamp h Loosen hose clamps 3 Remove tee 2 2 Loosen retai
53. aner element or replace the element when the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position e The air restriction reaches 3 75 kPa 15 inches 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 After Every 1000 Service Hours Service indicators are important instruments Use the following procedure to verify that the service indicator is operating properly Illustration 89 g00476445 1 Fitting Reset button 1 Unscrew the service indicator from fitting 1 A porous filter is part of the fitting 2 Inspect the porous filter for cleanliness Clean the filter if necessary Use compressed air or a clean nonflammable solvent 3 Apply vacuum suction to the service indicator The yellow diaphragm should enter the red zone and the piston should lock into position If this does not occur obtain a new service indicator 4 Reset the service indicator by pressing reset button 2 If the service indicator does not reset easily obtain a new service indicator Note Excessive force may crack the top of the service indicator 5 Install the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 96 Maintenance Section Engine Air Precle
54. ank Note Caterpillar does not recommend agitating the element Agitating may cause carbon particles to be distributed 2 Fill the wash tank with the cleaning agent and warm water to a maximum temperature of 60 C 140 F Follow the manufacturers recommendations for the cleaning agent Allow the element to soak for six hours 3 Drain the wash tank Do not use the cleaning agent more than one time Remove the element from the wash tank Rinse the element with the method for using pressurized water Note Refer to Drying the Air Cleaner Elements Refer to Inspecting the Air Cleaner Elements Drying the Air Cleaner Elements The oven method may be used in order to dry the elements If an oven is used do not expose the elements to temperatures that exceed 82 C 160 F Note Do not use compressed air in order to dry the elements The elements may be allowed to air dry Allow two days for the elements to air dry before the elements are inspected and installed Inspecting the Air Cleaner Elements Illustration 86 g00281693 Inspect the clean dry element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the element Rotate the element Inspect the element for tears and or holes Inspect the element for light that may show through the filter material If it is necessary in order to confirm the result compare the element to a new element that has the same pa
55. are seers See sine RRR IOS Se RRRS ISOROSI See se x 35 3 xs seis 330o 3 S eS 3 ee Sesece ance RRS nu nese 2R 2S0 saree oases oS Ss XxX ORS a Se SSS ox a xe z Se RO ee oe SS ee ee set sees Seer ORS eee ce SE i es eee et 3 x x ms x x 3s 289S eS 2 ROKR LPO pratt e ss maces Illustration 103 g00215989 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 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 104 Maintenance Section Engine Oil Level Check SEBU6966 06 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
56. ble load factor before a major overhaul Use the range of fuel consumption only as a guideline Table 21 Approximate Fuel Consumption Before A Major Overhaul Engine Fuel Consumption Model 3606 5 685 000 L 1 500 000 US gal 3608 7 580 000 L 2 000 000 US gal 3612 11 370 000 L 3 000 000 US gal 3616 15 160 000 L 4 000 000 US gal 1 The fuel consumption is based on fuel with these characteristics a low heat value of 42 780 kJ kg and density of 838 9 g L Remanufacturing or Rebuilding of Components Rework the following components e Air shutoff valve e Centrifugal oil filter bearings e Cylinder heads e Starting motor Replacement of Components Replace the following components Accessory group bearings Connecting rod bearings Cylinder head gaskets Cylinder head valves and valve guides Cylinder head valve spring guides Exhaust manifold gaskets Exhaust manifold seals and bellows Exhaust shields Front gear train bearings Fuel injectors Inlet air lines seals Oil temperature regulators and seals Water pump bearings and seals Water temperature regulators and seals Inspection and or Replacement of Components 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
57. cause of problems for governor actuators Only use new oil A container that is used to fill the governor actuator must be clean Rinse the container with the new oil before filling the container ses Illustration 116 g00274303 1 Sight gauge 2 Filler cap Observe the oil level in sight gauge 1 If the oil level is below the center of the sight gauge add oil Remove filler cap 2 Pour engine oil into the oil filler until the oil level is at the center of the sight gauge Clean the filler cap Install the filler cap Clean up any oil that has spilled SEBU6966 06 121 Maintenance Section Instrument Panel Inspect 101048507 Instrument Panel Inspect SMCS Code 7451 040 Inspect the instrument panel for good condition Perform the self test All of the warning lamps should illuminate If a warning lamp does not illuminate replace the bulb immediately If the alarm does not sound investigate the problem and correct the problem Check the condition of all of the gauges If a gauge is broken repair the gauge or replace the gauge immediately Frequently monitor the gauges 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 help to establish the trends of engine performance A gauge reading that is abnormal may indicate a problem with operation or a problem w
58. ct SMCS Code 1223 040 1223 Use a borescope to inspect the cylinders The inspection will provide information about the internal condition of the engine A borescope with a lens that can be rotated is recommended This type of borescope provides a clear view of the combustion chamber and of the bottom deck of the cylinder head Photographic documentation or video documentation is also recommended Consult your Caterpillar dealer for information on available borescopes To perform this procedure insert the borescope through the cylinder head bores for the fuel injectors Use the borescope to look for the following conditions e Valve wear e Deposits on the valve face Valve seat wear e Deposits on the valve seat 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 Indications of adequate spray patterns fuel injector on the piston crowns Deposits that are on the valve face and the valve seat can cause guttering of the valve face Inspect the valve seat and the valve face for excessive deposits If excessive deposits are found clean the valve and the valve seat or replace the components Clean the combustion chamber if necessary For information on replacing the components see the Service Manual Consult your Caterpillar dealer for assistance 100934883 Driven Equipment Check SMCS Code 3279 535 Check the
59. damage Ensure that the new water temperature reg ulator is installed in the original position Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 101983981 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 may be the result of excessive friction This could be due to misalignment Use an infrared thermometer to monitor the temperature of the damper during operation If the temperature reaches 93 C 200 F consult your Caterpillar dealer Inspect the damper for evidence of dents cracks and leaks of the fluid If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous and smooth If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace all of the seals Inspect the damper and repair or replace the damper
60. 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 102305963 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers For conventional heavy duty coolant antifreeze check the concentration of supplemental coolant additive SCA regularly The concentration of SCA can be checked with an S O S coolant analysis Level 1 Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant Never collect samples from expansion bottles Never collect samples from the drain for a system Keep the unused sampling bottles stored in plastic bags
61. ded Operating with the fuel flow through one side of the filter is recommended Operating With One Side of the Filter Caterpillar recommends operating with the fuel flow through one side of the filter during normal operation This practice enables the filter elements to be replaced without shutting down the engine When the maximum fuel filter differential pressure is reached redirect the fuel flow through the new filter element The dirty element may then be replaced during operation The new replacement element is ready for use when the next element is replaced Operating With Both Sides of the Filter When both sides of the filter are active each element filters 50 percent of the fuel flow This increases the time between replacement of the elements However this practice may require the engine to be shut down in order to replace the elements This may be suitable for intermittent operation but not for continuous operation 118 Maintenance Section Fuel System Secondary Filter Replace SEBU6966 06 During operation the fuel flow must be directed through one side of the filter in order to replace an element To avoid exceeding the maximum fuel filter differential pressure during operation the element must be replaced before the element has reached the maximum pressure To achieve optimum use of the filter elements direct the fuel flow through one side of the filter Replacing the Filter Element During Engine Operati
62. duct 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 1 Attach one end of a hose to drain cock 1 Insert the other end of the hose into a suitable container Open filler cap 3 Open drain cock 1 Allow the oil to drain 2 Close drain cock 1 Pour clean engine oil into the oil filler until the oil flows out of the vent hole in sight gauge 2 Approximately 1 4 L 1 50 qt of oil will be required Clean filler cap 3 Install the filler cap 3 Check the oil level in sight gauge 2 immediately after the engine is started Add more oil or drain oil until the oil level is at the center of the sight gauge Remove the hose from drain cock 1 Clean up any oil that has spilled Check the Operation of the Governor Actuator After the oil has been replaced check the governor actuator for proper operation Refer to the instructions that are provided by the OEM of the governor actuator or refer to the Service Manual Consult your Caterpillar dealer for assistance i01069930 Governor Actuator Oil Level Check SMCS Code 1264 535 OC 1264 535 NOTICE Contamination of oil is a major
63. e Cooling System 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 1 After the cooling system has been drained 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 to avoid air locks 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
64. e Section Turbocharger Nozzle Clean Table 32 Data For 3600 Engine Performance Serial number Customer identifier Date Service hours Engine load Engine rpm Performance Before Cleaning the Turbocharger Exhaust manifold pressure left Exhaust manifold pressure right Exhaust manifold temperature left Exhaust manifold temperature right Exhaust stack temperature left Exhaust stack temperature right Inlet manifold air pressure Cylinder Exhaust number port temperature Cylinder Exhaust number port temperature 9 10 11 12 13 14 N OO On BR OIN 15 8 16 Performance After Cleaning the Turbocharger Exhaust manifold pressure left Exhaust manifold pressure right Exhaust manifold temperature left Exhaust manifold temperature right Exhaust stack temperature left Exhaust stack temperature right Inlet manifold air pressure Cylinder Exhaust number port temperature Cylinder Exhaust number port temperature 10 12 13 14 15 COIN ID oa R W RDh 16 i00939998 Turbocharger Nozzle Clean SMCS Code 1052 070 For instructions on removal and installation of the turbocharger components see the Service Manual Disassembly and Assembly module Note This procedure may also be used for clean
65. e the total amount of oil that has been added since the previous oil change This will help to provide the most accurate oil analysis 100976229 Engine Oil Sample Obtain SMCS Code 1348 554 SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine 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 taking the sample complete the Label PEEP5031 for identification of the sample To help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The oils hours of use 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 La Illustration 106 Particle Sensor g00496859 1 Oil sampling valve Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples is better when the sampling valve is used The location of the sampling valve allows oil t
66. ed or spilled onto hot surfaces or electri cal components can cause a fire NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately Primary Filter eH aay Illustration 110 g00477706 1 Filter 2 Filter 3 Lock 4 Lever 5 Drain valve 1 To drain filter 1 lift lock 3 and turn lever 4 to the FILTER 2 RUN position Release the lock 2 Hold a suitable container under drain valve 5 Open the drain valve Allow the moisture to drain Close the drain valve 3 Lift lock 3 and move lever 4 to the BOTH RUN position for one minute 4 To drain filter 2 lift lock 3 and turn lever 4 to the FILTER 1 RUN position Release the lock 5 Repeat Steps 2 and 3 for filter 2 Water Separator For specific instructions on draining the water separator see the service information that is provided by the OEM of the water separator NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system 102046822 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent po
67. engine starting motor until the bar ring group pinion gear is fully disengaged from the fly wheel ring gear Serious damage to the engine could result Electric Barring Device Note This type of barring device may be electrically driven or manually driven Illustration 68 g00334420 Rear view of an electrically driven barring device Lubricating the Pinion pme Illustration 69 g01098831 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 SEBU6966 06 81 Maintenance Section Camshaft Roller Followers Inspect Lubricating the Reducer pag Illustration 70 g00991445 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 Q Illustration 71 g01098833 1 Grease fit
68. es 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 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 New parts are not necessary if the old parts can be reused repaired or salvaged Otherwise the old parts can be replaced or exchanged Your Caterpillar dealer can provide the parts that are needed to rebuild the engine at the least possible cost Overhaul Programs An economical way to obtain most of the parts that are needed for overhauls is to use Caterpillar remanufactured parts Caterpillar remanufactured parts are available at a fraction of the cost of new parts These parts have been rebuilt by Caterpillar and certified for use The following components are examples of the remanufactured parts e Cylinder heads e Oil Pumps SEBU6966 06 129 Maintenance Section Prelube Pump Lubricate e Turbochargers e Water pumps Consul
69. example for using the equation that is in Table 27 The data in the example assumes the following conditions e The specific fuel consumption is 205 grams per ekW hr e The LHV of the fuel is 42 000 kilojoules per kilogram Table 28 Example of the Equation for Calculating the Heat Rate 205 g 42 000 kJ kg 8608 kJ x x ekW hr kg 1000 g ekW hr The equation in Table 29 includes a conversion factor for calculating BTU from kJ The data is from the example in Table 28 SEBU6966 06 133 Maintenance Section Turbocharger Inspect Table 29 Conversion of kJ From the Heat Rate to BTU 8608 kJ 1 BTU 8159 BTU x ekW hr 1 055 kJ ekW hr Monitoring the Trends of Oil Consumption The consumption of lube oil depends on the following factors e Engine load e Hours of operation e Type of oil Monitor the engine s oil consumption by calculating the Specific Oil Consumption on a daily basis Be aware that the following conditions can produce misleading data on oil consumption e Improper operation of the lube oil centrifuge e Inaccurate measurement of additions of oil e Leaking of lube oil e Overfilling of the oil sump To measure additions of oil accurately use a meter to monitor additions of oil at the engine Also check the total oil consumption against the delivery of oil Calculating Specific Oil Consumption Use the equation that is in Table 30 in order to calculate the
70. f 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 turbocharger wheel and the turbocharger housing the turbocharger should be reconditioned or replaced 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber 4 Inspect the bore of the turbine housing for corrosion 5 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 6 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 100939535 Turbocharger Water Wash SMCS Code 1052 070 Deposits form on the vanes of the nozzle and the turbine wheel during normal operation The deposits can reduce efficiency and performance of the t
71. filler cap Illustration 77 g00130652 Location of the cooling system drain valves or drain plugs on the water pumps 1 Jacket water pump 2 Aftercooler and oil cooler pump SEBU6966 06 85 Maintenance Section Cooling System Coolant ELC Change ees epee mee cree ees oO rf G Illustration 78 g00475784 Location of the drain plug jacket water for 3606 and 3608 Engines Illustration 79 g00475850 Location of the drain plugs jacket water for 3612 and 3616 Engines 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 U S A 309 675 6277 Inside U S A 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL
72. for synchronization of the fuel injectors For instructions on the following procedures see the Service Manual Systems Operation Testing and Adjusting module Consult your Caterpillar dealer for assistance 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 The camshafts must be correctly timed with the crankshaft before the fuel timing is adjusted NOTICE The timing pins must be removed from the camshafts before the crankshaft is rotated or damage to the cylin der block will result SEBU6966 06 109 Maintenance Section Engine Timing Synchronization and Valve Lash Inspect Adjust 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 va
73. ge 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 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 SEBU6966 06 103 Maintenance Section Engine Oil Filter Change 9 Start the engine Check for oil leaks Replacing the Engine Oil Filters During Engine Operation Filter contains hot pressurized fluid when engine is running Follow instructions on control valve to avoid per sonal injury If rapid air movement exists to blow fluid Stop the engine to avoid fire If it is necessary to replace the oil filters during engine operation perform the following procedure LI
74. hat is flowing under pressure to be obtained during normal engine operation The 8T 9190 Fluid Sampling Bottle Group is recommended for use with the sampling valve The bottle group includes the parts that are needed for obtaining oil samples Instructions are also provided 106 Maintenance Section Engine Oil Temperature Regulator Replace SEBU6966 06 NOTICE Do not use the same vacuum sampling pump for ex tracting oil samples that is used for extracting coolant samples A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken Always use a designated pump for oil sampling and a designated pump for coolant sampling Failure to do so may cause a false analysis which could lead to customer and dealer concerns 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 For instructions see Special Publication PEHP6001 How To Take A Good Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine 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 replaci
75. he plates For instructions on adjustment see Special Instruction SEHS9162 Spring Isolator Group Installation and Adjustment Procedure Resilient Isolators ELS g00270544 Illustration 94 A Dimension between the top of the soleplate and the bottom of the engine support assembly Measure the loaded height of each isolator Use an inside micrometer and measure dimension A between the top of the soleplate and the bottom of the engine support assembly Measure each corner of each isolator in order to ensure that the top and the bottom of each isolator is parallel The four measurements for each isolator should not differ by more than 0 5 mm 02 inch Compare the measurements to the specifications from the engine commissioning Adjust the height of the engine support assembly in order to maintain the specifications for alignment Adjust the Height Of the Engine Support Assembly If Necessary Note When shims are used in order to maintain the height of the engine support assembly the alignment of the engine and the driven equipment must be verified 98 Maintenance Section Engine Mounts Inspect SEBU6966 06 Illustration 95 g00270557 1 Setscrew 2 Shim To adjust the height of the engine support assembly use setscrew 1 To raise the height of the engine support assembly add shims 2 To
76. he load that was estimated in Step 1 Use this figure for the equation in Table 23 Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases The oil consumption rate brake specific oil consumption is measured in grams per kW h Ib per bhp The brake specific oil consumption BSOC depends on the engine load Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine When an engine s oil consumption has risen to three times the original oil consumption rate due to normal wear an engine overhaul should be scheduled There may be a corresponding increase in blowby and a slight increase in fuel consumption Overhaul Inspection Refer to the Service Manual for the disassembly and assembly procedures that are necessary in order to perform the required maintenance on the items that are listed Consult your Caterpillar dealer for assistance To determine the reusability publications that are needed to inspect the engine refer to Guidelin
77. ing the turbine wheel 1 Remove the component from the turbocharger 2 Place the component in agitating water for 16 to 24 hours Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 3 Remove the component from the water Dry the component with compressed air 4 Install the clean dry component i00528664 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 compartment 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 136 Maintenance Section Water Pump Inspect SEBU6966 06 NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected
78. ing of the isolator Settling of the isolator will result in misalignment between the engine and the driven equipment Check the Center Bolt M NY ENC ZL gM NTE se UK SIS Z Illustration 97 g00745664 2 Locknut 3 Adjustable assembly A Clearance above the adjustable assembly Check the tightness of locknut 2 on the center bolt Use a minimum torque of 100 N m 75 Ib ft If locknut 2 is loose perform the following Steps 1 Tighten locknut 2 to 140 N m 105 Ib ft 2 Measure clearance A above adjustable assembly 3 SEBU6966 06 99 Maintenance Section Engine Oil Change 3 Compare the clearance to the specification from the engine commissioning The clearance and the specification from the engine commissioning must be equal Any difference in the dimension indicates that the height of the isolator has changed A change in the height of the isolator will result in misalignment between the engine and the driven equipment Engine Oil Change SMCS Code 1348 044 1348 Oil Change Interval Considerations for the oil change interval include the type of fuel and the engine application The establishment of an S O S oil analysis program will enable an evaluation of the used oil The evaluation can be used to determine the oil change interval that is suitable for your specific engine Change the engine oil when oil analysis determines that the
79. ion 120 line 1 represents the maintenance and repair costs for an owner that followed the recommendations for inspection maintenance and repair The peaks represent overhauls Line 2 represents the maintenance and repair costs for an owner that chose to operate beyond the recommended intervals The initial cost of the repair after failure philosophy is lower Also the first overhaul was delayed However the peaks are significantly higher than the peaks for the customer that used the repair before failure philosophy The higher peaks result from two key factors e Delaying an overhaul until a breakdown increases the chance of a catastrophic failure This type of failure requires more parts labor and cleanup e Excessive wear means that fewer components will be reusable More labor may be required for salvage or repair of the components When all of the costs are considered repair before failure is the least expensive alternative for most components and engines 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 e Costly unplanned downtime can be avoided e Many original parts can be reused according to the guidelines for reusable parts e The service life of the engine can be extended without the risk of a major catastrophe due to engine failure
80. ion 61 g00297165 For 12 and 16 cylinder engines one drain plug is located on the right side near the rear of the engine 1 Plug Illustration 62 g00297 166 For 12 and 16 cylinder engines one drain plug is located on the left side near the front of the engine 2 Plug Note Prepare a suitable container for the moisture 1 Remove plugs 1 and 2 2 Drain the moisture into a suitable container 3 Install the plugs 101219706 Aftercooler Core Clean Test SMCS Code 1064 070 1064 081 1064 Before cleaning the aftercooler core determine if the aftercooler requires cleaning Use the 152 2067 Differential Pressure Gauge to measure the differential pressure of the air side of the aftercooler If the differential pressure of the air side is greater than 2 kPa 8 inches of H20 clean the aftercooler core SEBU6966 06 77 Maintenance Section Air Shutoff Test Cleaning the Aftercooler See the Service Manual Disassembly and Assembly module for instructions on removal disassembly assembly and installation Note The following procedure may be used for cleaning both the aftercooler core and the oil cooler core 1 Remove the core Disassemble the core 2 Turn the core upside down in order to remove debris NOTICE Do not use a high pressure spray for cleaning the fins of the core A high pressure spray can damage the surface of the fi
81. iring 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 6 Disconnect the connectors at the following locations Inspect the connectors e Engine sensors Junction box Modules of the control panel a Inspect each pin and each socket for corrosion and damage If corrosion is found scrape large deposits Use cotton swabs with denatured 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 and Jaeger 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 Deutsch DT connectors ensure that the plug and the receptacle are securely connected 8 Close the circuit breaker or circuit breakers of the main power supply Engine Timing Synchronization and Valve Lash Inspect Adjust SMCS Code 1102 040 1105 535 1290 040 Change the fuel from heavy fuel oil to distillate fuel before performing this procedure The use of distillate fuel is necessary
82. ith the gauge 101428855 Magnetic Pickups Clean Inspect SMCS Code 1907 040 g00748456 Illustration 117 1 Magnetic pickup 2 Flywheel ring gear 1 Remove the magnetic pickup from the flywheel housing 2 Clean the face of the magnet Check the condition of the magnetic pickup 3 Install the magnetic pickup in the flywheel housing Turn the magnetic pickup clockwise until the magnet contacts a tooth of the flywheel ring gear 4 Turn the magnetic pickup counterclockwise for 1 1 4 turns 450 30 degrees Maintain a clearance of 0 70 0 15 mm 028 006 inch between the magnetic pickup and the tooth of the flywheel ring gear Tighten the locknut to 47 7 N m 35 5 Ib ft 102343231 Metal Particle Detector Inspect SMCS Code 7400 040 If the metal particle detector causes a shutdown inspect the detector ee J Illustration 118 g00546054 Metal particle detector 1 Remove the grid from the inside of the detector 2 If metal particles are found determine the source of the particles NOTICE Metal particles in the lube oil may indicate a serious condition that requires immediate attention If metal particles are found in the grid of the detector do not start the engine until the source of the particles is found and the condition is corrected Failure to do so could cause severe damage to the engine 3 Clean the grid with nonflammable solvent
83. ithin the appropriate specifications 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 If you elect to perform an overhaul without the services of a Caterpillar dealer be aware of the following recommendations Fuel Consumption Before A Top End Overhaul The overhaul interval that is listed in this Operation and Maintenance Manual Maintenance Interval Schedule is expressed in service hours A more accurate figure to use is fuel consumption Fuel consumption corresponds more accurately to the engine load Table 22 lists an average range of fuel consumption for a reasonable load factor before a top end overhaul Use the range of fuel consumption only as a guideline Table 22 Approximate Fuel Consumption Before A Top End Overhaul Engine Fuel Consumption Model 3606 2 842 500 L 750 000 US gal 3608 3 790 000 L 1 000 000 US gal 3612 5 685 000 L 1 500 000 US gal 3616 7 580 000 L 2 000 000 US gal 1 The fuel consumption is based on fuel with these characteristics a low heat value of 42 780 kJ kg and density of 838 9 g L Remanufacturing or Rebuilding of Components Rework the following components Air shutoff valve Cylinder heads Cylinder dowels Exhaust valves Exhaust valve seat inserts Inlet valves Inlet valve seat inserts Inner valve springs Outer
84. l 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 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 90 Maintenance Section Crankshaft Vibration Damper Inspect SEBU6966 06 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
85. l energy content of different fuels For this calculation the low heat value LHV of the fuel is divided by the electrical energy that was produced Calculating the Specific Fuel Consumption Use the equation that is in Table 25 to calculate the Specific Fuel Consumption Table 25 Equation For Calculating the Specific Fuel Consumption FxD ekW hr SFC F is the liters of fuel that have been burned D is the density of the fuel The density is expressed in grams per liter ekW hr is the electrical kilowatt hours that were produced with the fuel SFC is the specific fuel consumption Table 26 is an example for using the equation that is in Table 25 The data in the example assumes the following conditions e During this operation the engine used 18 440 liters of fuel e The density of the fuel was 987 grams per liter e The operation generated 88 800 ekW Table 26 Example of the Equation for Calculating the Specific Fuel Consumption 18 440 x 987 g L 1 205g x 88 800 ekW hr L ekW hr Calculating the Heat Rate The specific fuel consumption must be determined before the heat rate can be calculated Use the equation that is in Table 27 to calculate the heat rate Table 27 Equation For Calculating the Heat Rate SFC x LHV HR SFC is the specific fuel consumption LHV is the low heat value of the fuel HR is the heat rate Table 28 is an
86. lant 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 19 to interpret the results SEBU6966 06 89 Maintenance Section Cooling System Water Temperature Regulator Replace Table 19 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 pres
87. late fuel after an overhaul or after servicing the fuel system Perform the test before changing to heavy fuel If an unexpected problem occurs distillate fuel is easier to clean up For example if a leak develops after starting cleaning up heavy fuel oil would be more difficult than cleaning up distillate fuel Fuel Bypass Valve During normal operation the valves for the fuel supply lines and the fuel return lines are open The bypass valve between the supply lines and return lines is closed When the fuel supply lines and the fuel return lines are closed fuel does not flow to the fuel filters The filters will cool Hours may be required for heating the fuel filters before starting the engine When the fuel to an engine is changed the bypass valve must be adjusted in order to maintain the correct fuel system pressure Adjustment of the bypass valve also maintains the circulation of fuel through the fuel system when the fuel supply and return lines are closed For sites with more than one engine sharing one fuel oil conditioning module the fuel pressure to any operating engine will increase when another engine is shut down When the fuel to an engine is changed the bypass valve must be adjusted in order to maintain the correct fuel system pressure to any operating engine Normal supply pressure from the fuel oil conditioning module is 6 5 to 7 bars This pressure is needed in order to maintain a pressure of 550 to 620 kPa 80 to 90
88. ll cup 4 Fasten clips 3 7 Inspect a clean dry air cleaner element for good condition 8 Remove the tape or the cover from the air inlet to the turbocharger Install the air cleaner element 9 Secure the access door 10 If necessary reset the air cleaner service indicator Replace the Soot Filter Some applications use an air silencer that is wrapped in a washable soot filter The soot filter helps prevent airborne dust and debris from entering the air inlet As the soot filter becomes dirty the air restriction increases Replace the soot filter when the air restriction reaches 3 75 kPa 15 inches of H20 1 Remove the dirty soot filter from the air silencer 2 Inspect the air silencer Clean the air silencer if necessary 3 Inspect a clean dry soot filter for good condition Install the soot filter Cleaning the Air Cleaner Elements The air cleaner element can be used up to six times if the element is properly cleaned and inspected When the element is cleaned check the filter material for rips or tears Replace the element at least one time per year regardless of the number of cleanings Use clean 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 in
89. lves Prelube of the engine is required before the crankshaft is rotated for normal maintenance Activate the prelube pump for rotating the engine crankshaft NOTICE Do not use an impact wrench to operate the barring device The use of an impact wrench will cause gear tooth failure The barring device provides a means for slowly turning the flywheel in order to service the engine The barring device can also be used to prevent rotation of the crankshaft Refer to the Service Manual for information on operation of the barring device Fuel Injector Timing Fuel Timing The camshafts must be correctly timed with the crankshaft before the fuel timing is adjusted The fuel timing dimension is stamped on the engine Information Plate Fuel Injector Clamp The top surface of the clamp for the fuel injector must be parallel to the top surface of the cylinder head The specification for the clearance is described in the Service Manual Specifications module Fuel Injector Synchronization Synchronize the fuel injectors When this maintenance procedure is complete ensure that the barring device is disengaged from the flywheel and ensure that the handle of the barring device is secured in the disengaged position 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 bridge
90. n tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts 134 Maintenance Section Turbocharger Water Wash SEBU6966 06 Note Turbocharger components require clearances that are precise The turbocharger cartridge must be balanced due to high rpm Severe service applications can accelerate the wear of the components Severe service applications may require more frequent inspections of the turbocharger Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine or consult your Caterpillar dealer for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence o
91. n The layer of oxidation reduces the effectiveness of the zinc rod Replace the Zinc Rods 1 Use pliers to unscrew the old zinc rod from the plug If not enough material remains or the zinc rod has broken off drill the zinc from the plug 2 Clean the plug Illustration 124 g00748510 1 Shoulder 2 Threads 3 External threads of the plug Note Do NOT apply adhesive or sealant to the threads of the zinc rod 2
92. n rough In some cases the engine will stall Vent any air that is entrained in the fuel Check the operation of the viscosity control Ensure that the fuel is provided to the engine at 10 to 20 cSt Verify the temperature of the steam jacket Ensure that the temperature of the fuel to the engine does not exceed 135 C 275 F Observe the inlet pressure and the outlet pressure of the automatic backflush filter Record the data Slightly open all of the lines to the transducer in order to verify the presence of a flow of heavy fuel oil Every Week Verify the operation of the selector valve for the duplex filters Every 1000 Service Hours 1 Remove the duplex filter elements 2 Clean the inside of the filter housings 3 Clean the filter elements 4 Inspect the filter elements for good condition Replace the filter elements if necessary 5 Assemble the duplex filters Every 1500 Service Hours If the duplex filter elements were not replaced during the 1000 service hour interval install new filter elements SEBU6966 06 115 Maintenance Section Fuel Oil Separator Check Every 3000 Service Hours Install new duplex filter elements 100939024 Fuel Oil Separator Check SMCS Code 1280 535 Note A separator may also be known as a centrifuge The separator separates water and contaminants from the fuel oil The densities of heavy fuel and water are almost equal Therefore the difference in density
93. nection 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 Inspect the gaskets and the exhaust bellows joint If a leak is found make repairs 100524084 Water Pump Inspect SMCS Code 1361 040 A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head a piston seizure or other potential 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 the Service Manual for the disassembly and assembly procedure Inspect the water pump for wear cracks pin holes and proper operation Refer to the Service Manual or consult your Caterpillar dealer if repair is needed or replacement is needed 102329751 Zinc Rods Inspect Replace SMCS Code 1388 040 1388 510 Corrosion in sea water circuits can result in premature deterioration of cooling system components leaks and possible cooling system contamination The corrosion may be caused by the lack of zinc rods in the sea water system Zinc rods are installed in the sea water cooling system of the engine in order to help prevent the corrosive oxidation that is caused by sea water Electrical current is conducted through the contact of the zinc rods with the cooling system components The zinc rod
94. ng the oil temperature regulators see the Service Manual Disassembly and Assembly module 102354755 Engine Protection Devices Calibrate SMCS Code 7400 524 A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests For the calibration of temperature contactors see Special Instruction SEHS9827 Calibration of Temperature Contactors For the calibration of pressure contactors see Special Instruction SEHS9828 Calibration of Pressure Contactors For engines with the Caterpillar Marine Monitoring System see Owner s Manual SEBU7134 Marine Monitoring System Consult your Caterpillar dealer or refer to the Service Manual for more information 101428946 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 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
95. ning clamps 5 Remove breather assemblies 1 and O ring seals 4 3 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 4 Install new O ring seals 4 5 Allow the breather elements to dry before installation Install the breather assemblies in the original position Coat the rubber parts with clean engine oil or petroleum jelly in order to make installation easier 6 Install the retaining clamps and the hose clamps See the Service Manual Specifications module for the proper torque SEBU6966 06 97 Maintenance Section Engine Mounts Check 101052365 Engine Mounts Check SMCS Code 1152 535 Measure the Isolators Spring Type Isolators Illustration 92 g00545733 7C 0533 Generator Base Mounting Group 1 Snubber bolt t 2e rh RH 1 4 g a RAEN A ASSSSSSSSSSSSSSSSSSSSSSSTN TA Illustration 93 g00545734 7C 6537 Generator Base Mounting Group 1 Snubber bolt Obtain dimension B for each isolator If any of the following conditions are found adjust the isolators e Dimension B is different from the original dimension that was obtained during the engine commissioning Dimension B is not within 3 mm 12 inch for all of the isolators e Snubber bolts 1 are not finger tight against t
96. ns and reduce the flow of air through the core NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 3 Back flush the core with cleaner Caterpillar recommends the use of Hydrosolv liquid cleaner Consult your Caterpillar dealer for the part numbers and quantities that are available Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information 4 Steam clean the core in order to remove any residue Flush the fins of the aftercooler core Remove any other trapped debris 5 Wash the core with hot soapy water Rinse the core thoroughly with clean water Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 6 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the core in order to ensure cleanliness Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 8
97. o minutes Inspect the engine for oil leaks b Ensure that the oil level is at the FULL mark on the LOW IDLE side of the oil level gauge 10 Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes 11 Remove the oil level gauge and check the oil level Maintain the oil level to the FULL mark on the ENGINE STOPPED side of the oil level gauge 100936366 Engine Oil Centrifuge Check SMCS Code 1348 535 Heavy fuel oil introduces higher levels of combustion products into the crankcase than distillate fuel A centrifugal separator centrifuge is used for cleaning the engine oil This cleaning extends the service life of the oil The engine oil must be cleaned by this method at least one time during each eight hours of operation The lubrication systems of several engines can be serviced by a single centrifuge of sufficient size However mixing the oils can spread contaminants between the engines This will produce inaccurate results from oil analysis Therefore the oil from each engine must be processed in rotation This will help to prevent mixing the oils from different engines For each engine operate the centrifuge for the engine oil at least one time during each eight hours of engine operation Check the centrifuge according to the instructions that are provided by the OEM of the centrifuge See the engine s Technical Manual Perform the maintenance and
98. oil filter according to the instructions in the Service Manual 2 Thoroughly clean all of the parts of the centrifugal oil filter Carefully inspect all of the parts 3 Measure the clearance between the bearing and the base and measure the clearance between the bearing and the spindle Follow the instructions that are in the Service Manual Replace any part that does not meet the specifications that are in the Service Manual NOTICE Ensure that all of the rotor components are thoroughly clean before assembling the rotor Failure to do so can cause an out of balance condition that can cause rapid wear to the bearings and the spindle Note Install a new paper liner when the centrifugal oil filter is assembled 4 Assemble the centrifugal oil filter according to the instructions in the Service Manual 102305937 Cooling System Coolant DEAC 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 The coolant is foaming e Oil or fuel has entered the cooling system and the coolant is contaminated 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
99. ok 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 100935452 Engine Air Cleaner Element Replace SMCS Code 1051 510 1054 510 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent 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 If the air cleaner element becomes plugged the air pressure can split the filter material of the element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application e Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions du
100. on Filter contains hot pressurized fluid when engine is running Follow instructions on control valve to avoid per sonal injury If rapid air movement exists to blow fluid Stop the engine to avoid fire afi a Illustration 113 g00478070 1 Cover 2 Vent plug 3 Seal 4 Retainer 5 Element 6 Lever 7 Drain plug 1 Move lever 6 in order to direct the fuel flow away from the side of the filter that will be serviced 2 Shut off the heat to the side of the filter that will be serviced 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 discon nected fuel system component 3 Loosen vent plug 2 Do not remove the plug NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately NOTICE To prevent contamination of the new filter element ensure that the filter housing is completely drained 4 Remove drain plug 7 Drain the fuel into a suitable container 5 Remove cover 1 Be careful not to damage seal 3 6 Remove retainer 4 and element 5 Discard the used element 7 Clean
101. ondition Replace the components if necessary e Oil cooler core e Oil suction screen Oil Cooler Core For cleaning the oil cooler core see this Operation and Maintenance Manual Aftercooler Core Clean Test procedure The procedure may be used for cleaning both the aftercooler core and the oil cooler core Oil Suction Screen For cleaning the oil suction screen see this Operation and Maintenance Manual Engine Oil Change procedure 102301217 Overhaul Considerations SMCS Code 7595 043 Overhaul Information An overhaul is replacing the major worn components of the engine An overhaul interval is a maintenance interval that is planned The engine is rebuilt with certain rebuilt parts or new parts that replace the worn parts An overhaul also includes the following maintenance Inspection of all the parts that are visible during the disassembly Replacement of the seals and gaskets that are removed Cleaning of the internal passages of the engine and the engine block Most owners will save money by overhauling the engine at the intervals that are recommended in this Operation and Maintenance Manual Consider the graph in Illustration 120 SEBU6966 06 127 Maintenance Section Overhaul Considerations Illustration 120 g00745964 Y Cost X Time 1 Cost of maintenance and repair that is planned 2 Cost of maintenance and repair that is not planned In Illustrat
102. or repairs The absence of an alarm condition does NOT guarantee normal operation Not all parameters have alarms and or shutdowns Setpoints for alarms are outside of the normal ranges in order to avoid occasional nuisance warnings An alarm indicates a serious condition that requires immediate attention Service or repair is a reaction to an alarm condition A different approach is necessary in order to schedule service before an alarm condition occurs Monitor the trends of the engine s performance The following benefits can be realized e Reduction of engine performance will be noticed sooner e Problems can be predicted This enables prevention of the problems Service can be planned before an alarm condition occurs Planning for downtime will also reduce downtime e The cost of parts and labor for service that is planned will be less than the cost of repairs that are not anticipated Monitoring the Trends of Engine Performance To maintain a program that is successful several factors are important Record the data regularly when the engine is operating at similar loads and speeds Obtain accurate data At regular intervals review the data in a graphic format Perform corrections before damage and or downtime occurs Accurate data is provided by accurate instruments and proper use of the instruments The gauges and the sensing devices must be in good condition This is especially true for thermocouples Est
103. prevent excessive injection pressures when the fu el is changed to heavy fuel oil the engine must not be operated at more than 75 percent of rated load Note The complete procedure for changing the fuel may require an hour of time This depends on the load conditions and the volume of fuel in the system 1 Operate the engine and or engines at a reduced load Move the selector switch for fuel on the fuel booster module from distillate fuel to heavy fuel oil Monitor fuel temperature and viscosity during the changeover to heavy fuel Maintain the fuel supply pressure to each engine at 550 to 620 kPa 80 to 90 psi If necessary adjust the fuel bypass valve Be careful to avoid sudden changes in either fuel temperature or fuel viscosity during the changeover Check the routing of the fuel valve Route sufficient fuel through the fuel cooler before the fuel is returned to the fuel booster module Make sure that the fuel viscosity stabilizes at approximately 15 to 20 cSt at the unit injectors After the changeover is complete and the fuel temperature and viscosity are stable shut off the distillate fuel supply to the fuel booster module Changeover from Heavy Fuel Oil to Distillate Fuel After Engine Shutdown This procedure is based on the following conditions e The engine was stopped during operation with heavy fuel oil e The jacket water heater is operating 1 Adjust the engine s fuel supply line from hea
104. re that the water and sediment is drained from the fuel storage tank when the tank is refilled This will help prevent water and or sediment from being pumped from the fuel storage tank into the settling tank 100455138 Governor Actuator Linkage Check SMCS Code 1265 535 Check the governor actuator linkage for proper operation Refer to the Service Manual for the procedure to adjust the governor actuator linkage Lubricate the Fuel Control Linkage Illustration 114 g00274295 1 Grease fitting Some governor actuator linkages have grease fittings 1 Lubricate the moving parts of the governor actuator linkage with MPG or equivalent grease 120 Maintenance Section Governor Actuator Oil Replace SEBU6966 06 102345076 Governor Actuator Oil Replace SMCS Code 1264 510 OC 1264 510 NOTICE Contamination of oil is a major cause of problems for governor actuators Only use new oil A container that is used to fill the governor actuator must be clean Rinse the container with the new oil before filling the container 1 2 q B o 3 amp j Illustration 115 g00274299 1 Drain cock 2 Sight gauge 3 Filler cap NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the pro
105. rmance and the performance of the system that processes the fuel Sample the fuel according to the recommendations in Special Instruction REHSO104 Guidelines for 3600 Heavy Fuel Oil HFO Engines 114 Maintenance Section Fuel Oil Conditioning Module Check SEBU6966 06 100938862 Fuel Oil Conditioning Module Check SMCS Code 1280 535 1901 535 Operate the fuel conditioning module fuel booster module group on viscosity control during all normal operations This automatic sensing and control will account for slight variations in the supply of fuel These variations in the fuel even occur within a single shipment of fuel Properly adjust the viscosity control in order to account for losses of heat in the engine piping as fuel is delivered The viscosity of the fuel at the engine must be between 10 cSt and 20 cSt The temperature of the fuel at the engine must not exceed 135 C 275 F When the supply of fuel is changed monitor the viscometer during the changeover in order to ensure that the viscosity control is responding correctly Correct fuel temperature is important at the engine The fuel must be sufficiently preheated before the injectors or the following conditions will result e Extremely high pressures in the injection system e An increase of the mechanical load on many components e An increase of the thermal load e Poor atomization of the fuel in the cylinder which leads to incomplete combus
106. rt number Do not use an element that has any tears and or holes in the filter material Do not use an element with damaged pleats gaskets or seals Discard damaged elements Storing Air Cleaner Elements If an element that passes inspection will not be used immediately store the element for future use Illustration 87 g00281694 SEBU6966 06 95 Maintenance Section Engine Air Cleaner Service Indicator Inspect Do not use paint a waterproof cover or plastic as a protective covering for storage Restricted air flow may result To protect against dirt and damage wrap the elements in Volatile Corrosion Inhibiter VCI paper Place the element into a cardboard box for storage For identification mark the outside of the container and mark the element Include the following information e Date of cleaning e Number of cleanings Store the container in a dry location For more detailed information on cleaning the air cleaner element refer to Special Publication SEBF8062 Procedure to Inspect and Clean Air Filters 100935673 Engine Air Cleaner Service Indicator Inspect SMCS Code 7452 040 A service indicator may be mounted on the air cleaner or in a remote location ele By Illustration 88 g00476444 Service indicator Some engines may be equipped with a different service indicator Observe the service indicator Clean the air cle
107. s oxidize rather than the cooling system components Rapid deterioration of zinc rods may indicate the presence of uncontrolled electrical currents from improperly installed electrical attachments or improperly grounded electrical attachments The engineer for the operation must determine the interval for inspecting the zinc rods The interval for inspecting the zinc rods will depend on the size of the zinc rods and the number of zinc rods that are installed For the location of the zinc rods see the literature that is provided by the OEM of the installation Inspect the Zinc Rods 1 Remove the zinc rod 2 Inspect the zinc rod SEBU6966 06 137 Maintenance Section Zinc Rods Inspect Replace Ensure that the zinc rod will remain effective until 3 Apply 9S 3263 Thread Lock Compound to the next scheduled inspection the shoulder 1 of a new zinc rod Apply the compound ONLY to the shoulder of the zinc rod a If the zinc rod has deteriorated excessively Install the zinc rod onto the plug install a new zinc rod 4 Coat the external threads of the plug 3 with 5P 3413 Pipe Sealant Install the zinc rod See Specifications SENR3130 Torque Specifications for the torque for the plug Illustration 123 g00481100 b Tap the zinc rod lightly with a hammer If the zinc rod breaks install a new zinc rod 3 If the zinc rod will be reused scrape the layer of oxidation from the zinc rod before installatio
108. s with a consistent load cycle record the data at the same time for each day e If the load can be controlled set the load to the same amount for each reading Some parameters that are NOT affected by the load ARE affected by the engine rpm Obtain the readings for these parameters when the engine is operating at the same rpm Some parameters are not affected by either the load or the rpm See Table 24 Table 24 Parameters of Engine Operation Parameters That Depend On the Load Aftercooler and oil cooler water temperature outlet Exhaust manifold pressure Exhaust manifold temperature Exhaust port temperature Generator stator temperature Inlet air restriction Inlet manifold air pressure boost pressure Inlet manifold air temperature Jacket water coolant temperature outlet Parameters That Depend On the RPM Fuel filter differential pressure Jacket water pressure Lube oil pressure Oil filter differential pressure Parameters That Are Independent of the Load and RPM Aftercooler and oil cooler water temperature inlet Jacket water coolant temperature inlet Lube oil temperature Note A gauge reading that is abnormal may indicate a problem with operation or a problem with the gauge 56D 640 620 600 580 950 540 520 500 460 460 440 420 400 380 350 340 320 300 230 250 1
109. 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 101216672 Fuel Changeover SMCS Code 1280 Caterpillar 3600 Series Heavy Fuel Engines are designed to use heavy fuels for starting operating and stopping These engines can also operate on distillate fuel Also these engines may be operated on distillate fuel when the supply of heavy fuel is restricted reduced or eliminated During the changeover between fuels these engines can use a mixture of distillate fuel and heavy fuel oil Use caution not to change between heavy fuel and distillate fuel too quickly Differences in the control of the fuel temperature can cause thermal shock and a lack of lubricity to the unit injectors The following recommendations are based on having a system that meets Caterpillar recommendations and industry standards The design of the system includes these features e A three way valve for the selection of heavy fuel or distillate fuel e A separate isolated distillate fuel supply for the engine and or engines Circumstances for Changing the Fuel Caterpillar 3600 Series Heavy Fuel Engines are designed to use heavy fuels for normal operation However it is preferable to operate with distillate fuel before stopping the engine for the following circumstances e Performance of service on fuel system components such as fuel filters
110. spect the elements before cleaning Inspect the elements for damage to the seal the gaskets and the outer cover Discard any damaged elements Four methods are used to clean air cleaner elements e Pressurized water e Pressurized air e Vacuum cleaning e Washing with nonsudsing detergent Pressurized Water Pressurized water will clean the element unless carbon and oil have accumulated on the surface of the element The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Do not use a spray nozzle Note When the element is 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 water 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 water directly at the element A direct stream of water could cause dirt to be forced into the pleats Note Refer to Drying the Air Cleaner Elements Refer to Inspecting the Air Cleaner Elements Pressurized Air Pressurized air can be used to clean elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 85 g00281692 Note When the elements are cleaned always begin with the clean side inside in order to force dirt particles toward the
111. ssible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately 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 discon nected fuel system component Primary Filter Servicing the Primary Filters During Engine Operation Illustration 111 g00477786 Primary filters in the FILTER 1 RUN position 1 Lock 2 Lever 3 Drain valve 4 Nut SEBU6966 06 117 Maintenance Section Fuel System Secondary Filter Replace 1 To service FILTER 2 lift lock 1 and turn lever 2 to the FILTER 1 RUN position Release the lock 2 Hold a suitable container under drain valve 3 Open the drain valve Allow the moisture to drain Close the drain valve 3 Remove nut 4 Remove the filter case O lt Illustration 112 g00477788 5 Element 6 Seals 4 Remove element 5 and seals 6 5 Clean the filter case the element and the seals with clean nonflammable solvent Allow the parts to dry 6 Inspect the element and the seals for good condition Obtain new parts if necessary See the Parts Manual for the engine 7 Assemble the clean dry element seals and filter case Use
112. st dirt and debris may require more frequent service of the air cleaner element Replace the element when the air restriction reaches 3 75 kPa 15 inches of H20 Replace the element when the red piston of the service indicator locks in the visible position e The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected Replace the element at least one time per year Perform this replacement regardless of the number of cleanings Replace the dirty paper elements with clean elements Before installation thoroughly inspect the element for tears and or holes in the filter material Inspect the gasket or the seal of the element for damage Maintain a supply of suitable elements for replacement purposes Illustration 84 g00476341 1 Access door 2 Element 3 Clips 4 Cup 5 Screen 1 Open access door 1 Remove element 2 2 Seal the air inlet to the turbocharger with a cover or tape This will help to prevent dirt from entering the turbocharger when the body of the air cleaner is cleaned 3 Loosen clips 3 Remove cup 4 Clean the inside of the cup 4 Clean screen 5 with pressurized air or water SEBU6966 06 93 Maintenance Section Engine Air Cleaner Element Replace 5 Use a cloth to clean the inside of the access door and the body of the air cleaner 6 Insta
113. sure 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 the recommended amount of supple mental coolant additive concentration 3 Add the proper amount of SCA For the proper amount of SCA refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic The proper concentration of SCA depends on the type of coolant that is used For the proper concentration of SCA refer to Special Publication SEBU 7003 3600 and C280 Diesel Engine Fluids Recommendations 4 Clean the cooling system filler cap Install the cooling system filler cap 102168842 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulators for these systems e Jacket water e Oi
114. t are provided by the OEM of the oil mist detector e Clean the two fresh air bores in the measuring device e Clean the glasses for the infrared filter in the measuring device e Replace the sintered bronze filters in the measuring device Yearly Replace the sintered bronze filters in the pressure regulator Follow the instructions that are provided by the OEM of the oil mist detector 101217065 Overhaul Major SMCS Code 7595 020 MJ 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 Other factors must also be considered for determining a major overhaul e The total amount of fuel consumption 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 SEBU6966 06 123 Maintenance Section Overhaul Major Monitor the engine as the engine accumulates service hours
115. t 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 100939520 Prelube Pump Lubricate SMCS Code 1319 086 L a Illustration 121 g00478820 Grease fittings Lubricate the two motor bearings Apply one pump of MPGM to each fitting with a hand operated grease gun 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
116. tch the oil 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 Illustration 101 g00215989 5 Wire rack 6 O ring seal 7 Element 4 Elements 7 are mounted on wire racks 5 inside the housing Use a pan to catch the oil that drips when wire racks 5 are removed Remove wire racks 5 Remove used elements 7 Clean up any oil that is spilled NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine dama
117. tective Devices Check aeiee 106 Oil Mist Detector Clean Replace 0 122 Initial 1000 Service Hours or 6 Months Engine Timing Synchronization and Valve Lash INnSpeCUAJUSE arire EAE E 108 Engine Valve Rotators Inspect a 110 Every 1000 Service Hours Fuel Oil Conditioning Module Check 4 114 Every 1000 Service Hours or 6 Months Barring Device Lubricate 0 80 Cooling System Coolant Sample Level 2 OD AUN orones era yiee ain niea 88 Engine Air Cleaner Service Indicator Inspect 95 Engine Mounts Check eeeeeeeeecteeeeeeeenteeeeerees 97 Engine Oil Filter Change s es 101 Exhaust Piping Inspect 0 eee 110 Fuel System Primary Filter Water Separator Element Replace ccccceceeeeeeeeeeeeeeenes 116 Fuel System Secondary Filter Replace 117 Magnetic Pickups Clean Inspect 0 05 121 Prelube Pump Lubricate eeeeeeeees 129 Every 1500 Service Hours Fuel Oil Conditioning Module Check 4 114 Every 2000 Service Hours or 1 Year Engine Valve Rotators Inspect eee 110 Oil Mist Detector Clean Replace 0 122 Every 2000 Service Hours or 1 Year Aftercooler Condensation Drain i e 76 Engine Timing Synchronization and Valve Lash INSPECUACJUSE oieee 108 SEBU6966 06 75 Maintenance Section Maintenance Interval Schedule Every Year Cooling Sys
118. tem Supplemental Coolant Additive SCAJ TeStAdd iihi eieaa 88 Every 3000 Service Hours Fuel Oil Conditioning Module Check 114 Every 4000 Service Hours or 1 Year Aftercooler Core Clean Test ceecee 76 Air Starting Motor Lubricator Bowl Clean 78 Cylinders Inspect occ ceeeeeeeeenteeeeeeetteeeeeeeaaes 91 Exhaust Manifold Inspect cceeeeeeee 110 Fuel System Fuel Injector Clean Inspect 115 Starting Motor Inspect isese 129 Turbocharger Nozzle Clean 135 Every 8000 Service Hours or 1 Year Engine Protection Devices Calibrate 106 Every 8000 Service Hours or 2 Years Camshaft Roller Followers Inspect 05 81 Cooling System Water Temperature Regulator Replace iin cee ete A E A EOE 89 Crankshaft Vibration Damper Inspect 90 Driven Equipment Check c cccceeeeetteeees 91 Engine Oil Temperature Regulator Replace 106 Exhaust Shields Inspect cecceeeeeeteeees 110 Governor Actuator Oil Replace 0 08 120 Turbocharger Inspect n se 133 Water Pump Inspect sseeeerieirrirreeresrerrrnes 136 Between 8000 and 12 000 Service Hours Overhaul Top End eeeeeeeeeeeeeeeeeeeeeeteeeeeeenaaes 125 Overhaul Considerations 126 Every 8000 Service Hours or 3 Years Cooling System Coolant DEAC Change 82 Cooling System Coolant Extender EL
119. that is needed for efficient separation is very small For optimum efficiency the separator must be operated and maintained according to the recommendations of the OEM of the separator The correct supply of heat is critical to proper operation of the separator Small variations in the temperature of the fuel oil to the separator may cause a large change in the density of the fuel oil It is very important to keep the fuel temperature constant Regulate the inlet temperature to the separator to a tolerance of 2 C The temperature of the fuel to the separator depends on the viscosity of the fuel The heater before the separator must operate at the correct temperature for the viscosity of the fuel However the maximum temperature of the fuel from the heater to the separator is 98 C Operate the separator according to the instructions that are provided by the OEM of the separator e Check the module according to the instructions that are provided by the OEM of the module See the engine s Technical Manual e Perform the maintenance and service activities that are described in the literature e Respond to any alarm immediately Determine the cause of the alarm and make corrections as soon as possible i01216970 Fuel System Fuel Injector Clean Inspect SMCS Code 1290 040 1290 070 For instructions on the following topics see the Service Manual Disassembly and Assembly module e Removal and installation of
120. the following items with clean nonflammable solvent e Inside of the filter housing e Components inside the filter housing e Retainer e Cover e Seal e Drain plug Wipe the items dry with a clean cloth Ensure that the surfaces for the seal are clean 8 Install a new filter element Secure the element with retainer 4 Install drain plug 7 9 Inspect seal 3 for good condition Obtain a new seal if necessary See the Parts Manual for the engine 10 Install seal 3 in cover 1 To make installation easier coat the seal with clean diesel fuel Install the cover 11 Turn on the heat to the side of the filter that has been serviced SEBU6966 06 119 Maintenance Section Fuel Tank Water and Sediment Drain 12 Turn handle 6 in order to fill the housing of the new element Observe the area around vent plug 2 for fuel flow When fuel flows free of air bubbles tighten the vent plug Clean up any fuel that has spilled Replacing the Filter Elements With the Engine Stopped 1 Ensure that the fuel to the filter is OFF 2 Refer to Replacing the Filter Element During Engine Operation Perform Steps 3 through 12 for both sides of the fuel filter 100939327 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Day Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Condensation
121. the fuel injectors e Cleaning the bores for the fuel injectors 1 Remove the fuel injectors from the cylinder head 2 Perform the following procedures according to Special Instruction SEHS9741 Cleaning 3600 Unit Injectors e Cleaning e Disassembly e Inspection e Assembly Obtain new fuel injectors if necessary 3 Clean the bores for the fuel injectors 4 Install the fuel injectors 101216981 Fuel System Fuel Injector Tip Cooling Module Check SMCS Code 1290 535 Cooling the fuel injector tips provides the following benefits e Control of erosion e Prevention of deposit formation Check the coolant level Ensure that a sufficient amount of coolant is in the cooling module Inspect the components the piping and the connections for leaks Make repairs if necessary Monitor the temperature and pressure of the system Record the gauge readings on an hourly basis Compare the new data to the recorded data Check the differential pressure for the filter Replace the filter element if necessary Check the module according to the instructions that are provided by the OEM of the module See the engine s Technical Manual Perform the maintenance and service activities that are described in the literature 116 Maintenance Section Fuel System Primary Filter Water Separator Drain SEBU6966 06 100938031 Fuel System Primary Filter Water Separator Drain SMCS Code 1260 543 1263 543 Fuel leak
122. ting 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 101904185 Camshaft Roller Followers Inspect SMCS Code 1209 040 For instructions on disassembly and assembly of the valve lifter group see the Service Manual Disassembly and Assembly module Inspect the following components for wear at each metal to metal contact point e Rollers for the valve lifters e Camshaft Inspect each roller for wear excessive movement and end play If excessive wear or other signs of deterioration are found replace the damaged components 100449365 Centrifugal Oil Filter Inspect SMCS Code 1328 040 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 72 g00270570 1 Valve 2 Base Note If the engine is operating close valve 1 to the centrifugal oil filter that will be cleaned Prepare a cover for base 2 The cover will prevent the oil mist from flowing through the orifice in the base 82 Maintenance Section Cooling System Coolant DEAC Change SEBU6966 06 1 Disassemble the centrifugal
123. tion Fouling of the combustion chamber e Fouling of the exhaust system Excessive preheat temperatures can also cause problems Excessive preheat temperatures may cause a thermal breakdown of the fuel especially if the fuel contains large amounts of cracked constituents This thermal breakdown may lead to plugging of the system that is used to treat the fuel Deposits may also form in the system The fuel system components must be carefully operated and maintained continuously The delivery of clean fuel at the proper viscosity is essential to reliable engine performance Frequently sample and analyze the fuel for cleanliness at the engine Carefully document these samples in case future questions arise regarding quality of the fuel or operation of the engine Immediately resolve any problems if a discrepancy is detected The engine operator must remember that there are no alarms for fuel quality Only the proper operation and maintenance of the entire system leads to successful operation of heavy fuel engines The proper operation also includes the sampling and analysis of fuel oil Daily Note When the fuel supply is changed monitor the viscosity in order to ensure that the viscosity control is operating properly Perform the maintenance that is recommended by the OEM of the module Check the operation of the deaerator system This system removes air from the fuel Air that is mixed with the fuel will cause the engine to ru
124. tions 80 Maintenance Section Barring Device Lubricate SEBU6966 06 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 102355233 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 The barring device can also be used to prevent rotation of the crankshaft When the barring device is in the engaged position the engine starting system is disabled When the barring device is not used the barring device must be fully disengaged from the flywheel and secured in the disengaged position Refer to the Service Manual for information on operation of the barring device NOTICE Do not operate the
125. up any spilled oil with absorbent towels or pillows DO NOT use absorbent particles to clean up the oil Illustration 99 g00540945 2 Cover 3 Seal 4 Screen a Remove cover 2 and seal 3 Discard the used seal Slide screen assembly 4 from the tube b Wash the screen assembly in clean nonflammable solvent Allow the screen assembly to dry before installation 4 Clean the bottom of the sump Remove side covers in order to gain access to the sump When the bottom of the sump is clean install the side covers 5 Install the oil suction screen Install the cover and a new seal 6 Change the engine oil filters See this Operation and Maintenance Manual Engine Oil Filter Change topic Maintenance Section 7 Clean the centrifugal oil filters a Disassemble the centrifugal oil filters according to the instructions in the Service Manual b Thoroughly clean all of the parts of the centrifugal oil filter Carefully inspect all of the parts NOTICE Ensure that all of the rotor components are thoroughly clean before assembling the rotor Failure to do so can cause an out of balance condition that can cause rapid wear to the bearings and the spindle Note Install a new paper liner when the centrifugal oil filter is assembled c Assemble the centrifugal oil filters according to the instructions in the Service Manual SEBU6966 06
126. urbocharger Cleaning will help to minimize deposits The cleaning procedure removes light deposits Severe service applications may require more frequent cleaning Consult your Caterpillar dealer about scheduling maintenance for specific applications Note Make several copies of Table 32 for future use 1 Before cleaning the turbocharger record the data for the engine performance in the appropriate cells of Table 32 Compare the data to the data from the engine commissioning If the data is similar cleaning the turbocharger may not be necessary If cleaning is not necessary record new data and compare the data after 25 service hours If cleaning is necessary proceed to Step 2 2 Clean the turbocharger according to Special Instruction SEHS9929 Turbocharger Water Wash Procedure 3 Operate the engine at the load and rpm that was used before the cleaning procedure Record the data for the engine performance in the appropriate cells of Table 32 4 Compare the before data to the after data Also compare the data to the data from the engine commissioning Efficient operation of the turbocharger is indicated by normal ranges for exhaust manifold pressure exhaust port temperature and inlet manifold air pressure If the turbocharger does not function with normal efficiency after this cleaning the turbocharger may require disassembly for a complete mechanical cleaning SEBU6966 06 135 Maintenanc
127. valve springs Fuel injectors Valve spring guides Valve spring locks Valve rotators Note The angles of the valves and seats are different If the valves and seats are not replaced lap the valves and seats The valve and the outer diameter of the seat must have 360 degrees of contact If the valves and the seats require regrinding see the Service Manual Specifications module for the angles 126 Maintenance Section Overhaul Considerations SEBU6966 06 Inspection and or Replacement of Components 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 Replace the components if necessary e Cylinder sleeves e Exhaust shields e Starting motor e Thermocouples Replacement of Components Replace the following components e Connecting rod bearings e Cylinder head gaskets and seals e Exhaust manifold gaskets Fuel transfer pump seals Inlet air lines seals e Oil cooler seals e Oil pump bearings and seals e Oil temperature regulators and seals Turbocharger bearings bushings and seals e Valve lubricator pump if equipped e Water pump bearings and seals e Water temperature regulators and seals Cleaning and Inspection of Components Clean the following components Inspect the components for good c
128. vy fuel oil to distillate fuel The clean distillate fuel will become contaminated with heavy fuel oil while the engine s fuel system is being flushed Adjust the fuel return line in order to return the fuel to the day tank for heavy fuel oil 2 Adjust the fuel bypass valve in order to maintain fuel pressure of 550 to 620 kPa 80 to 90 psi to any engine and or engines that are operating 3 Start the pump for the distillate fuel supply to the engine that is being flushed Monitor the fuel pressure to the engine 4 Monitor the fuel that is returned to the day tank for heavy fuel oil When the fuel that is returning to the tank is not contaminated with heavy fuel oil switch the fuel return line to the day tank for distillate fuel 5 Stop the pump for the distillate fuel supply 6 Close the valves for the fuel supply and the fuel return at the engine Make sure that the valves for the coolant supply and the coolant return for the injector tips are closed Proceed with the maintenance 100937115 Fuel Analysis Obtain SMCS Code 1280 554 The composition of fuel varies between different sources Also the composition of the fuel within a single delivery can vary For these reasons frequent sampling of the fuel is required throughout the engine s fuel system The frequency of sampling and the locations for obtaining the samples will vary because of these factors on site conditions quality of the fuel engine perfo
129. wing components main bearings rod bearings turbocharger bearings and cylinder heads Aluminum debris may indicate problems with the bearings of the front gears If aluminum debris is found inspect the crankshaft vibration damper and the bearings of the front idler gear Due to normal wear and friction 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 102050563 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 LY PA Illustration 104 990748492 1 Oil level gauge dipstick 2 Oil filler i ADD RS FULL ENGINE STOPPED nn nn ADD FULL LOW IDLE Illustration 105 g00748491 3 ENGINE STOPPED WITH OIL COLD side 4 ENGINE AT LOW IDLE WITH WARM OIL side 5 ADD mark 6 FULL mark 1 Ensure that oil level gauge 1 is seated a If the engine is stopped remove oil level gauge 1 Observe the oil level on ENGINE STOPPED WITH OIL COLD side 3 b If the engine is operating reduce the engine speed to low idle Remove oil level gauge 1 and observe the oil level on ENGINE AT LOW

3600 Heavy Fuel Engines-Maintenance Intervals - Safety

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