SEBU6355-03

October 2004

Operation and
Maintenance
Manual
G3500 Engines
3RC1-Up (Engine)
4KC1-Up (Engine)
2JF1-Up (Engine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SEBU6355-03 3
Table of Contents

Table of Contents Reference Materials ............................................ 107

Index Section
Foreword ................................................................. 4
Index .................................................................... 112
Safety Section
Safety Messages .................................................... 6

General Hazard Information ................................. 10

Burn Prevention .................................................... 13

Fire Prevention and Explosion Prevention ............ 13

Crushing Prevention and Cutting Prevention ........ 14

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

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

Before Starting Engine .......................................... 15

Engine Starting ..................................................... 15

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

Product Information Section

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

Product Identification Information ........................ 21

Operation Section
Lifting and Storage ................................................ 23

Gauges and Indicators .......................................... 24

Engine Features and Controls .............................. 27

Engine Starting ..................................................... 46

Engine Operation .................................................. 51

Engine Stopping ................................................... 52

Maintenance Section
Refill Capacities .................................................... 55

Maintenance Interval Schedule (Turbocharged

Aftercooled) ......................................................... 58

Maintenance Interval Schedule (Naturally

Aspirated) ............................................................ 60

Reference Information Section

Customer Service ............................................... 105
4 SEBU6355-03
Foreword

Foreword Use service hours to determine intervals. Calendar

intervals shown (daily, annually, etc) may be used
instead of service meter intervals if they provide more
Literature Information convenient schedules and approximate the indicated
service meter reading.
This manual contains safety, operation instructions,
lubrication and maintenance information. This Recommended service should always be
manual should be stored in or near the engine area performed at the service hour interval. The actual
in a literature holder or literature storage area. Read, operating environment of the engine also governs
study and keep it with the literature and engine the maintenance schedule. Therefore, under
information. extremely severe, dusty, wet or freezing cold
operating conditions, more frequent lubrication and
English is the primary language for all Caterpillar maintenance than is specified in the maintenance
publications. The English used facilitates translation schedule may be necessary.
and consistency in electronic media delivery.
The maintenance schedule items are organized for
Some photographs or illustrations in this manual a preventive maintenance management program. If
show details or attachments that may be different the preventive maintenance program is followed, a
from your engine. Guards and covers may have periodic tune-up is not required. The implementation
been removed for illustrative purposes. Continuing of a preventive maintenance management program
improvement and advancement of product design should minimize operating costs through cost
may have caused changes to your engine which are avoidances resulting from reductions in unscheduled
not included in this manual. Whenever a question downtime and failures.
arises regarding your engine, or this manual, please
consult with your Caterpillar dealer for the latest
available information. Maintenance Intervals
Perform maintenance on items at multiples of the
Safety original requirement. Each level and/or individual
items in each level should be shifted ahead or back
This safety section lists basic safety precautions. depending upon your specific maintenance practices,
In addition, this section identifies hazardous, operation and application. We recommend that
warning situations. Read and understand the basic the maintenance schedules be reproduced and
precautions listed in the safety section before displayed near the engine as a convenient reminder.
operating or performing lubrication, maintenance and We also recommend that a maintenance record be
repair on this product. maintained as part of the engine’s permanent record.

Operation See the section in the Operation and Maintenance

Manual, “Maintenance Records” for information
Operating techniques outlined in this manual are regarding documents that are generally accepted
basic. They assist with developing the skills and as proof of maintenance or repair. Your authorized
techniques required to operate the engine more Caterpillar dealer can assist you in adjusting your
efficiently and economically. Skill and techniques maintenance schedule to meet the needs of your
develop as the operator gains knowledge of the operating environment.
engine and its capabilities.

The operation section is a reference for operators.

California Proposition 65 Warning
Photographs and illustrations guide the operator Battery posts, terminals and related accessories
through procedures of inspecting, starting, operating contain lead and lead compounds. Wash hands after
and stopping the engine. This section also includes a handling.
discussion of electronic diagnostic information.

Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
SEBU6355-03 5
Foreword

Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
programs. If you experience a major engine failure,
there are also numerous after failure overhaul options
available from your Caterpillar dealer. Consult with
your dealer for information regarding these options.
6 SEBU6355-03
Safety Section
Safety Messages

Safety Section
i02115892

Safety Messages
SMCS Code: 1000; 7405

g01077951
Illustration 1

There may be several specific safety messages Replace any safety message that is damaged or
on your engine. The approximate location and a missing. If a safety message is attached to a part
description of the safety messages are reviewed in of the engine that is replaced, install a new safety
this section. Please become familiar with all of the message on the replacement part. Your Caterpillar
safety messages. dealer can provide new safety messages.

Ensure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and Do not operate or work on this engine unless you
soap for cleaning the safety messages. Do not have read and understand the instructions and
use solvents, gasoline, or other harsh chemicals. warnings in the Operation and Maintenance Man-
Solvents, gasoline, or harsh chemicals could loosen ual. Failure to follow the instructions or heed the
the adhesive that secures the safety messages. The warnings could result in injury or death. Contact
safety messages that are loosened could drop off any Caterpillar dealer for replacement manuals.
of the engine. Proper care is your responsibility.
SEBU6355-03 7
Safety Section
Safety Messages

The safety messages that may be attached on the Read the Manual Before Operating
engine are illustrated and described below.
(2)
Coupling (1)

g00306265
Illustration 3

g00305692
Illustration 2 The safety message for reading the manual before
operating the unit is located on the outside of the
The safety message for the coupling is located on door of the control panel.
the sides of the flywheel housing.

Do not operate or work on this engine or genera-

If engine runs and coupling is not properly re- tor set unless you have read and understand the
strained, personal injury or property damage may instructions and warnings in the Operation and
result. Maintenance Manuals.

Before starting engine, do one of the following: Failure to follow the warnings and instructions
could result in injury or death. Contact any
1. Align and couple the equipment. Caterpillar dealer for replacement manuals. Prop-
er care is your responsibility.
2. Remove the loose parts.

3. Center and restrain the loose parts.

8 SEBU6355-03
Safety Section
Safety Messages

Open Vandal Door (3) Hot Pressurized Fluid (4)

The safety message for keeping the vandal door
open during operation is located on the outside of the
door of the control panel.

g00305896

g01061488
Illustration 4
Always operate this unit with the vandal door
open. Operating the unit with the vandal door The safety message for hot pressurized fluid is
closed restricts access to the emergency stop located on the cover of the oil filter.
button and could result in injury or death.

Filter contains hot pressurized fluid when engine

is running. Follow instructions on control valve to
avoid injury if rapid air movement exists to blow
fluid. Stop engine to avoid fire.
SEBU6355-03 9
Safety Section
Safety Messages

Jumper Cable Connections (5) Flash Fire (6)

g00897261 g01061123
Illustration 5 Illustration 6

The safety message for the connections for the The safety messages for flash fire are located on the
jumper cables is located near the electric starting crankcase covers.
motor. This motor can be located on either side of
the engine.

Flash fire may result in personal injury, if

crankcase covers are removed within fifteen
IMPROPER JUMPER CABLE CONNECTIONS CAN minutes after emergency shut down. Do not
CAUSE EXPLOSION RESULTING IN PERSONAL restart engine until cause for shutdown has been
INJURY. corrected.

BATTERIES MAY BE LOCATED IN SEPARATE

COMPARTMENTS. WHEN USING JUMPER CA-
BLES, ALWAYS CONNECT POSITIVE (+) CABLE
TO POSITIVE (+) TERMINAL OF BATTERY CON-
NECTED TO STARTER SOLENOID AND NEGA-
TIVE (-) CABLE FROM EXTERNAL SOURCE TO
STARTER NEGATIVE (-) TERMINAL (IF MACHINE
NOT EQUIPPED WITH STARTER NEGATIVE TER-
MINAL, CONNECT TO ENGINE BLOCK.) FOLLOW
PROCEDURE IN THE OPERATION MANUAL.
10 SEBU6355-03
Safety Section
General Hazard Information

Prelube Pump (7) i02016074

General Hazard Information

SMCS Code: 1000; 4450; 7405

g00306385
Illustration 7

The safety message for the prelube pump is located

on the prelube pump. g00104545
Illustration 8

Attach a “Do Not Operate” warning tag or a similar

warning tag to the start switch or to the controls
Motor must be grounded in accordance with na- before the engine is serviced or before the engine is
tional electrical code and local codes, by trained repaired. These warning tags (Special Instruction,
personnel to prevent serious electrical shocks. SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine and to
Lifting provisions are intended for lifting the motor each operator control station. When it is appropriate,
only. disconnect the starting controls.

Motor has an automatic reset thermal protector. If Do not allow unauthorized personnel on the engine,
motor overheats, thermal protector will open mo- or around the engine when the engine is being
tor circuit. serviced.

After motor cools sufficiently, thermal protector Engine exhaust contains products of combustion
will reset without warning and restart motor. which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
To service motor, disconnect power source from area. If the engine is in an enclosed area, vent the
motor and any accessory devices and allow motor engine exhaust to the outside.
to come to a complete standstill.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.

• Filler caps
• Grease fittings
• Pressure taps
• Breathers
• Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
SEBU6355-03 11
Safety Section
General Hazard Information

Pressure Air and Water

Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.

When pressure air and/or pressure water is used for

cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a protective face shield.

The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
g00702020 275 kPa (40 psi).
Illustration 9

• Wear a hard hat, protective glasses, and other Fluid Penetration

protective equipment, as required.

• When work is performed around an engine that is

operating, wear protective devices for ears in order
to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

• Ensure that all protective guards and all covers are

secured in place on the engine.

• Never put maintenance fluids into glass containers.

Glass containers can break.
g00687600
Illustration 10
• Use all cleaning solutions with care.
Always use a board or cardboard when you check
• Report all necessary repairs. for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
Unless other instructions are provided, perform
serious injury and possible death. A pin hole leak can
the maintenance under the following conditions:
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
• The engine is stopped. Ensure that the engine from a doctor that is familiar with this type of injury.
cannot be started.

• Disconnect the batteries when maintenance Containing Fluid Spillage

is performed or when the electrical system is
serviced. Disconnect the battery ground leads. Care must be taken in order to ensure that fluids
Tape the leads in order to help prevent sparks. are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
• Do not attempt any repairs that are not understood. engine. Prepare to collect the fluid with suitable
Use the proper tools. Replace any equipment that containers before opening any compartment or
is damaged or repair the equipment. disassembling any component that contains fluids.

California Proposition 65 Warning Refer to Special Publication, NENG2500, “Tools and

Shop Products Guide” for the following items:
Some engine exhaust constituents are known to the
State of California to cause cancer, birth defects, and • Tools that are suitable for collecting fluids and
other reproductive harm. equipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids and

equipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

12 SEBU6355-03
Safety Section
General Hazard Information

Asbestos Information • Comply with applicable rules and regulations

for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposal

of asbestos.

• Stay away from areas that might have asbestos

particles in the air.

Softwrap
Keep the engine room ventilation operating at full
Illustration 11
g00702022 capacity. Wear a National Institute of Occupational
Safety and Health (NIOSH) approved particulate
Caterpillar equipment and replacement parts that are respirator. Wear appropriate protective clothing
shipped from Caterpillar are asbestos free. Caterpillar in order to minimize direct contact. Use good
recommends the use of only genuine Caterpillar hygiene practices and wash hands thoroughly after
replacement parts. Use the following guidelines handling softwrap. Do not smoke until washing hands
when you handle any replacement parts that contain thoroughly after handling softwrap. Clean up debris
asbestos or when you handle asbestos debris. with a vacuum or by wet sweeping. Do not use
pressurized air to clean up debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain Reference: The applicable material safety data
asbestos fibers. Inhaling this dust can be hazardous sheets can be found at the following web site by
to your health. The components that may contain searching by the part number or the name of the
asbestos fibers are brake pads, brake bands, lining product:
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually http://dsf2ws.cat.com/msds/servlet/
bound in a resin or sealed in some way. Normal cat.cis.ecs.msdsSearch.controller.
handling is not hazardous unless airborne dust that UserIdentificationDisplayServlet
contains asbestos is generated.
Dispose of Waste Properly
If dust that may contain asbestos is present, there
are several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.

• A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be
used.
g00706404
Illustration 12
• Use exhaust ventilation on permanent machining
jobs. Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
• Wear an approved respirator if there is no other disposed of according to local regulations.
way to control the dust.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
SEBU6355-03 13
Safety Section
Burn Prevention

i02088921 i01027886

Burn Prevention Fire Prevention and Explosion

SMCS Code: 1000; 4450; 7405 Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
A flash fire may result in personal injury if the
is performed on the engine. Relieve all pressure in
crankcase covers are removed within fifteen minutes
the appropriate system before any lines, fittings or
related items are disconnected. after an emergency shutdown.

Fire may result from lubricating oil or from fuel that

Coolant is sprayed on hot surfaces. Fire may cause personal
injury and property damage. Inspect all lines and
When the engine is at operating temperature, the tubes for wear or for deterioration. The lines must
engine coolant is hot. The coolant is also under be properly routed. The lines must have adequate
pressure. The radiator and all lines to the heaters or support and secure clamps. Tighten all connections
to the engine contain hot coolant. Any contact with to the recommended torque. Leaks can cause fires.
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the Determine whether the engine will be operated in an
cooling system is drained. environment that allows combustible gases to be
drawn in through the air inlet system. These gases
Check the coolant level after the engine has stopped could cause the engine to overspeed. This could
and the engine has been allowed to cool. Ensure result in bodily injury, property damage, or damage
that the filler cap is cool before removing the filler to the engine.
cap. The filler cap must be cool enough to touch with
a bare hand. Remove the filler cap slowly in order If the application involves the presence of combustible
to relieve pressure. gases, consult your Caterpillar dealer in order to
obtain additional information concerning suitable
Cooling system conditioner contains alkali. Alkali can protection devices.
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth. Leaking fuel or fuel that is spilled onto hot surfaces or
onto electrical components can cause a fire.
Oils All fuels, most lubricants, and some coolant mixtures
Hot oil and hot lubricating components can cause are flammable. Diesel fuel is flammable. Gasoline is
personal injury. Do not allow hot oil or hot components flammable. The mixture of diesel fumes and gasoline
to contact the skin. fumes is extremely explosive.

If the application has a makeup tank, remove the cap Do not smoke while the engine is refueled. Do not
for the makeup tank after the engine has stopped. smoke in the refueling area.
The filler cap must be cool to the touch.
Store all fuels and all lubricants in properly marked
containers. Store the protective containers in a safe
Batteries place.

The liquid in a battery is an electrolyte. Electrolyte is Do not smoke in battery charging areas. Batteries
an acid that can cause personal injury. Do not allow give off flammable fumes which can explode.
electrolyte to contact the skin or the eyes.
Do not smoke in areas that contain flammable
Do not smoke while checking the battery electrolyte material.
levels. Batteries give off flammable fumes which can
explode. Store oily rags and other flammable material in
protective containers.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The Do not weld on pipes or tubes that contain flammable
use of gloves is recommended. fluids. Do not flame cut pipes or tubes that contain
flammable fluids. Before pipes or tubes are welded
or flame cut, clean the inside and clean the outside
of the pipes or tubes thoroughly with nonflammable
solvent.
14 SEBU6355-03
Safety Section
Crushing Prevention and Cutting Prevention

Do not allow flammable materials to accumulate on Unless other maintenance instructions are provided,
the engine. never attempt adjustments while the engine is
running.
Do not expose the engine to flames.
Stay clear of all rotating parts and of all moving
Exhaust shields (if equipped) protect hot exhaust parts. Leave the guards in place until maintenance
components from oil or fuel spray in case of a line, is performed. After the maintenance is performed,
a tube, or a seal failure. Exhaust shields must be reinstall the guards.
installed correctly.
Keep objects away from moving fan blades. The fan
Dispose of oil according to local regulations. Oil blades will throw objects or cut objects.
filters and fuel filters must be properly installed. The
housing covers must be tightened to the proper When objects are struck, wear protective glasses in
torque when the housing covers are reinstalled. order to avoid injury to the eyes.

Batteries must be kept clean. The covers (if equipped) Chips or other debris may fly off objects when objects
must be kept on the cells. Use the recommended are struck. Before objects are struck, ensure that no
cables, connections, and battery box covers when one will be injured by flying debris.
the engine is operated.
i01372247
Check the electrical wires daily for wires that are
loose or frayed. Before the engine is operated,
tighten all loose electrical wires. Repair all frayed
Mounting and Dismounting
electrical wires. SMCS Code: 1000; 4450; 7405
Wiring must be kept in good condition. Wires must Inspect the steps, the handholds, and the work area
be properly routed and securely attached. Routinely before mounting the engine. Keep these items clean
inspect the wiring for wear or for deterioration. Loose and keep these items in good repair.
wiring, unattached wiring, or unnecessary wiring
must be eliminated. All wires and all cables must be Mount the engine and dismount the engine only at
of the recommended gauge. Do not use a wire or a locations that have steps and/or handholds. Do not
cable that is smaller than the recommended gauge. climb on the engine, and do not jump off the engine.
The wires and cables must be connected to a fuse or
to a circuit breaker, as required. Do not bypass fuses Face the engine in order to mount the engine or
and/or circuit breakers. Arcing or sparking could dismount the engine. Maintain a three-point contact
cause a fire. Secure connections, recommended with the steps and handholds. Use two feet and one
wiring, and properly maintained battery cables will hand or use one foot and two hands. Do not use any
help prevent arcing or sparking. controls as handholds.

Fire Extinguisher Do not stand on components which cannot support

your weight. Use an adequate ladder or use a work
Ensure that fire extinguishers are available. Be platform. Secure the climbing equipment so that the
familiar with the operation of the fire extinguishers. equipment will not move.
Inspect the fire extinguishers and service the fire
extinguishers regularly. Service the fire extinguisher Do not carry tools or supplies when you mount the
according to the recommendations on the instruction engine or when you dismount the engine. Use a hand
plate. line to raise and lower tools or supplies.

i01359666 i00702251

Crushing Prevention and Ignition Systems

Cutting Prevention SMCS Code: 1550
SMCS Code: 1000; 4450; 7405 Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and
Support the component properly when work beneath wiring.
the component is performed.
SEBU6355-03 15
Safety Section
Before Starting Engine

Do not attempt to remove the valve covers when the If there is a possibility that unburned gas remains in
engine is operating. The transformers are grounded the exhaust system, refer to the purge procedure in
to the valve covers. Personal injury or death may this Operation and Maintenance Manual, “Engine
result and the ignition system will be damaged if the Starting” topic in the Operation Section.
valve covers are removed during engine operation.
The engine will not operate without the valve covers. Start the engine from the operator’s compartment or
from the engine start switch.
i00659904
Always start the engine according to the procedure
Before Starting Engine that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
SMCS Code: 1000 Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Inspect the engine for potential hazards. Knowing the procedure will also help to prevent
personal injury.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the To ensure that the jacket water heater (if equipped)
area is free of personnel. and/or the lube oil heater (if equipped) is working
properly, check the water temperature and the oil
Ensure that the engine is equipped with a lighting temperature during heater operation.
system that is suitable for the conditions. Ensure that
all lights work properly. Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
All protective guards and all protective covers must engine and operate the engine in a well ventilated
be installed if the engine must be started in order area. If the engine is started in an enclosed area,
to perform service procedures. To help prevent an vent the engine exhaust to the outside.
accident that is caused by parts in rotation, work
around the parts carefully. i00659907

Do not bypass the automatic shutoff circuits. Do not Engine Stopping

disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The SMCS Code: 1000
circuits are also provided in order to help prevent
engine damage. To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
On the initial start-up of a new engine or an engine according to the instructions in this Operation and
that has been serviced, be prepared to stop the Maintenance Manual, “Engine Stopping” topic
engine if an overspeed condition occurs. This may (Operation Section).
be accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system. Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency
See the Service Manual for repairs and for Stop Button for normal engine stopping. After an
adjustments. emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corrected.
i02136012

Engine Starting On the initial start-up of a new engine or an engine

that has been serviced, make provisions to stop
SMCS Code: 1000 the engine if an overspeed occurs. This may be
accomplished by shutting off the fuel supply to the
If a warning tag is attached to the engine start switch engine, or shutting off the ignition system.
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.

All protective guards and all protective covers must

be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
16 SEBU6355-03
Product Information Section
Model Views and Specifications

Product Information
Section

Model Views and

Specifications
i01626872

Model View Illustrations

SMCS Code: 1000; 4450

The illustrations show various typical features of

G3500 Engines. The illustrations do not show all of
the options that are available.
SEBU6355-03 17
Product Information Section
Model Views and Specifications

g00842723
Illustration 13
(1) Exhaust bypass (8) Oil filler (15) Exhaust
(2) Aftercooler (9) Lifting eye (16) Turbocharger
(3) Instrument panel (10) Oil level gauge (dipstick) (17) Auxiliary water pump
(4) Crankcase breather (11) Air cleaner (18) Gas shutoff valve
(5) Oil filter (12) Jacket water pump (19) Gas regulator
(6) Guard (crankshaft vibration damper) (13) Oil screen (20) Flywheel housing
(7) Engine control module (ECM) (14) Oil drain

i01627027 Fuel System

Product Description The engines can be equipped with a high pressure
SMCS Code: 1000; 4450 gas fuel system or a low pressure gas fuel system.
Three different fuel systems are available:
The Caterpillar G3500 Engines were developed
in order to provide gas engines for industrial • Low Emission (LE) with high pressure gas
applications and for generator set applications. The
engines have the ability to burn a wide variety of • LE with low pressure gas
gaseous fuels.
• Standard (stochiometric) with high pressure gas
18 SEBU6355-03
Product Information Section
Model Views and Specifications

The LE engine with high pressure gas requires Ignition System

a gas pressure within a range of 207 to 310 kPa
(30 to 45 psi). The air/fuel ratio is adjusted so that The engine is equipped with an Electronic Ignition
there is excess oxygen in the engine exhaust. This System (EIS). The EIS provides dependable firing
reduces the NOx emissions. and low maintenance. The EIS provides precise
control of the following factors:
The LE engine with low pressure gas requires a gas
pressure within a range of 10 to 34 kPa (1.5 to 5 psi). • Spark voltage
The LE engines with NOx ratings of two grams have • Spark duration
a nominal air/fuel ratio that results in approximately
eight percent of free oxygen in the exhaust. The LE • Ignition timing
engines are turbocharged and aftercooled.
The EIS also provides diagnostic capability that
The Standard engines require gas pressure within a enhances troubleshooting. The primary ignition wiring
range of 138 to 172 kPa (20 to 25 psi). The nominal is routed internally through the engine.
air/fuel ratio results in approximately two percent of
free oxygen in the exhaust. The Standard engines The engines are equipped with protection from
are available with natural aspiration or turbocharged detonation (combustion knock). The detonation
with aftercooling. sensors are mounted on each side of the cylinder
block. The ignition timing is retarded when excessive
The engines can be equipped with a dual fuel system detonation is sensed. If detonation continues after full
in one of the following configurations: retardation, then the engine control module (ECM)
shuts down the engine.
• A carburetor for high pressure gas and a carburetor
for low pressure gas
Lubrication System
• Two parallel carburetors for low pressure gas The engine lubrication oil is supplied by a pump
that is driven by a gear. The oil is cooled and the
For low pressure gas engines, the carburetor is
oil is filtered. A bypass valve provides unrestricted
located between the air cleaner and the turbocharger.
flow of lubrication oil to the engine parts if the oil
For high pressure gas engines, the carburetor is
filter elements become plugged. The bypass valve
located after the aftercooler and above the throttle.
will open if the oil filter differential pressure reaches
A governor and an actuator controls the carburetor.
276 kPa (40 psi).
The governor maintains the engine rpm. The two
following types of carburetors are available:
Cooling System
• Fixed venturi
The standard cooling system has a centrifugal pump
• Adjustable jet that is driven by a gear. Four temperature regulators
regulate the temperature of the coolant.
The low pressure gas engines can use either the
fixed venturi or the adjustable jet. Standard engines The turbocharged engine has a Separate Circuit
and LE engines with high pressure gas use the Aftercooler (SCAC). The aftercooler is required to
adjustable jet. operate at one of the following three temperatures.
The temperature depends on the engine rating and
The turbocharged aftercooled engines are equipped the application.
with flame arrestors. The flame arrestors are installed
at the entrance of each inlet port. The flame arrestors • 32 °C (90 °F)
prevent the engine backfire. The Engine backfire can
occur in the following circumstances: • 54 °C (129 °F)
• Malfunction of ignition • 70 °C (158 °F)
• Engine shutdown
The flame arrestors will extinguish the flame before
the flame can ignite in the inlet manifold.
SEBU6355-03 19
Product Information Section
Model Views and Specifications

Cogeneration uses energy from heat which would i02117082

otherwise be wasted. In a cogeneration engine, the
oil cooler is not in the jacket water circuit because Specifications
the jacket water is too hot. The circuit for the oil
cooler and the circuit for the aftercooler may be SMCS Code: 1000
either a combined circuit or a separate circuit. In
Table 1
the combined system, the auxiliary pump circulates
water through both the aftercooler and oil cooler Engine Specifications
cores. The combined system uses a thermostatic
G3508 G3512 G3516
control to regulate the oil temperature. This prevents
overcooling. Rated rpm 1000 to 1500
Cylinders 65 degree 65 degree 65 degree
Jacket water for cogeneration can be supplied and Vee 8 Vee 12 Vee 16
at temperatures up to 127 °C (260 °F max). The arrangement
customer must supply a pump for circulating the
heated jacket water. The temperature of the jacket Bore 170 mm (6.7 inch)
water is controlled by the customer. Stroke 190 mm (7.5 inch)

For engines that use landfill gas, the jacket water Displacement 34.5 L 51.8 L 69 L
coolant temperature is maintained at approximately (2105 in3) (3158 in3) (4210 in3)
110 °C (230 °F min). This temperature depends on Compression Standard 9:1
the design of the cooling system and the ambient Ratio
conditions. This temperature is required in order to Low Emission 11:1
prevent condensation of the water vapor that is in the Aspiration Naturally aspirated
fumes of the crankcase. Condensation of the water
enables acids to form. Acids are more likely to form Turbocharged aftercooled
because landfill gas contains contaminants such as Separate circuit aftercooling
chlorides, fluorides, and halides. Acids will cause Rotation Counterclockwise
severe internal damage to the engine. (flywheel
end)
For engines that use landfill gas, the coolant that
Firing Order 1-2-7-3-4- 1-12-9-4- 1-2-5-6-3-
is supplied to the aftercooler is maintained at
5-6-8 5-8-11-2-3- 4-9-10-15-
a temperature of 54 °C (129 °F). This prevents 10-7-6 16-11-12-
condensation of moisture in the inlet air piping. 13-14-7-8
Inlet valve 0.51 mm (0.020 inch)
Engine Service Life lash

Engine efficiency and maximum utilization of engine Exhaust 1.02 mm (0.040 inch)
performance depend on adherence to proper valve lash
operation and maintenance recommendations. This
includes the use of recommended lubricants, fuels,
and coolants.

For the engine maintenance that is required,

refer to the Operation and Maintenance Manual,
“Maintenance Interval Schedule” in the Maintenance
Section.

g00845204
Illustration 14
(A) Inlet valves
(B) Exhaust valves
(C) Flywheel
20 SEBU6355-03
Product Information Section
Model Views and Specifications

g00845207
Illustration 15
(A) Inlet valves
(B) Exhaust valves
(C) Flywheel

g00845212
Illustration 16
(A) Inlet valves
(B) Exhaust valves
(C) Flywheel
SEBU6355-03 21
Product Information Section
Product Identification Information

Product Identification i02135788

Information Reference Information

SMCS Code: 1000; 4450
i02117168
Identification of the items in Table 2 may be needed
Plate Locations and Film in order to obtain parts and service. Some of the
Locations numbers are on the engine Serial Number Plate
and/or Information Plate. Locate the information
SMCS Code: 1000; 4450 for your engine. Record the information on the
appropriate space in Table 2. Make a copy of this
list for a record. Retain the information for future
Engine Identification reference.
Caterpillar engines are identified with serial numbers, The top level part numbers in the Parts Manual for
with performance specification numbers, and with the engine are listed with the engine arrangement
arrangement numbers. In some of the cases, number.
modification numbers are used. These numbers
are shown on the Serial Number Plate and the The packaging arrangement may also be called a
Information Plate that are mounted on the engine. pricing arrangement or a customer arrangement. This
is the total package with attachments and options
Caterpillar dealers need these numbers in order to that are not included in the engine arrangement.
determine the components that were included with
the engine. This permits accurate identification of The performance specification can be used by
replacement part numbers. your Caterpillar dealer with the Technical Marketing
Information system. Before the engine leaves the
factory, the engine performance is tested. Detailed
performance data is recorded. The performance
specification number can be used for obtaining the
data.

g01078319
Illustration 17

Serial Number Plate (1)

The Serial Number Plate is on the left side of the
cylinder block near the front of the engine.

The following information is stamped on the Serial

Number Plate: engine serial number, model, and
arrangement number.

Information Plate (2)

The Information Plate is on the left side top surface of
the cylinder block in front of the front cylinder head.

The following information is stamped on the

Information Plate: compression ratio, aftercooler
temperature, power (kilowatts and horsepower), full
load rpm, and other information.
22 SEBU6355-03
Product Information Section
Product Identification Information

Table 2
Reference Numbers
Engine Model
Serial Number
Arrangement Number
Packaging Arrangement
Turbocharger
Fuel Filter Element
Lubrication Oil Filter
Element
Auxiliary Oil Filter Element
Air Cleaner Element
Fan Drive Belt
Alternator Belt
Capacity of the Lubrication
System
Oil type
Capacity of the Cooling
System
Performance Specification
Number
Low Idle rpm
High Idle rpm
Full Load rpm
Power Rating
SEBU6355-03 23
Operation Section
Lifting and Storage

Operation Section i02115127

Product Storage
Lifting and Storage SMCS Code: 7002

Engine Storage
i02108082

Product Lifting If the engine will not be started for several weeks, the
lubricating oil will drain from the cylinder walls and
SMCS Code: 7000; 7002 from the piston rings. Rust can form on the cylinder
liner surface, which will increase engine wear which
can reduce engine service life.

To help prevent excessive engine wear, use the

following guidelines:

• Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).

• If freezing temperatures are expected, check the

cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
Illustration 18
g00103219 (Maintenance Section).

If an engine is out of operation and if use of the engine

NOTICE
is not planned, special precautions should be made.
Never bend the eyebolts and the brackets. Only load
If the engine will be stored for more than one month,
the eyebolts and the brackets under tension. Remem-
a complete protection procedure is recommended.
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
If the power module will be stored for more than six
comes less than 90 degrees.
months the fuel system must also be purged:
When it is necessary to remove a component at an
1. Remove the flange for the fuel inlet to the power
angle, only use a link bracket that is properly rated for
module.
the weight.
2. Remove the fuel filter plug “A”.
Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All 3. Use a dry air supply (10 psi max) to purge the
supporting members (chains and cables) should be fuel lines.
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being Your Caterpillar dealer will have instructions for
lifted. preparing the engine for extended storage periods.

Some removals require lifting the fixtures in order to For more detailed information on engine storage, see
obtain proper balance and safety. Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”.
To remove the engine ONLY, use the lifting eyes that
are on the engine.

Lifting eyes are designed and installed for the specific

engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.
24 SEBU6355-03
Operation Section
Gauges and Indicators

Gauges and Indicators Jacket Water Coolant Temperature –

This gauge indicates the temperature of the
i01663514 engine coolant at the outlet for the jacket
water. The temperature may vary according to the
Gauges and Indicators load. The temperature should never be allowed to
exceed the boiling temperature of the pressurized
SMCS Code: 7450 cooling system. The operating range is 88 to 100 °C
(190 to 210 °F). Higher temperatures may occur
Gauges provide indications of engine performance. under certain conditions. Engines that use fuel with
Ensure that the gauges are in good working order. a low Btu content may have temperatures up to
Determine the normal operating range by observing 110 °C (230 °F). Cogeneration engines may have a
the gauges over a period of time. maximum temperature up to 127 °C (260 °F).

Noticeable changes in gauge readings can indicate

The engine should operate within the normal
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change temperature range. The sensor for jacket water
even if the readings are within specifications. coolant temperature must be fully submerged in order
to detect the temperature correctly. If the engine
Determine and correct the cause of any significant
change in the readings. Consult your Caterpillar is operating above the normal temperature range,
dealer for assistance. perform the following procedure:

Your engine may not have the same gauges or all of 1. Reduce the load and/or the engine rpm.
the gauges that are described below.
2. Inspect the cooling system for leaks.

NOTICE 3. Determine if the engine must be shut down

If no oil pressure is indicated, STOP the engine. The immediately or if the engine can be cooled by
engine will be damaged from operating without oil reducing the load and/or rpm.
pressure.
Inlet Manifold Air Temperature – This
gauge indicates the inlet manifold air
Engine Oil Pressure – This gauge
temperature to the cylinders. The sensor
indicates the pressure of the engine oil. This
for inlet manifold air temperature is located after the
pressure will be highest after a cold engine
aftercooler.
is started. The pressure will decrease as the engine
warms up. The pressure will increase when the
engine rpm is increased. The pressure will stabilize NOTICE
when the engine rpm and temperature are stable. High inlet manifold air temperature increases the risk
The typical range at low idle rpm is 186 to 344 kPa of detonation. Detonation can cause damage to the
(27 to 50 psi). The typical range at rated rpm is engine. Ensure that the aftercooling system is operat-
345 to 600 kPa (50 to 87 psi). ing properly.

Oil Filter Differential Pressure – This For operating temperatures and shutdown
gauge indicates the difference in pressure temperatures, see this Operation and Maintenance
between the inlet side and the outlet side of Manual, “Alarms and Shutoffs” topic (Operation
the engine oil filters. As the oil filter elements become Section).
plugged, the pressure will increase. Replace the
engine oil filter elements when the oil filter differential Inlet Manifold Air Pressure (TA
pressure reaches 103 kPa (15 psi). Engines) and Inlet Manifold Vacuum
(NA Engines) – For TA engines, this
gauge indicates the air pressure (turbocharger
boost pressure) in the air plenum (air inlet manifold)
after the aftercooler. For NA engines, this gauge is
the pressure of the inlet manifold vacuum. For all
engines, this pressure depends on the engine rating,
the load, and the operating conditions.

The display on the engine panel is the gauge

pressure. The gauge pressure is the difference
between the barometric pressure and the absolute
pressure.
SEBU6355-03 25
Operation Section
Gauges and Indicators

The Digital Diagnostic Tool can be used to display the

pressure that is sensed by the manifold air pressure NOTICE
sensor. If the engine is operating, the display is the An overspeed can result in serious damage to the en-
absolute pressure. If the engine is not operating, the gine. To help prevent engine damage, never allow the
display is the barometric pressure. engine to exceed the rated rpm.

Note: For more information on Inlet Manifold Air

Pressure and Inlet Manifold Vacuum, see one of the Note: The rated rpm is stamped on the engine
following two publications: Information Plate.

• Engine Performance, LEBQ6117, “G3500 Service Hour Meter – The meter indicates
Industrial” the total number of clock hours of engine
operation.
• Engine Performance, LEBQ6169, “G3500
Generator Set” Fuel Filter Differential Pressure – This gauge is
provided by the customer. This gauge indicates the
Pyrometer – The pyrometer indicates the exhaust difference in fuel pressure between the inlet side
stack temperature at the exhaust elbows. For engines and the outlet side of the fuel filter. As the fuel filter
with two exhaust stacks, the two exhaust stack element becomes plugged, the difference in pressure
temperatures may vary slightly. This may be due to between the two sides of the fuel filter increases.
variation of the sensitivity of the two thermocouples.
For high pressure gas fuel systems, service the fuel
• For Low Emission engines, the nominal exhaust filter when the fuel filter differential pressure reaches
stack temperature is less than 554 °C (1030 °F). 34 kPa (5 psi).

• For Standard engines, the nominal exhaust stack For low pressure gas fuel systems, service the
temperature is less than 510 °C (950 °F). fuel filter when the fuel filter differential pressure
reaches1.7 kPa (.25 psi).
• The exhaust stack temperature of NA engines
depends on the engine rpm and the oxygen that is
in the exhaust. For NA engines, the nominal range Optional Gauges
is 538 to 649 °C (1000 to 1200 °F).
Air Cleaner Differential Pressure –
The pyrometer also indicates the temperature of This gauge indicates the difference in air
the exhaust gas of each individual cylinder. These pressure between the inlet side and the
temperatures are measured at the exhaust port of engine side of the air filter element. The pressure
each cylinder head. The exhaust temperature will is measured from the turbocharger air inlet. As the
vary slightly between the cylinders. Table 3 lists air filter element becomes plugged, the difference
nominal temperatures and maximum temperatures. in pressure between the two sides of the air
cleaner element will increase. For optimum engine
Table 3 performance, replace the air filter elements or clean
the air filter elements when the air cleaner pressure
Exhaust Port Temperatures differential reaches 2.5 kPa (10 inches of H2O).
Engine Nominal Maximum Maximum air cleaner differential pressure is 3.7 kPa
Temperature Temperature (15 inches of H2O).
Low Emission 621 °C (1150 °F) 670 °C (1238 °F)
Ammeter – This gauge indicates the
Standby (Low amount of charge or discharge in the
621 °C (1150 °F) 700 °C (1292 °F)
Emission ) battery charging circuit. Operation of the
Standard 643 °C (1190 °F) 700 °C (1292 °F) indicator should be to the right side of “0”(zero).
Standby
643 °C (1190 °F) 730 °C (1346 °F) Engine Oil Temperature – This gauge
(Standard )
indicates the engine oil temperature after
the oil has passed through the oil cooler.
Tachometer – This gauge indicates the The oil cooler is thermostatically controlled. The
engine rpm. oil temperature is controlled by an 82 °C (180 °F)
temperature regulator that is in contact with the oil.
The maximum oil temperature at rated rpm and rated
load is 104 °C (220 °F).
26 SEBU6355-03
Operation Section
Gauges and Indicators

Coolant Pressure – This gauge can be

used for jacket water pressure or auxiliary
water pressure. On cogeneration engines,
this gauge is a differential pressure gauge.
SEBU6355-03 27
Operation Section
Engine Features and Controls

Engine Features and Gas Pressure Regulator

Controls The gas pressure regulator maintains a pressure

differential between the air and the fuel that is
supplied to the carburetor. Set the pressure of the fuel
i02015329 supply to a maximum of 1.5 kPa (6 inch of H2O) more
Performance Parameters than the pressure of the air supply. The gas pressure
regulator will maintain the pressure differential in
SMCS Code: 1000 response to changes in the air pressure. If high idle
is important, lower the differential pressure to 1 kPa
(4 inch of H2O). The higher differential pressures will
Note: For information on the following topics, see
the Service Manual, “Systems Operation/Testing and give better engine response to load changes.
Adjusting” or see Special Instruction, SEHS9769,
A water manometer is used to measure the pressure
“Installation and Initial Start-Up Procedure for G3500
Engines”. differential. This measurement is taken when the
engine is operating at high idle rpm. When a load is
applied, the fuel pressure will usually decrease by
• Adjusting the carburetor approximately 0.25 to 0.5 kPa (1 to 2 inch of H2O).
If the performance of the gas pressure regulator
• Adjusting the control linkage for the carburetor is erratic, the gas pressure regulator may require
service.
• Adjusting the exhaust bypass
Consult your Caterpillar dealer for assistance. Temperature of the Fuel Supply
Changes in the temperature of the fuel supply affects
Air/Fuel Ratio the air/fuel ratio. Warmer fuel is less dense than cold
fuel. This results in a leaner mixture that causes a
The correct air/fuel ratio is very important for the noticeable reduction of power. The recommended
following considerations: temperature differential of the air and the fuel is
2.8 °C (5 °F).
• Margin of detonation
The maximum fuel temperature depends on the
• Control of emissions temperature regulator of the aftercooler:
• Achieving optimum service life for the engine • For engines with a 32 °C (90 °F) aftercooler, the
maximum temperature of the air/fuel mixture is
If the air/fuel ratio is not appropriate for the fuel and 38 °C (100 °F).
the operating conditions, a failure of the engine may
occur. The service life of the turbocharger, the valves,
and other components may be reduced.
• For engines with a 54 °C (130 °F) aftercooler, the
maximum temperature of the air/fuel mixture is
60 °C (140 °F).
Fuel Supply Pressure
For more information, see Application and Installation
Fluctuations of the fuel pressure can change the Guide, LEKQ7260, “Low BTU Engines”. Consult your
air/fuel ratio. For high pressure gas fuel systems, Caterpillar dealer for assistance.
the maximum fluctuation that is allowed in the fuel
pressure is 3.4 kPa (0.50 psi). For low pressure gas Temperature of the Air Supply
fuel systems, the maximum fluctuation that is allowed
in the fuel pressure is 1.7 kPa (0.25 psi). Ensure Changes in the temperature of the air supply affects
a stable fuel pressure to the engine by installing the air/fuel ratio. In addition to seasonal changes,
a second gas pressure regulator prior to the gas the air temperature changes overnight. Control of the
pressure regulator on the engine. temperature in the engine room will help to maintain
the air/fuel ratio.

To optimize the inlet air temperature, use ducting and

a heat exchanger. This will help to avoid exposure
to hot air from a generator. For more information,
see Application and Installation Guide, LEKQ7250,
“Air Intake”. Consult your Caterpillar dealer for
assistance.
28 SEBU6355-03
Operation Section
Engine Features and Controls

Carburetor • Throttle actuator

Engines That Use Bio-Gas • Input switches
The carburetor that is used on some applications For more information regarding the Air/Fuel
tends to supply a rich air/fuel mixture during partial Ratio Control, see the Service Manual, “Systems
load operation. The rich air/fuel mixture and rapid Operation/Testing and Adjusting”.
loading can cause detonation. This depends on the
following factors:
Angle of the Throttle Plate
• Temperature of the inlet air and fuel The angle of the throttle plate is adjusted for full
load operation. The angle is adjusted by changing
• Btu of the fuel the setting of the exhaust bypass valve. The proper
angle depends on the type of governor or actuator
• Air/fuel setting that is used.
• Carburetor jet • For the Woodward 3161 Governor and the EG3P
Actuator, adjust the angle of the throttle plate
• Ignition timing between 60 and 65 degrees.
• Deposits in the combustion chamber The following factors affect the angle of the throttle:
To reduce the risk of detonation during loading, adjust
the ramp time so that the load is applied over five • LHV of the fuel
to ten minutes.
• Setting of the air/fuel ratio (inlet manifold air
pressure)
If detonation still occurs, or if startability is inhibited,
the air/fuel ratio for partial load operation can be
made leaner. Install 7E-1569 Washers behind each • Setting of the exhaust bypass (wastegate)
gas valve of the carburetor. Use a maximum of three
washers per valve. After the washers are installed, • Altitude
adjust the setting for the oxygen at full load.
Ensure that the angle of the throttle plate is properly
set. This will maintain the margin for detonation. This
Optional Air/Fuel Ratio Control will also enable the engine to accept load changes
without lugging.
The engine may be equipped with an air/fuel ratio
control system. The system provides the following
capabilities:
Setting of the Exhaust Bypass
(Wastegate)
• Control of exhaust emissions
The engines are equipped with exhaust bypass
• Adjustment for changes in the fuel BTU valves that are adjustable. This enables the throttle
position to be correctly set for the application.
• Engine speed governing Adjustments must be made for the following
variables:
The system consists of the following components:
• Altitude
• Electronic Control Module (ECM)
• Setting of the air/fuel ratio
• Oxygen sensor
• Methane number of the fuel
• Oxygen buffer
The exhaust bypass is adjusted in order to achieve
• Speed sensor the proper angle of the throttle plate when the engine
is operating under a rated load.
• Inlet manifold pressure sensor
Oil Consumption
• Inlet manifold temperature sensor
High loads will cause the engine to consume more oil.
• Fuel valve
SEBU6355-03 29
Operation Section
Engine Features and Controls

The rate of oil consumption is called the Brake • Precise control of ignition timing
Specific Oil Consumption (BSOC). The unit of
measure is grams per brake kilowatt hour (pounds The electronic ignition system provides control for the
per brake horsepower hour). The BSOC depends on following activities:
the following factors: engine model, aspiration, and
operating load. • Diagnostics of the engine control system
Table 4 lists the normal mid-life BSOC for G3500 • Ignition timing
Engines under the following conditions:
• Protection from detonation
• Load factor of 100 percent
If operating parameters are outside of acceptable
• Maintenance is performed according to this limits, the electronic ignition system provides
Operation and Maintenance Manual, “Maintenance warnings. The system may inhibit the engine
Interval Schedule” (Maintenance Section). operation or may shut down the engine. Also, the
system can display some of the operating parameters
Table 4 of the engine.
BSOC for G3500 Engines
The electronic ignition system includes the following
Naturally Aspirated Engine 0.913 g/bkw h components:
(0.0015 lb/bhp h)
Turbocharged Aftercooled Engine 0.426 g/bkw h • Detonation sensors
(0.0007 lb/bhp h)
• EIS control module
i02015359 • Engine speed/timing sensor
Sensors and Electrical • Ignition harness
Components • Manifold air pressure sensor
SMCS Code: 1900; 7400
• Sensor harnesses
Note: This section contains some general information
about the engine electronic system and sensors. For • Spark plugs
more information, see the following publications:
• Transformers
• Systems Operation/Testing and Adjusting,
SENR6412, “G3500 Engines” Control of the Electronic Ignition System

• Specifications, SENR6417, “G3500 Engine

Attachments”

• Systems Operation/Testing and Adjusting,

SENR6418, “G3500 Engine Attachments”

• Electronic Troubleshooting, SENR6413, “G3500

Engines”

Electronic Ignition System (EIS)

The Caterpillar Electronic Ignition System was
designed to replace the type of ignition system that
has a magneto. The following benefits are the most Illustration 19
g00309805
significant advantages of the electronic ignition
EIS control module
system:

• Addition of more extensive system diagnostics

• Elimination of parts that are prone to mechanical
wear
30 SEBU6355-03
Operation Section
Engine Features and Controls

The EIS control module is a sealed unit with no Junction Box

serviceable parts. Sensors are used in order to
monitor engine operation. Wiring harnesses connect
the sensors to the control module. The module uses
information from the sensors in order to determine
the ignition timing. The information is also used to
provide diagnostics.

Note: On newer engines, there is a small door on

the front face of the control module. Replace the
computer chip inside the control module if updates or
special modifications are required.

The primary ignition wiring is routed through the

engine block. Ignition timing is based on the following
variables: g00787967
Illustration 20
• Map of ignition timing that is desired (1) Junction box
(2) Emergency stop button
• Engine parameters
Junction box (1) contains these components:
The operator can use an electronic service tool to
change the following parameters: • Gauges

• Desired timing • Meters

• Map of speed and timing • Indicators

The EIS control module has outputs to each ignition • Switches
transformer. The module also uses sensors and
internal circuitry to monitor the system components. The junction box also contains the electrical terminal
If a problem develops in a component or a wiring strips that connect the sensors, pickups, and relays
harness, the control module will sense the problem. to the gauges. In addition, the junction box provides
The control module will notify the operator by creating shutoff protection for the engine.
a diagnostic code.
Emergency stop button (2) is mounted on the junction
box. When this button is pressed, both the fuel and
Ignition Transformers the ignition are shut off.
Each cylinder has an ignition transformer that is
located under the valve cover. To initiate combustion NOTICE
in each cylinder, the engine control module sends a Do not use this method to stop the engine unless
pulse to the primary coil of the ignition transformer. an emergency has occurred. Continuous emergency
The transformer increases the voltage which creates shutdowns can cause damage to some engine com-
a spark across the spark plug electrode. ponents. This will leave unburned fuels in the combus-
tion chambers and in the exhaust system. If an emer-
For the electronic ignition system, the transformers gency shutdown occurs, purge the system by cranking
are grounded through the valve cover. Use caution the engine for 5 to 10 seconds with the ignition shutoff.
when a valve cover is removed.
The emergency stop button must be reset before
Always disconnect the ignition harness from the
the engine will start. Turn the button clockwise. The
transformer when a valve cover is removed.
spring-loaded button will move to the reset position.
An ignition harness connects each transformer to the
G3500 Engines use an energize-to-run system.
engine control module. The harness is routed inside
The system can also be configured as an
the engine along the camshaft.
energize-to-shutoff system.
SEBU6355-03 31
Operation Section
Engine Features and Controls

g00310783
Illustration 21
Gas shutoff valve (GSOV)

For an energize-to-run system, the gas shutoff valve

(GSOV) must remain energized in order to supply
fuel to the engine.
g00851236
Illustration 22
For an energize-to-shutoff system, the GSOV must
be energized in order to shut off the fuel to the engine. The coolant level sensor is mounted in the expansion
tank. If the coolant level is too low, the sensor can
The junction box is used to monitor the following activate an alarm or a shutoff. Coolant must be added
parameters: to the cooling system in order to correct the condition.
• Engine oil pressure
Detonation
• Engine coolant temperature
If the engine oil pressure is too low, or if the coolant
temperature is too high, a relay will shut off the fuel.

Sensors
Sensors provide information to the junction box and
the engine control module. The information enables
the module to control the engine as efficiently as
possible over a wide range of operating conditions.
The information is used for monitoring engine
operation via gauges and indicators on the junction
box and/or the control panel.
g00455704
Illustration 23
The sensors also enable the activation of alarms and Detonation sensor
shutoffs in response to abnormal operation.
The detonation sensors monitor the engine for
Air Inlet Temperature detonation. One sensor is mounted in the center of
each cylinder bank. The sensor produces a voltage
A probe for monitoring the air inlet temperature is signal that is proportional to the engine detonation.
located in the air inlet manifold. No adjustment can This information is processed by the engine control
be made to the temperature range. Excessive inlet module in order to determine detonation levels. To
air temperature can activate an alarm or a shutdown. eliminate detonation, the engine control module
retards the engine timing, if necessary. If excessive
Coolant Level detonation continues, the engine control module will
shut down the engine.
Monitoring of the coolant level is an optional
attachment.
32 SEBU6355-03
Operation Section
Engine Features and Controls

Engine Oil Pressure Manifold Air Pressure

g00455784 g00309908
Illustration 24 Illustration 26
Oil pressure sensor Manifold air pressure sensor

The engine oil pressure sensor is located in the side The manifold air pressure sensor is connected to the
of the engine block. The sensor measures the oil air inlet manifold. The sensor monitors the absolute
pressure in the bearing oil gallery. Low oil pressure manifold air pressure. This is the atmospheric
will cause a shutdown. pressure plus the gauge pressure. The information is
used by the engine control module to determine the
engine load. The output of the sensor can be read
Engine Speed/Timing Sensor with the Digital Diagnostic Tool.

Overspeed

g00309907
Illustration 25
Engine speed/timing sensor
g00318743
Illustration 27
The engine speed/timing sensor provides accurate
information about the speed of the crankshaft and the (1) Magnetic pickup for the governor
(2) Magnetic pickup for the service meter
position of the crankshaft. A ring that is mounted on
the camshaft provides the information that is detected
by the sensor. The engine control module uses the Two magnetic pickups are mounted in the flywheel
information in order to determine ignition timing. housing. The magnetic pickups monitor the rpm of
the flywheel ring gear. The following conditions will
cause a shutdown:

• The engine rpm exceeds the setpoint for

overspeed.

• The control system does not receive a signal from

the magnetic pickup.
SEBU6355-03 33
Operation Section
Engine Features and Controls

Water Temperature

Unburned gas in the air inlet and exhaust system

may ignite when the engine is started. Personal
injury and/or property damage may result.

Before starting an engine that may contain un-

burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.

If an engine protective device shuts off the engine,

always determine the cause of the shutoff. Make
the necessary repairs before attempting to start the
g00455866
Illustration 28 engine.
Water temperature sensor
Become familiar with the following information:
The water temperature sensor is located in the
water temperature regulator housing. To monitor • Types of the alarm and shutoff controls
the coolant temperature, the element must be in
contact with the coolant. If overheating occurs due to • Locations of the alarm and shutoff controls
low coolant level or no coolant, the sensor will not
function properly. The sensor can be wired into an • Conditions which cause each control to function
alarm system or an indicator in order to indicate high
water temperature. After an overheated engine is • Resetting procedure that is required before starting
allowed to cool, the contactor is automatically reset. the engine

i02145508 Testing Alarms and Shutoffs

Alarms and Shutoffs Alarms must function properly in order to provide
timely warning to the operator. Shutoffs help to
SMCS Code: 7400 prevent damage to the engine. It is impossible
to determine if the engine protective devices are
Engines may be equipped with optional engine in good working order during normal operation.
protective devices that are not included in this section. Malfunctions must be simulated in order to test the
This section contains some general information about engine protective devices.
the function of typical engine protective devices.
NOTICE
Alarms and shutoffs are electronically controlled. During testing, abnormal operating conditions must be
The operation of all alarms and shutoffs utilize simulated.
components which are actuated by a sensing unit.
The alarms and shutoffs are set at critical operating The tests must be performed correctly in order to pre-
temperatures, pressures, or speeds in order to vent possible damage to the engine.
protect the engine from damage.

The alarms function in order to warn the operator Periodic testing of engine protective devices for
when an abnormal operating condition occurs. The proper operation is recommended maintenance. To
shutoffs function in order to shut down the engine prevent damage to the engine, only authorized
when a more critical abnormal operating condition service personnel or your Caterpillar dealer
occurs. The shutoffs help to prevent damage to the should perform the tests.
engine.

Shutoffs may cause unburned gas to remain in the

air inlet and in the exhaust manifold.
34 SEBU6355-03
Operation Section
Engine Features and Controls

Setpoints for Alarms and Shutoffs Table 6

Setpoints For Cogeneration Engines
Inlet Manifold Air Temperature
Condition Setpoint
Table 5 lists information on the operating Alarm signal of differential 34.5 kPa (5 psi)
temperatures and the shutdown temperatures for pressure of jacket water
inlet manifold air temperature. The temperatures pressure
are associated with different water temperature
Alarm signal of jacket 127 °C (260 °F)
regulators for separate circuit aftercoolers. The water coolant temperature
temperatures are also associated with different types
of gas engines. Alarm signal of engine oil 102 °C (215 °F)
temperature
Table 5
Shutdown temperature of 104 °C (220 °F)
Approximate Operating Temperatures And engine oil
Shutdown Temperatures For G3500 Engine
Inlet Manifold Air Temperature Alarm signal of inlet air 68 °C (154 °F)
temperature or shutdown(1)
Opening Approximate Shutdown (1) High inlet air temperature is a shutdown for NA engines. High
Temperature Operating Temperature inlet air temperature is an alarm for all other engines.
for the Water Temperature
Temperature Table 7
Regulator
(SCAC) Setpoints For Engines that use Bio-Gas Fuel
32 °C (90 °F) 43 °C (110 °F) 47 °C (117 °F) Condition Setpoint
Low Emission
engine Alarm signal of differential 48.3 kPa (7 psi)
pressure of jacket water
54 °C (130 °F) 64 °C (147 °F) 68 °C (154 °F) pressure
Low Emission
engine Alarm signal of jacket 124 °C (255 °F)
water coolant temperature
70 °C (158 °F) 78 °C (172 °F) 81 °C (178 °F)
Low Emission Arming relay of jacket 98 °C (208 °F)
engine water pressure

32 °C (90 °F) 41 °C (106 °F) 45 °C (113 °F) Shutdown temperature of 107 °C (225 °F)
Standard engine engine oil

54 °C (130 °F) 62 °C (144 °F) 66 °C (151 °F) Shutdown temperature of 68 °C (154 °F)
Standard engine inlet air

Cogeneration and Bio-Gas Fuel Engines Without A Caterpillar Remote

Applications Control Panel (Status)

G3500 Engines that are in cogeneration and bio-gas The customer must provide the relay logic for engines
applications operate with jacket water coolant that are not equipped with a Caterpillar Remote
temperatures that are higher than normal. The Control Panel (Status). The customer must provide
protective system is optional for cogeneration the relay logic for the following parameters:
engines. The protective system is standard for
engines that use bio-gas fuel . • Oil pressure (high idle limit)

Table 6 lists the setpoints for cogeneration engines. • Oil pressure (low idle limit)
Table 7 lists the setpoints for engines that use bio-gas
fuel. • Jacket water coolant temperature (high
temperature)

• Overspeed
The specific limits are listed in Table 8. Relay logic
must be provided for shutting off the engine in case
any of the limits are reached. Consult your Caterpillar
dealer for assistance.
SEBU6355-03 35
Operation Section
Engine Features and Controls

Table 8
G3500 Engine Shutdown Setpoints
Rated Minimum Oil Jacket Overspeed
RPM Pressure Water(1) RPM
Temp.
High Low
Idle Idle
RPM RPM
1000 275 100 105 °C 1200
kPa kPa (221 °F)
(40 psi) (15 psi)
1400 275 100 105 °C 1680
kPa kPa (221 °F)
(40 psi) (15 psi)
1500 275 100 105 °C 1800
kPa kPa (221 °F)
(40 psi) (15 psi)
1800 275 100 105 °C 2160
kPa kPa (221 °F)
(40 psi) (15 psi)
(1) To prevent overheating, the coolant pressure must be a
minimum of 27.6 kPa (4 psi).

i02013999

Control Panel g00785285

Illustration 29
SMCS Code: 7451 Remote Control Panel (Status)
(1) “WARNING” indicator
Remote Control Panel (Status) (2)
(3)
“SHUTDOWN” indicator
“POWER ON” indicator
(4) “DIAGNOSTIC RESET” switch
This section contains some general information about (5) Status control module
the Remote Control Panel (Status). For more detailed (6) Engine control switch
(7) “EMERGENCY STOP” button
information, see these publications:
The yellow “WARNING” indicator (1) flashes or stays
• Systems Operation/Testing and Adjusting, lighted in order to indicate the occurrence of an
SENR6420, “Control Panel (Status-Timing)”
abnormal operating condition. A warning is not severe
enough to cause a shutdown. However, this signifies
• Electronic Troubleshooting, SENR6413, “G3500 a serious problem. If a warning occurs, a diagnostic
Engines”.
code for the condition is logged in the engine control
module. Correct the cause of the warnings as soon
as possible in order to avoid problems with operation.

The red “SHUTDOWN” indicator (2) illuminates

continuously when an adverse operating condition
causes a shutdown. A diagnostic code for the
condition is logged in the engine control module. If
the engine is shut down due to parameters that are
out of acceptable limits, the red indicators on the
status control module (5) will also illuminate.

“POWER ON” indicator (3) illuminates continuously

when power is supplied to the control panel.
36 SEBU6355-03
Operation Section
Engine Features and Controls

“DIAGNOSTIC RESET” switch (4) is a toggle switch

that is used to clear diagnostic codes from the engine
control module. The switch cannot clear individual
codes. Use of the switch will clear all codes that are
active in the engine control module. Do not clear the
codes until the problems that caused the codes
are addressed.

Status control module (5) has several engine

monitoring and control functions.

Engine control switch (6) is used to control starting

the engine and stopping the engine.

“EMERGENCY STOP” button (7) is used to stop the

engine in an emergency situation. When the button is
pressed, the status control module shuts off the fuel
via the gas shutoff valve. The module also terminates
the ignition. The “EMERGENCY STOP” button must
be reset before the engine will start.

Status Control Module Illustration 30

g00785287

(1) Liquid crystal display (LCD)

The status control module receives information from (2) Switch
the following sources: (3) “OVERCRANK” indicator
(4) “LOW OIL PRESSURE” indicator
(5) “OVERSPEED” indicator
• The operator (6) “EMERGENCY STOP” indicator
(7) “HIGH COOLANT TEMPERATURE” indicator
• Magnetic pickups (8) “AUXILIARY SHUTDOWN” indicator

• Transducers (oil pressure and water temperature) Liquid Crystal Display (LCD) – Symbols for the
following parameters are located under LCD (1).
• Optional remote sources The LCD provides a digital display of the status of
these parameters. When the status of a parameter is
The basic performance of the status control module displayed, an arrow at the bottom of the LCD points
includes the following functions: the corresponding symbol. The display can be in
metric units or English units.
When the status control module receives a signal to
start the engine, the module enables fuel to flow to Hour meter – When the arrow points to
the engine. The module activates the starting motor. this symbol, the hours of engine operation
After the rpm for crank termination is achieved, the are displayed.
module deactivates the starting motor.
Engine speed – When the arrow points to
When the status control module receives a signal to this symbol, the engine rpm is displayed.
stop the engine, the module shuts off the fuel. The
module sends a signal to the engine control module.
The engine control module terminates the ignition. System battery voltage – When the arrow
points to this symbol, the voltage of the
electrical system’s battery is displayed.

Engine oil pressure – When the arrow

points to this symbol, the engine oil
pressure is displayed.

Coolant temperature – When the

arrow points to this symbol, the Coolant
temperature is displayed.
SEBU6355-03 37
Operation Section
Engine Features and Controls

The parameters are displayed sequentially. To lock Note: A verify button for overspeed is located on the
the display onto one of the parameters, press switch back of the status control module. This enables a test
(2). To resume the sequential display, press the of the overspeed protection system to be performed.
switch again. See Systems Operation/Testing and Adjusting,
SENR6420, “Control Panel (Status-Timing)” for
The LCD is also used to display diagnostic codes. information on the service procedure.
A diagnostic code indicates that the system has
detected a problem with a component that is “EMERGENCY STOP” – Indicator (6) will
associated with the status control module. When a flash if the “EMERGENCY STOP” button is
diagnostic code is displayed, the arrow that indicates used to stop the engine.
the display of the parameters will be missing. A
flashing “dIAG” will be displayed. If more than one Note: Do not use the coolant temperature sensor
diagnostic code is present, the diagnostic codes will to monitor the operation of jacket water heaters (if
be displayed in sequence. equipped).
To clear the diagnostic codes from the LCD, turn the “HIGH COOLANT TEMPERATURE” –
engine control switch to the “OFF/RESET” position. If the coolant temperature exceeds the
For information on diagnostic codes, see these setpoint, the fuel will be shut off. Indicator
publications: (7) will flash.
• Systems Operation/Testing and Adjusting,
SENR6420, “Control Panel (Status-Timing)” “AUXILIARY SHUTDOWN” indicator (8) indicates
that an external request was used to stop the engine.
• Electronic Troubleshooting, SENR6413, “G3500 If the auxiliary shutdown is not used, the “AUXILIARY
Engines”. SHUTDOWN” indicator can be used as a spare
indicator.
• Electronic Troubleshooting, SENR6517, “G3500
Air/Fuel Ratio Control”. Engine Control Switch
The status control module has six indicators
(Illustration 30) that indicate engine shutdowns. The
shutdowns that are associated with the indicators are
described below.

“OVERCRANK” – If the engine fails to

start within a programmed amount of time or
if the number of crank cycles are exceeded,
the status control module will deactivate the starting
sequence. Indicator (3) will flash. The engine control
switch must be turned to the “OFF/RESET” position
before another attempt to start the engine can be
made.
g00307929
Illustration 31
“LOW OIL PRESSURE” – There are two
setpoints for low oil pressure. The setpoints Engine control switch in the “OFF/RESET” position
depend on the engine rpm. One setpoint
is for engine rpm that is below the oil step speed The engine control switch is a rotary switch that has
setting. The other setpoint is for engine rpm that is four positions:
above the oil step speed setting. If the engine oil
pressure decreases below the setpoint, the fuel to • “OFF/RESET”
the engine will be shut off. Indicator (4) will flash.
• “AUTO”
“OVERSPEED” – If the engine rpm
exceeds the setpoint for overspeed, the fuel
• “MAN. START”
and the ignition will be shut off. Indicator
(5) will flash.
• “COOLDOWN/STOP”
38 SEBU6355-03
Operation Section
Engine Features and Controls

Note: Only the indicators on the status control

module are reset when the engine control switch
is turned to the “OFF/RESET” position. Diagnostic
codes must be cleared with the “DIAGNOSTIC
RESET” switch (Illustration 29).

“OFF/RESET” – When the engine control switch is

turned to this position (12 o’clock), the indicators on
the status control module are reset and the engine
shuts down immediately. The power to the engine
control module and the status control module is shut
off. This method is not recommended for normal
stopping.

“AUTO” – When the engine control switch is in this

position (3 o’clock), the system is configured for
remote operation. When the remote start/stop initiate
contact closes, the engine will start. When the remote
start/stop initiate contact opens, the engine will
shut down. If the cooling cycle is programmed, the
engine will operate for the cooldown period before
the engine stops.

“MAN. START” – When the engine control switch

is turned to this position (6 o’clock), the engine will
start. The engine will continue to operate when the
switch is in this position. However, if a setpoint for a
shutdown is exceeded, the engine will shut down.

“COOLDOWN/STOP” – This is the preferred

method for normal stopping. When the engine control
switch is turned to this position (9 o’clock), the
engine will continue to operate until a programmable
cooling cycle has elapsed. The cooling cycle can be
programmed for a 0 to 30 minute period. The default
setting is five minutes.
SEBU6355-03 39
Operation Section
Engine Features and Controls

Electronic Modular Control Panel II

(EMCP II)

g01041282
Illustration 32
Electronic Modular Control Panel II (EMCP II)
(1) Generator set control (GSC) (5) Optional alarm module (ALM) (8) Panel light switch (PLS)
(2) Diagnostic reset switch (6) Optional synchronizing lights module (9) Emergency stop push button (ESPB)
(3) Engine control switch (ECS) (SLM) (10) Voltage adjust rheostat (VAR)
(4) Panel lights (7) Optional speed potentiometer

The electronic modular control panel II (EMCP II) is Diagnostic Reset Switch (2) – The diagnostic
located above the generator distribution housing. The reset switch is a toggle switch that is used to clear
control panel consists of a main panel with indicators, diagnostic codes from the engine control module.
meters and control switches. This control panel may The switch cannot clear individual codes. Use of the
be equipped with optional modules in order to match switch will clear all the codes that are active in the
the customers’ needs and requirements. engine control module.

The left side of the control panel contains the Note: Do not clear the codes until the problems that
Generator Set Control (GSC). This is the main caused the codes are addressed.
component of the system. The GSC displays
the following information: generator output, fault Engine Control Switch (3) – The engine control
conditions, and key engine parameters. The center switch (ECS) determines the status of the control
section of the control panel contains switches and an panel. In the AUTOMATIC position, the engine will
optional alarm module. The right side of the control start automatically when a contact is closed. The
panel may be blank, or the right side of the control engine will shut down after two of the following
panel may contain the Synchronizing Lights Module conditions are met:
or the Custom Alarm Module.
• The contact opens.
The main control panel may not contain all of the
components which are shown. Some components • A programmable cooldown period has elapsed.
are optional. The optional components may not be
required for your particular application. The cooldown period can be programmed to give a
0 to 30 minute cooldown period before the engine
Generator Set Control (1) – The generator set shuts down.
control (GSC) is the main component of the EMCP
II. See the topic “Generator Set Control (GSC)” in In the MANUAL START position, the engine will start
this section. and the engine will run. The engine will continue to
run while the ECS is in that position.
40 SEBU6355-03
Operation Section
Engine Features and Controls

In the STOP position, the fuel solenoid will shut down Generator Set Control (GSC)
the engine after a programmable cool down time
period has elapsed. Functions and features of the GSC
In the OFF/RESET position, the fault lights are reset The left side of the control panel contains the
and the engine shuts down immediately. generator set control (GSC). The GSC is the main
component of the system. The GSC displays the
Panel Lights (4) – Panel lights (PL) are controlled following information: generator output, generator
by panel lights switch (8). The panel lights switch (8) set functions, fault conditions, and key engine
is an ON/OFF switch. parameters. The GSC accepts information from the
following sources: operator, engine speed sensor,
Alarm Module (5) – The alarm module (ALM) is engine oil pressure sensor, water temperature
optional. The ALM provides a visible, audible warning sensor, and optional remote sources. This information
of engine conditions before these conditions become is used to determine the “on/off” state of the engine’s
severe enough to shut down the engine or severe air, fuel, and starter.
enough to keep the engine from starting.
During normal operating conditions, a signal tells the
Synchronizing Lights Module (6) – The GSC to start the generator set. The GSC turns on
synchronizing lights module uses synchronizing lights the engine’s fuel and the engine’s starter. When the
for paralleling the generator sets. The synchronizing engine speed reaches the crank termination speed,
lights module is optional. the starter is disengaged. When the GSC receives a
signal to stop the engine, the GSC shuts the fuel off.
Speed Potentiometer (7) – The speed
potentiometer (SP) is optional. The SP can be The functions of the GSC are listed below:
used with the generator set that has an electronic
governor. When the governor is equipped with a • The GSC controls the starting and the stopping of
speed adjusting motor, the governor switch (GS) the engine (normal conditions).
can be mounted instead of the SP. The GS raises
or the GS lowers the engine speed. The GS is also • The GSC shows engine conditions and generator
an option. output information on two displays. The displays
also show fault codes and GSC programming
Panel Light Switch (8) – The panel lights switch information.
controls the panel lights (4).
• The GSC monitors the system for faults. If a
Emergency Stop Push Button (9) – The fault occurs, the GSC performs a controlled fault
emergency stop push button (ESPB) is used to shut shutdown or the GSC provides a fault alarm. The
down the engine during an emergency situation. The GSC uses indicators and displays in order to
ESPB shuts off the fuel. The ESPB also activates the describe the fault.
optional air shutoff, if equipped.
• The GSC contains programmable features
Voltage Adjust Rheostat (10) – The voltage adjust for certain applications or requirements of the
rheostat (VAR) is used to adjust the generator output customers.
voltage to the desired level.
The features of the GSC are listed below:
Below, you can find the descriptions of the following
main modules of the EMCP II: • Cycle Crank: The GSC can be programmed to
crank for adjustable time periods.
• Generator Set Control (GSC)
• Governor Control: When the engine oil pressure
• Alarm Module (ALM) increases past the low oil pressure setpoint,
the GSC will indicate to the governor. The GSC
• Synchronizing Lights Module indicates that the governor should increase the
engine speed from idle rpm to rated RPM.

• Cooldown: When the GSC receives a signal to

perform a normal shutdown, the GSC will wait for
an amount of time that has been preprogrammed
before shutting down the engine via the fuel control.
SEBU6355-03 41
Operation Section
Engine Features and Controls

• Automatic Operation: In the automatic mode, the The fault indicators are used to show that a fault is
GSC can be started by a remote initiating signal. present. The fault indicators also describe the fault.
Upon loss of the signal (contact opening), the GSC The fault indicators are divided into three groups.
will perform a normal shutdown. The three groups are listed below:

• Alarm Module Communication: The GSC can • Fault alarm indicator (17)
transmit fault conditions and alarm conditions to
an alarm module (AM). • Fault shutdown indicator (18)
• Power Down.: The EMCP II system is designed • Dedicated shutdown indicators (19)
to remove power from the GSC when the engine
control switch (ECS) is in the OFF/RESET mode The yellow fault alarm indicator (17) FLASHES when
and when the proper jumper wire is removed. The the GSC detects an alarm fault. The alarm fault does
GSC will not allow the generator set to power down not cause the engine status to change. The engine
until both the crank termination relay and the fuel can be started. The engine will continue operating,
control relay are off for about 70 seconds. The GSC only if the engine is running at the time of the alarm
will remain up if the jumper wire is not removed. fault. Fault alarm indicator (17) is accompanied by an
alarm fault code that is shown on upper display (20).
• Fuel Solenoid Type: The GSC can be The fault code is shown when the alarm codes key
programmed to work with an “energized to run” fuel (21) is pressed.
system or programmed to work with an “energized
to shutdown” fuel system. The red fault shutdown indicator (18) FLASHES when
the GSC detects a shutdown fault. The engine will be
Fault indicators shut down if the engine is running. The engine will
not be allowed to start. Fault shutdown indicator (18)
is accompanied by a fault code that is immediately
shown on the upper display (20).

The red dedicated shutdown indicators (19) represent

the following shutdown faults: low oil pressure,
emergency stop, high water temperature, engine
overspeed, low coolant level and engine overcrank.
When the GSC detects a fault in one of these areas,
the dedicated shutdown indicator that corresponds
to the fault FLASHES. The engine is shutdown
if the engine is running, and the engine is not
allowed to start. No fault codes are associated with
the dedicated shutdown indicators because each
indicator has a descriptive label.

Many of the dedicated shutdown faults depend on

certain setpoints in the GSC.

The conditions that are required to activate the

dedicated fault shutdowns and the results of each
g00787844 dedicated fault are in the following list:
Illustration 33
Display area of the GSC Low Oil Pressure – The engine oil pressure drops
(11) Low oil pressure indicator below the setpoints for low oil pressure shutdown
(12) Emergency stop indicator that are programmed into the GSC. There are two
(13) High water temperature indicator
(14) Engine overspeed indicator
low oil pressure setpoints. One setpoint is used when
(15) Low coolant level indicator the engine is at idle speed. The other setpoint is used
(16) Overcrank indicator when the engine is at rated speed. When a low oil
(17) Fault alarm indicator pressure fault occurs, the low oil pressure indicator
(18) Fault shutdown indicator FLASHES, and the engine is shut down. The engine
(19) Dedicated shutdown indicators
(20) Upper display is not allowed to start until the fault is corrected.
(21) Alarm codes key
42 SEBU6355-03
Operation Section
Engine Features and Controls

Emergency Stop – The operator presses the Display

emergency stop push button (ESPB) on the front
panel. When an emergency stop condition occurs,
the emergency stop indicator FLASHES and the
engine is shut down. The engine is not allowed to
start until the condition is corrected.

High Water Temperature – The engine coolant

temperature rises above the setpoint for high water
temperature shutdown that is programmed into the
GSC. When the high water temperature fault occurs,
the high water temperature indicator FLASHES. The
engine is shutdown and the engine is not allowed to
start until the fault is corrected.

Engine Overspeed – The engine speed exceeds

the setpoint for engine overspeed that is programmed
into the GSC. When a fault for engine overspeed
occurs, the engine overspeed indicator FLASHES.
The engine is shutdown and the engine is not allowed
to start until the fault is corrected.

Low Coolant Level – The engine coolant level g00787849

Illustration 34
drops below the probe of the coolant loss sensor.
When the low coolant level fault occurs, the engine Display area of the GSC
coolant level indicator FLASHES. The engine is shut (20) Upper display
down. The engine is not allowed to start until the fault (22) Lower display
(23) The leftmost key
is corrected. (24) The phase select key
(25) The engine meter key
Overcrank – The engine does not start within the
setpoint for total cycle crank time that is programmed The display consists of the upper display and
into the GSC. When the overcrank fault occurs, the the lower display. Both displays are used for
overcrank indicator FLASHES. The engine is not programming functions when the GSC is in the
allowed to start until the fault is corrected. service mode.

Note: The GSC can be programmed to override Upper display

the shutdown for low oil pressure and high water
temperature faults. When the operator overrides The upper display (20) shows the following
the shutdown faults, the GSC responds to the parameters: AC voltage, current, and frequency of
faults as though the faults are alarm faults. The one phase of the generator output. Each phase can
corresponding dedicated shutdown indicator is be viewed one at a time by pushing phase select key
ON CONTINUOUSLY. The engine continues to (24). The upper display (20) is also used to show the
run. The engine can be restarted, if necessary. various fault codes for system faults.
When the dedicated shutdown indicator is ON
CONTINUOUSLY, the setpoint for shutdown has Lower display
been exceeded, but the GSC is programmed to
override the shutdown fault. The GSC does not treat The lower display (22) shows system battery voltage,
the shutdown fault as a shutdown fault. The GSC engine hours, engine speed, engine oil pressure,
treats the shutdown fault as an alarm fault. At the engine coolant temperature and the relay status.
factory, the GSC is programmed to treat a low oil
pressure fault and a high water temperature fault The value for one of these conditions is shown for
as shutdown faults. The operator or the service two seconds. Then, the display scrolls to the value
technician must decide to override these shutdown for the next condition. A small pointer identifies
faults. The operator or the service technician must the engine condition that corresponds to the value
program the GSC to treat the shutdown faults as which is showing. When the engine meter key (25) is
alarm faults. pressed, the lower display (22) stops scrolling. The
lower display (22) continuously shows one particular
value. The pointer flashes above the condition of the
value that is showing. When engine meter key (25)
is pressed for a second time, the display (22) will
return to scrolling.
SEBU6355-03 43
Operation Section
Engine Features and Controls

The relay status indicators are on the bottom of the Phase Select Key (24) – This key selects the phase
lower display (22). When a GSC relay is activated, of the generator output that is displayed on the GSC.
the corresponding indicator is shown on lower display When you press this key, the display shows the
(22). When a relay is not activated, the corresponding voltage, current, and frequency of each phase one
indicator is not shown. at a time.

Keypad Engine Meter Key (25) – This key controls the

viewing of engine parameters on the lower display.
Pressing the key stops the scrolling of engine
conditions. The value for one particular engine
condition will show continuously. The pointer flashes
indicating that the scrolling is stopped. The scrolling
of the engine conditions will resume when the engine
meter key is pressed again.

Lamp Test Key (26) – Pressing this key performs a

lamp test on the GSC and the optional alarm module.
On the GSC, the eight fault indicators are ON
CONTINUOUSLY. Every segment of upper display
(20) and lower display (22) is ON. On the optional
alarm module, all of the indicators are ON and the
horn sounds. The lamp test function turns off if an
operator presses the key and the operator holds the
key for more than ten seconds.

Exit Key (27) – This key only functions when the

GSC is in Service Mode.

g00787845
Service Mode Key (28) – Pressing this key causes
Illustration 35 the GSC to enter service mode.
Keypad area of the GSC
(17)
(18)
Fault alarm indicator
Fault shutdown indicator
Alarm Module
(20) Upper display
(21) Alarm codes key The alarm module (ALM) is optional. The alarm
(22) Lower display module provides visible warnings and the alarm
(23) Leftmost key module provides audible warnings of engine
(24) Phase select key
(25) Engine meter key
conditions before these conditions become severe
(26) Lamp test key enough that the engine will shut down or the engine
(27) Exit key will be unable to start.
(28) Service mode key
(29) Keypad One basic alarm module is used to satisfy the
requirements for the following modules: standby
Keypad (29) is used to control the information that is NFPA 99 alarm module, standby NFPA 110 alarm
shown on upper display (20) and lower display (22). module, NFPA 99 remote annunciator panel, and
The seven keys have two sets of functions: normal prime power alarm. This is accomplished by using
functions and service functions. The normal functions different inputs to the module and different decals on
of the keys are described in the following paragraphs: the front of the module in order to indicate alarms
or shutdown conditions.
Alarm Codes Key (21) – If fault alarm indicator
(17) is FLASHING, pressing this key causes upper The front of the alarm module consists of the
display (20) to show the corresponding alarm fault following indicators:
code. If this key is pressed again, the generator AC
output information will be shown on the upper display • Four amber indicators
(20). If fault alarm indicator (17) is OFF, this key has
no function. • Four red indicators
Leftmost Key (23) – This key only functions when • An audible alarm
the GSC is in service mode. This key is used to scroll
right. • Acknowledge/Silence switch
44 SEBU6355-03
Operation Section
Engine Features and Controls

The amber indicators may display the following The synchronizing lights module contains the
parameters: synchronizing lights (30) and the synchronizing
switch (31).
• High Coolant Temperature
Synchronizing Lights (30) – The synchronizing
• Low Coolant Temperature lights (30) are used as an aid in paralleling units at
no load and under load. Each light is connected to
• Low Coolant Level the side with the load of the generator output circuit
breaker. The lights are used to indicate when the
• Low Oil Pressure voltages are in-phase. Close the circuit breaker in
order to connect the generator with the load.
• Generator On Load
Synchronizing Switch (31) – The synchronizing
• Charger Malfunction switch has two positions: ON (“I”) and OFF
(“0”). When this switch is in the ON position, the
• Low Engine Oil Level synchronizing lamps are enabled. The generator
circuit breaker can be closed manually when
• Low Fuel Level the synchronizing switch is on and the lights are
synchronized.
The red indicators may display the following
conditions: Note: Refer to Operation Section, “Parallel
Operation” for information regarding the paralleling
• Not In AUTO of two generators.

• Low DC Voltage When a reverse power relay is added to

a synchronizing lights module, the original
• Air Damper Closed synchronizing lights module will change in the
following ways:
• Low Oil Pressure Shutdown
• The reverse power relay is mounted on the control
• Overcrank Shutdown panel interior.

• High Coolant Temperature Shutdown • A reverse power fault is indicated by the Fault
Shutdown Indicator on the front of the GSC.
• Overspeed Shutdown
The reverse power relay is a single phase protective
Synchronizing Lights Module relay. This relay is energized by power in only one
direction. In a reverse power fault, the relay contacts
close and the engine shuts down. This will take the
generator off the line. The reverse power relay is
equipped with a test switch and adjustments.

i01516191

Governors and Actuators

SMCS Code: 1264

Isochronous – The engine rpm remains constant

from high idle at no load to full load operation. This is
known as zero percent droop.
g00787922 Droop – Droop represents a decrease in rpm from
Illustration 36
The location of the Synchronizing Lights Module on the EMCP II high idle at no load to full load operation.
(30) Synchronizing lights
(31) Synchronizing switch

The optional synchronizing lights module is mounted

on the right side of the control panel.
SEBU6355-03 45
Operation Section
Engine Features and Controls

Woodward 3161 Governor This governor is recommended for applications when

the following two conditions occur:
The 3161 Governor is standard equipment on
G3500 Industrial Engines. This is a hydromechanical • The installation involves a device that can
governor that is capable of isochronous operation. automatically parallel the generators.
In addition to isochronous operation, the governor
can be externally adjusted to eight percent droop. • The generator set is operated in parallel to a utility
A manual speed control is standard. Pneumatic when a load is transferred.
speed control and electric remote speed controls are
available. Woodward ProAct Governor
Woodward 2301A Speed Control The ProAct governor is a digital control system with
an electrically powered actuator. The actuator is
Governor directly coupled to the throttle. The control has two
complete sets of dynamic adjustments in order to
The 2301A Speed Control Governor is standard for
assist operation under different conditions such as
the G3500 Generator Set Engines and optional for
dual fuel and/or parallel to stand alone electrical
the G3500 Industrial Engines. This is an electric
power generation. The control can operate in
isochronous governor (with droop adjustment) that
isochronous mode or droop mode.
drives an EGP3 Actuator. The governor is used
mainly for standby operation and for stand alone
operation. When the generator set is operated
parallel to a utility, the governor can only control the
engine in droop mode. In isochronous mode, the
governor must have additional components in order
to share a load with another unit or with a utility.

Woodward 2301A Load Sharing

Governor
The 2301A Load Sharing Governor is an electric
isochronous governor with speed droop that can be
adjusted. This governor is specifically designed to
divide the load between parallel generators. The
sharing of the load is automatic and proportional. The
isochronous speed is maintained. The governor can
be used for applications that are either a single unit
or a multiple unit. The governor can also be used in
standby mode.

Woodward 701A Governor

The 701A Governor is for use when the governor
must be integrated with controllers. The controllers
combine operations with the following devices:

• Automatic parallel devices

• Automatic loading devices
• Export/import controllers
For satisfactory performance, different governor
gains are required for each mode of operation. The
governor has provisions for multiple gain settings.
Multiple gain settings allow the governor adjustments
and engine performance for the various modes of
operation to be optimized.
46 SEBU6355-03
Operation Section
Engine Starting

Engine Starting • Ensure that all clamps and connections are secure.
• Inspect the air cleaner service indicator (if
i02151084 equipped). Service the air cleaner filter element
when the yellow diaphragm enters the red zone, or
Before Starting Engine the red piston locks in the visible position.

SMCS Code: 1000; 1400; 1450

Cooling System
Note: Certain procedures are required before an
engine is started for the first time. See Special • Inspect the cooling system for leaks or loose
Instruction, SEHS9769, “Installation and Initial connections. Inspect the condition of all the hoses
Start-UP Procedure for G3500 Engines”. and pipes for the cooling system. Ensure that the
connections are properly clamped.
Perform the required daily maintenance and other
periodic maintenance before starting the engine. This • Inspect the water pumps for evidence of leaks.
can prevent major repairs at a later date. See this
Operation and Maintenance Manual, “Maintenance • Check the coolant level. Add coolant, if necessary.
Interval Schedule” (Maintenance Section). For information on the proper coolant to use, see
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” (Maintenance
Walk-Around Inspection Section).

NOTICE Driven Equipment

For any type of leak, clean up the fluid. If leaking is ob-
served, find the source and correct the leak. If leaking • If necessary, check the oil levels of the driven
is suspected, check the fluid levels more often than equipment. Perform any maintenance that is
recommended until the leak is found or fixed, or until required for the driven equipment. Refer to the
the suspicion of a leak is proved to be unwarranted. literature that is provided by the OEM of the driven
equipment.
To obtain maximum service life for your engine, make
a thorough inspection before starting the engine. • If the engine is equipped with a clutch, ensure that
Make a walk-around inspection of the installation. the clutch is disengaged.
Look for items such as oil or coolant leaks, loose
bolts and trash buildup. Remove any trash. Make • For generator set engines, ensure that the main
repairs, if necessary. circuit breaker is open.

• The guards must be in the proper place. Repair Electrical System

damaged guards or replace missing guards.
Inspect the wiring for the following conditions:
• Ensure that the areas around the rotating parts are
clear. • Loose connections

Air Inlet System • Wiring that is worn or frayed

Inspect the gauge panel and the control panel
for good condition. Reset any shutoff or alarm
components.
Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal Fuel System
injury and/or property damage may result.

Before starting an engine that may contain un-

burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on NEVER use a flame to check for gas leaks. Use a
purging unburned gas in the “Starting the Engine” gas detector.
section.
An open flame can ignite mixtures of air and fuel.
This will cause explosion and/or fire which could
• Ensure that the air inlet piping and the air filters result in severe personal injury or death.
are in place.
SEBU6355-03 47
Operation Section
Engine Starting

• Check the fuel lines for leaks with a gas detector. Air Starting Motor
• Inspect the fuel lines for loose fittings and leaks. • Drain moisture and sediment from the air tank and
Ensure that the fuel lines are properly clamped. from any other air piping.

• Ensure that the fuel is supplied to the engine at the • Check the oil level in the lubricator. Keep the
correct pressure for the engine. lubricator at least half full. Add oil, if necessary.
For temperatures above 0 °C (32 °F), use a
nondetergent 10W oil. For temperatures below
Lubrication System 0 °C (32 °F), use air tool oil.

• Check the air pressure for starting. The air starting

motor requires a minimum of 690 kPa (100 psi).
The maximum allowable air pressure is 1030 kPa
(150 psi). Open the air supply valve.

Electric Starting Motor

• Disconnect any battery chargers that are not
protected against the high current drain that is
created when the electric starting motor engages.

Inspect the wiring, the electrical cables, and the

battery for the following conditions:
g00760044
Illustration 37
Oil level gauge (dipstick) • Loose connections
(1) “ADD” mark
(2) “FULL” mark • Wires that are worn or frayed
• Corrosion
NOTICE
Excessive engine oil will increase oil consumption and
result in excessive deposits in the combustion cham- i01857649
ber. Do not overfill the engine with oil.
Cold Weather Starting
• Check the engine crankcase oil level. Maintain the SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
oil level between the “ADD” and “FULL” marks on
the “ENGINE STOPPED WITH OIL COLD” side of Note: Oil pan immersion heaters are not
the oil level gauge. For information on the proper recommended for heating the lube oil. To ensure the
oil to use, see this Operation and Maintenance compatibility of the components, only use equipment
Manual, “Refill Capacities and Recommendations” that is recommended by Caterpillar.
(Maintenance Section).
A jacket water heater is required for starting in
• Check for leaks at the following components: temperatures as low as 0 °C (32 °F). The jacket
crankshaft seals, crankcase, oil filters, oil gallery water heater can maintain the water temperature at
plugs, sensors, and valve covers. approximately 32 °C (90 °F). The heated water will
help to keep the oil in the engine block warm enough
• Inspect the tubes, tee pieces, and clamps on the to flow when the engine is started. A jacket water
crankcase breathers. heater is required for starting when the temperature
is less than 16 °C (60 °F).
Starting System For air starting motors, a larger volume of starting
Note: If the engine is equipped with a system for air and/or a higher air pressure may be necessary in
external support, prepare the system before starting order to start the engine at colder temperatures.
the engine. Ensure that all of the systems for engine
support are enabled. Perform all prestart checks for For electric starting, extra battery capacity may be
the control system. necessary.

Consult your Caterpillar dealer for more information

on the starting aids that are available for cold weather
starting.
48 SEBU6355-03
Operation Section
Engine Starting

i02153547 Unburned gas may remain in the air inlet and exhaust
system after several unsuccessful attempts to start
Starting the Engine the engine. The unburned gas may increase to a
concentration that may ignite during a successive
SMCS Code: 1000; 1450 attempt to start the engine.

Perform the following procedure in order to purge

the unburned gas:
Engine exhaust contains products of combustion
which may be harmful to your health. Always start 1. Turn the manual gas shutoff valve to the CLOSED
and operate the engine in a well ventilated area position.
and, if in an enclosed area, vent the exhaust to the
outside. 2. Disable the ignition by grounding the “G” lead in
the ignition harness.

NOTICE 3. Turn the engine control switch to the START

For initial start-up of a new or rebuilt engine, and for position. Crank the engine for one full crank cycle
start-up of an engine that has been serviced, make in order to purge the unburned gas.
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the 4. Turn the engine control switch to the OFF/RESET
fuel supply and/or the ignition to the engine. position.

5. Enable the ignition by disconnecting the “G” lead

from ground.

Unburned gas in the air inlet and exhaust system 6. Turn the manual gas shutoff valve to the OPEN
may ignite when the engine is started. Personal position.
injury and/or property damage may result.
7. Continue with your previous procedure.
Before starting an engine that may contain un-
burned gas, purge the unburned gas from the air Automatic Starting
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.

When the engine is in the AUTOMATIC mode, the

Do not start the engine or move any of the controls
engine can start at any moment. To avoid personal
if there is a “DO NOT OPERATE” warning tag or
injury, always remain clear of the the engine when
similar warning tag attached to the start switch or to
the engine is in the AUTOMATIC mode.
the controls.

Ensure that no one will be endangered before the If the engine control switch is in the “AUTO” position,
engine is started and when the engine is started. the engine will automatically start when the remote
start/stop initiate contact closes. The engine will
Perform the procedures that are described in this accelerate to rated rpm when the oil pressure is
Operation and Maintenance Manual, “Before Starting sufficient.
Engine” (Operation Section).
Manual Starting
Purging Unburned Gas
1. Ensure that fuel is supplied to the engine.
The following events cause unburned gas to remain
in the air inlet and in the exhaust manifold: 2. Ensure that the main circuit breaker is open.

• Emergency stop
• Engine overspeed
• Unsuccessful successive attempts to start the
engine
SEBU6355-03 49
Operation Section
Engine Starting

1. Turn the engine control switch to the “OFF/RESET”

NOTICE position.
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load. 2. Turn the gas supply OFF.

If the engine fails to start within 30 seconds, release 3. Allow the starting motor to cool for two minutes.
the starter switch or button and wait two minutes to Crank the engine for approximately 15 seconds
allow the starting motor to cool before attempting to in order to disperse any unburned gas from the
start the engine again. engine and the exhaust system.

4. Allow the starting motor to cool for two minutes.

Turn the gas supply ON. Repeat the starting
procedure.

i02097945

Starting with Jump Start

Cables
SMCS Code: 1000; 1401; 1402; 1900

g00319402 Improper jump start cable connections can cause

Illustration 38
Engine control switch in the “Man. Start” position an explosion resulting in personal injury.

3. Turn the engine control switch to the “Man. Start” Prevent sparks near the batteries. Sparks could
position in order to start the engine. cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
4. Allow the engine to idle for three to five minutes.
The engine speed should stabilize at low idle rpm. If the installation is not equipped with a backup
Check all of the pressure gauges. Inspect the battery system, it may be necessary to start the
engine for leaks and listen for unusual noises. engine from an external electrical source.
When all systems are normal, the rpm may be
increased. Many batteries which are considered unusable are
still rechargeable. After jump starting, the alternator
Table 9
may not be able to fully recharge batteries that
Rated RPM And Low Idle RPM are severely discharged. The batteries must be
Rated rpm 1000 1200 1400 1500 1800
charged to the proper voltage with a battery charger.
For information on testing and charging, refer to
Low idle rpm 700 900 1000 1000 1200 the Special Instruction, SEHS7633, “Battery Test
Procedure”.
Starting Failure
Note: If the cycle crank feature is enabled, the Status
Control Module (SCM) will attempt to start the engine
for the programmed period. If the engine fails to start
within the programmed period, the SCM will execute
an overcrank fault. The “OVERCRANK” indicator on
the Remote Control Panel (Status) will illuminate. The
SCM must be reset before the engine can be started.
Turn the engine control switch to the “OFF/RESET”
position.

If the engine fails to start after cranking for 30

seconds, stop cranking. Perform the following
procedure:
50 SEBU6355-03
Operation Section
Engine Starting

i00914166
NOTICE
Using a battery source with the same voltage as the
After Starting Engine
electric starting motor. Use ONLY equal voltage for
SMCS Code: 1000
jump starting. The use of higher voltage will damage
the electrical system.
For new installations and engines that are recently
rebuilt, carefully monitor the engine in order to detect
Do not reverse the battery cables. The alternator can
any unusual engine performance.
be damaged. Attach ground cable last and remove
first.
The engine rpm can be increased from low idle rpm
to rated rpm after one minute.
When using an external electrical source to start the
engine, turn the engine control switch to the “OFF”
Engines that use pipeline natural gas are capable of
position. Turn all electrical accessories OFF before
ramping to full load in 30 seconds or less. For engines
attaching the jump start cables.
that use bio-gas, increased time for ramping the
load will help to provide protection from detonation.
Ensure that the main power switch is in the OFF posi-
Avoid detonation during loading. Generally, no load
tion before attaching the jump start cables to the en-
gine being started. operation to full load operation can be accomplished
in five to ten minutes without any problems.

1. Turn the start switch on the stalled engine to the It may be necessary to apply some load in order to
OFF position. Turn off all accessories. attain normal operating temperatures. The operator
can ramp the load manually. For automatic loading,
2. Connect one positive end of the jump start cable programmable logic control can be used.
to the positive cable terminal of the discharged
battery. Connect the other positive end of the jump Engaging the Driven Equipment
start cable to the positive cable terminal of the
electrical source.
Generator Set Engines
3. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical 1. Increase the engine speed to rated rpm.
source. Connect the other negative end of the
jump start cable to the engine block or to the 2. Ensure that the outlet temperature of the jacket
chassis ground. This procedure helps to prevent water reaches 77 °C (170 °F). Ensure that the
potential sparks from igniting combustible gases gauges are in the normal ranges for the engine
that are produced by some batteries. rpm.

4. Charge the batteries. The engine will not continue 3. Close the main circuit breaker in order to apply
to run after starting if the batteries have not been the load.
charged.
Industrial Engines
5. Start the engine.
1. Increase the engine rpm. Ensure that the gauges
6. Immediately after the stalled engine is started, are in the normal ranges for the engine rpm.
disconnect the jump start cables in reverse order.
2. Engage the driven equipment with no load on the
Refer to the Electrical Schematic for your engine. driven equipment.
Consult your Caterpillar dealer for more information.
The engine can be loaded up to 50 percent of full
load before the outlet temperature of the jacket
water reaches 77 °C (170 °F). The temperature is
usually achieved in two to four minutes. After this
temperature is reached, begin to ramp the engine
to full load.

3. Ramp to full load after the outlet temperature of

the jacket water reaches 77 °C (170 °F). Five
minutes may be required.
SEBU6355-03 51
Operation Section
Engine Operation

Engine Operation For example, an engine is operating at 20 percent

of the rated torque. The engine may be operated at
this load factor for a maximum of one-half hour. After
i02097665 the one-half hour, operate this engine for at least two
hours at a load factor of more than 70 percent.
Engine Operation
To keep engine maintenance at a minimum, follow
SMCS Code: 1000 the guidelines that are listed in Table 10.

Proper operation and maintenance are key factors in Table 10

attaining the maximum service life and economy for Time Limits For Low Load Operation
the engine. Follow the instructions in this Operation
and Maintenance Manual in order to minimize Engine Torque NA Engines TA Engines
operating costs and maximize the service life of the 0 to 30% 1/2 hour 1/2 hour
engine.
31 to 50% 2 hours 2 hours
Observe the gauges frequently while the engine is
51 to 60% 24 hours Continuous(1)
operating. Record the data from the gauges in a log
regularly. Compare the data to the specifications 61 to 100% Continuous Continuous(1)
for normal engine operation. Comparing the data (1) For continuous operation of TA engines, the manifold air
over time will help to detect changes in engine pressure should be greater than the atmospheric pressure.
performance.

Investigate any significant change in the gauge

readings. Monitor the engine operation and take
action when discrepancies are found.

Operating the Engine and the

Driven Equipment
Check the gauges and the driven equipment
frequently while the engine is operating under a load.
The engine can be operated for extended periods
of time at full load.

Partial Load Operation

Extended operation at low idle or at a reduced load
will cause increased oil consumption and carbon
buildup in the cylinders. Carbon buildup results in
the following effects:

• Power loss
• Poor performance
• Accelerated wear of components
Caterpillar Engines can be operated at very light
loads (torques) for limited times with no harmful
effects. Table 10 lists the limits for hours of operation
at various torques.

After the time limit for reduced load operation has

expired, operate the engine for a minimum of two
hours at a torque that is more than 70 percent.
52 SEBU6355-03
Operation Section
Engine Stopping

Engine Stopping
i02145782

Emergency Stopping
SMCS Code: 1000; 7418

NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.

g00786735
Ensure that any system that provides external Illustration 40
support to the engine is secured after the engine is Remote control panel (status)
stopped. (1) Emergency stop button
(2) Engine control switch
(3) “AUXILIARY SHUTDOWN” indicator
NOTICE
Do not start the engine until the problem necessitating
Emergency stop button (1) is in the OUT position
the emergency stop has been located and corrected.
for normal engine operation. Push the button for
emergency stopping. This shuts off both the fuel
Pressing the Emergency Stop Button may cause and the ignition. The engine will not start when the
unburned gas to remain in the air inlet and in the button is locked. To reset the button, turn the button
exhaust manifold. clockwise. The spring-loaded button will return to the
OUT position.

NOTICE
Unburned gas in the air inlet and exhaust system Do not use this method to stop the engine unless
may ignite when the engine is started. Personal an emergency has occurred. Continuous emergency
injury and/or property damage may result. shutdowns can cause damage to some engine com-
ponents. This will leave unburned fuels in the combus-
Before starting an engine that may contain un- tion chambers and in the exhaust system. If an emer-
burned gas, purge the unburned gas from the air gency shutdown occurs, purge the system by cranking
inlet and exhaust system. Refer to the topic on the engine for 5 to 10 seconds with the ignition shutoff.
purging unburned gas in the “Starting the Engine”
section.
The control panel must also be reset before the
engine will start. To reset the control panel, turn
engine control switch (2) to the “OFF/RESET”
Emergency Stop Button position.

The customer may also provide other means for

emergency stopping. This will cause the fuel to be
shut off, but the ignition may not be shut off. This
shutdown will cause “AUXILIARY SHUTDOWN”
indicator (3) to illuminate. The control panel must
be reset before the engine will start. To reset the
control panel, turn engine control switch (2) to the
“OFF/RESET” position.

g00786734
Illustration 39
(1) Emergency stop button on a junction box
SEBU6355-03 53
Operation Section
Engine Stopping

i02204806

Manual Stop Procedure

SMCS Code: 1000; 7418

NOTICE
Stopping the engine immediately after the engine has
been operating under a load can result in overheating
and accelerated wear of the engine components.

Allow the engine to gradually cool before stopping the

engine.

g00320124
Note: Remove the load at a rate that will avoid Illustration 41
detonation. Engine control switch in the “OFF/RESET” position

1. Disengage the driven equipment. b. Turn the engine control switch to the
“OFF/RESET” position. The engine will
a. For generator set engines, open the main immediately shut off.
circuit breaker.
c. If the engine control switch is in the “AUTO”
b. For industrial engines, unload the compressor position, open the remote start/stop initiate
or pump. Disengage the clutch (if equipped). contact. If the cooldown feature is utilized, the
Place the transmission and/or other engine will operate for a programmed period of
attachments for the power take-off in time before the engine stops. Otherwise, the
NEUTRAL. engine will immediately shut off.

Note: Extended idling can cause excessive oil The engine will coast to a stop. Ensure that any
consumption and related problems. See this system that provides external support to the engine
Operation and Maintenance Manual, “Engine is secured after the engine is stopped.
Operation” topic (Operation Section).

2. Reduce the engine rpm to low idle.

Note: If the cooldown feature is not utilized, operate

the engine at low idle rpm for a cooldown period
before stopping the engine. If the engine has been
operated at a low load, operate the engine at low idle
for approximately 30 seconds before stopping the
engine. If the engine has been operated at a high
load, operate the engine at low idle for one minute
before stopping the engine.

3. Use one of the following methods in order to stop

the engine:

a. Turn the engine control switch to the

“COOLDOWN/STOP” position. If the cooldown
feature is utilized, the engine will operate for a
programmed period of time before the engine
stops. Otherwise, the engine will immediately
shut off.
54 SEBU6355-03
Operation Section
Engine Stopping

i00662051

After Stopping Engine

SMCS Code: 1000

• Check the engine crankcase oil level. Maintain

the oil level between the “ADD” and “FULL” marks
on the “ENGINE STOPPED” side of the oil level
gauge.

• If necessary, perform minor adjustments. Repair

any leaks and tighten loose bolts.

• Note the service hour meter reading. Perform the

maintenance that is scheduled in this Operation
and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section).

NOTICE
Only use antifreeze/coolant mixtures recommended in
the Coolant Specifications of this manual. Failure to do
so can cause engine damage.

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

• If freezing temperatures are expected, check the
coolant for protection against freezing. The cooling
system must be protected against freezing to the
lowest expected outside temperature. Add the
proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all

driven equipment. Refer to the instructions that are
provided by the OEM of the driven equipment.
SEBU6355-03 55
Maintenance Section
Refill Capacities

Maintenance Section Lubricant Capacities

The capacity of the engine crankcase includes the
capacity of the oil filters that are installed at the
Refill Capacities factory.

Table 12
i02117538
Lubrication System
Refill Capacities and Approximate Refill Capacities

Recommendations Engine Liters US Gallons

G3508 224 59
SMCS Code: 1348; 1395; 7560
G3512 307 81
402 106
Lubrication System G3516

Lubricant Recommendations Auxiliary Oil Filters

Due to significant variations in the quality and in Table 13
the performance of commercially available oils, Approximate Capacities for Auxiliary Oil Filters
Caterpillar makes the following recommendations:
Capacity
Auxiliary Oil Filter Capacity With
• Cat NGEO (Natural Gas Engine Oil) Without
System Elements
Elements(1)
• Cat NGEO EL250 117-9550 Oil Filter 132 L 176 L
Assembly(2) (35 US gal) (46.5 US gal)
• Cat NGEO EL350 118-8419 Oil Filter 132 L 176 L
Assembly(3) (35 US gal) (46.5 US gal)
The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during 119-2104 Oil Filter 178 L 244 L
cold engine start-up, and the maximum ambient Assembly(4) (47 US gal) (64 US gal)
temperature during engine operation. To determine (1) Auxiliary oil filter systems increase the oil capacity in order
the oil viscosity that is required for starting a cold to increase the service life of the oil. Caterpillar recommends
soaked engine, refer to the minimum temperature in operation without the auxiliary oil filter elements.
(2) This assembly contains 14 elements. This assembly is for use
Table 11. To select the oil viscosity for operation at
with G3508 Engines.
the highest anticipated ambient temperature, refer (3) This assembly contains 14 elements. This assembly is for use
to the maximum temperature in the Table. Use the with G3512 Engines.
highest oil viscosity that is available in order to meet (4) This assembly contains 21 elements. This assembly is for use
the required temperature during start-up. with G3516 Engines.

Table 11
Fuel
Engine Oil Viscosity
Cat NGEO Ambient Temperature Fuel Recommendations
Grade of
Viscosity Minimum Maximum Caterpillar gas engines will operate successfully on
SAE 30(1) 0 °C (32 °F) 40 °C (104 °F) a broad range of gaseous fuels. Pipeline natural
gas has been used for many years. Commercial
SAE 40(1) 5 °C (41 °F) 50 °C (122 °F) fuel gases are mixtures of gases. These fuels
(1) Cat NGEO is available in these grades only. Multigrade oils are consist primarily of hydrocarbons (combinations of
NOT recommended for use in Caterpillar Gas Engines. If other hydrogen and carbon) and some inert gases. The
grades of viscosity are selected, ensure that the oil meets the compositions of these gas mixtures have extreme
requirements for Caterpillar Gas Engines.
variations. Fuels such as wellhead gas, bio-gas,
and manufactured gas need to be reviewed for
For further information about oils, see Special acceptability. Analyze the fuel in order to determine
Publication, SEBU6400, “Caterpillar Gas Engine the following characteristics:
Lubricant, Fuel, and Coolant Recommendations”.
• Composition
• Contaminants
56 SEBU6355-03
Maintenance Section
Refill Capacities

• Heat value Water

• Methane number Deionized water or distilled water is

recommended for use in engine cooling systems.
• Specific gravity If distilled water or deionized water is not available,
use water with the properties that are listed in Table
Field gas can have varying characteristics of 14.
combustion. Field gas can contain numerous
harmful impurities. The impurities can alter the BTU Table 14
content. The impurities can also alter the methane Caterpillar Minimum Acceptable Water Requirements
number. The impurities include everything from
water up to complex hydrocarbons that can lead to Property Maximum Limit ASTM Test
detonation and severe engine damage. To minimize 40 mg/L “D512”,
these effects, Caterpillar recommends the following Chloride (Cl)
(2.4 grains per US gal) “D4327”
guidelines:
100 mg/L
Sulfate (SO4) “D516”
1. Evaluate the fuel with the Caterpillar Methane (5.9 grains per US gal)
Number Program, LEKQ6378. 170 mg/L
Total Hardness “D1126”
(10 grains per US gal)
Methane values below 30 are not recommended
340 mg/L
for use in a Caterpillar engine. Fuels with a Total Solids
(20 grains per US gal)
“D1888”
methane number that is below 30 must first be
processed in order to remove harmful impurities Acidity pH of 5.5 to 9.0 “D1293”
in the fuel and raising the methane number into
the acceptable range.
NOTICE
2. If necessary, use an engine that is configured Use of water that does not meet the recommendations
for a fuel that has a high energy. Consult the for the cooling system will damage the cooling system.
appropriate manual for the engine in order to
determine the recommended engine timing. Do not use these types of water in the cooling system:
sea water, softened water that has been conditioned
3. Reduce the oil change interval according to the with salt, hard water, and tap water.
results of the oil analysis.
Only use water that meets the recommendations for
For further information on fuels, see Special the cooling system.
Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”. If you are not sure about the properties of your water,
consult one of the following sources for a water
Cooling System analysis:

Coolant Recommendations • Caterpillar dealer

During shipping and storage, the engine must be • Local water utility company
protected from damage that can be caused by
freezing of the cooling system. If the engine is • Agricultural agent
shipped to a site with freezing temperatures and/or
if the engine is stored in a location with freezing • Independent laboratory
temperatures, the cooling system must contain
Glycol
antifreeze that will withstand the lowest ambient
temperature. Frequently check the concentration
of glycol in the coolant/antifreeze. Make sure that NOTICE
the concentration is adequate in order to prevent Do not use Extended Life Coolant (ELC) with
freezing. Otherwise, the cooling system must be Caterpillar Gas Engines.
completely drained.
ELC was not formulated for use in Caterpillar Gas En-
Coolant/antifreeze is normally composed of three gines.
elements: water, glycol, and additives. Each element
must meet specific guidelines. Use only the coolant/antifreeze that is recommended.
SEBU6355-03 57
Maintenance Section
Refill Capacities

Preferred – Caterpillar NGEC (Natural Gas Engine Additives

Coolant)
Preferred – Caterpillar SCA (Supplemental Coolant
Alternatively, use Caterpillar DEAC (Diesel Engine Additive)
Antifreeze/Coolant) or a commercial heavy-duty
coolant/antifreeze that meets “ASTM D6210” or Acceptable – A commercial SCA that provides
“ASTM D4985” specifications. 1200 mg/L (70 grains per US gal) or 1200 ppm of
nitrites in the final mixture of coolant/antifreeze
NOTICE
Do not use a commercial coolant/antifreeze that only Note: Caterpillar NGEC or a 50/50 concentration
meets the ASTM “D3306” specification. This type of of Caterpillar DEAC does not require a treatment
coolant/antifreeze is made for light duty automotive with an SCA at the initial fill. Commercial
applications. heavy-duty coolant/antifreeze that meets “ASTM
D6210” or “ASTM D4985” specifications may require
Use only the coolant/antifreeze that is recommended. a treatment with an SCA at the initial fill. Read the
label or the instructions that are provided by the OEM
of the product.
Acceptable – In applications that do not require
protection from boiling or from freezing, a mixture of To ensure that the correct amount of SCA is in the
Cat SCA and water that meets the properties that are cooling system, the concentration of SCA must be
listed in Table 14 is acceptable. tested on a scheduled basis. Obtain an S·O·S coolant
analysis (Level 1) or use a test kit to check the
Note: The preferred coolant/antifreeze and the concentration of the SCA according to this Operation
acceptable mixture of SCA and water require and Maintenance Manual, “Maintenance Interval
different concentrations of SCA. Refer to the Special Schedule”.
Publication, SEBU6400, “Supplemental Coolant
Additive (SCA)” topic. For further information on coolant, see Special
Publication, SEBU6400, “Caterpillar Gas Engine
Table 15 is a list of the coolant/antifreeze that is Lubricant, Fuel, and Coolant Recommendations”.
recommended for Caterpillar Gas Engines. The
service life of the coolant/antifreeze that is used in Coolant Capacities
Caterpillar Gas Engines is also listed. To achieve
this service life, the coolants must be properly To properly maintain the cooling system, the Total
maintained. The maintenance program includes Cooling System capacity must be determined. The
S·O·S coolant analysis. Total Cooling System capacity will vary between
individual installations. The External System
Table 15
capacity includes the following components: engine,
Recommended Coolant/Antifreeze and Service expansion tank, heat exchanger, radiator, and piping.
Life of the Coolant/Antifreeze Refer to the specifications that are provided by
Coolant/Antifreeze Service Life (1) Caterpillar or by the OEM of the equipment. Record
the Total Cooling System capacity in the following
Cat NGEC Table:
Three Years
Cat DEAC Table 16
Commercial Heavy-Duty Cooling System
Coolant/Antifreeze that Two Years Approximate Refill Capacities
meets “ASTM D6210”
System G3508 G3512 G3516
Commercial Heavy-Duty
Coolant/Antifreeze that One Year Jacket 114 L 148 L 205 L
meets “ASTM D4985” Water 30 US gal 39 US gal 53 US gal
System
Catr SCA and Water Two Years Only
Commercial SCA and SCAC 13 L 15 L 16.5 L
One Year
Water System 3.5 US gal 4 US gal 4.5 US gal
(1) The service life of coolant is also limited by use (service hours). Only
Refer to the specific engine’s Operation and Maintenance
Manual, “Maintenance Interval Schedule”. External
System
Total
Cooling
System
58 SEBU6355-03
Maintenance Section
Maintenance Interval Schedule

i02118533 Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 71
Maintenance Interval Schedule Engine Mounts - Check ........................................ 79
(Turbocharged Aftercooled) Engine Speed/Timing Sensor - Clean/Inspect ...... 86
Valve Stem Projection - Measure/Record ........... 101
SMCS Code: 1000; 4450; 7500
Every 1000 Service Hours
Before performing any operation or maintenance
Aftercooler Condensation - Drain ......................... 62
procedures, ensure that the safety information,
Belts - Inspect/Adjust/Replace .............................. 66
warnings, and instructions are read and
understood. Carburetor Air/Fuel Ratio - Check/Adjust ............. 67
Crankshaft Vibration Damper - Inspect ................. 73
Engine Crankcase Breather - Clean ..................... 78
Failure to adhere to proper maintenance intervals
may result in the degradation of the engine’s Engine Oil - Change ............................................. 80
Engine Oil Filter (Auxiliary) - Change ................... 81
performance and/or the accelerated wear of the
Engine Oil Filter - Change .................................... 82
engine’s components.
Engine Valve Lash - Inspect/Adjust ...................... 87
Exhaust Piping - Inspect ....................................... 88
Before each consecutive interval is performed, all
Gas Pressure Regulator Condensation - Drain .... 89
of the maintenance requirements from the previous
interval must be performed. Hoses and Clamps - Inspect/Replace .................. 89
Ignition System Spark Plugs - Check/Adjust/
Replace ............................................................... 90
When Required Ignition System Timing - Check/Adjust ................. 93
Batteries - Replace ............................................... 64 Inlet Air System - Inspect ...................................... 93
Engine Air Cleaner Element - Replace ................. 75 Radiator - Clean .................................................... 99
Engine Oil Filter - Change .................................... 82
Overhaul Considerations ...................................... 97 Every 2000 Service Hours
Valve Stem Projection - Measure/Record ........... 101
Actuator Control Linkage - Lubricate .................... 62
Cooling System Coolant Sample (Level 1) -
Daily Obtain ................................................................. 70
Air Starting Motor Lubricator Oil Level - Check .... 63 Cooling System Supplemental Coolant Additive
Air Tank Moisture and Sediment - Drain ............... 64 (SCA) - Test/Add ................................................. 71
Control Panel - Inspect ......................................... 67 Engine Speed/Timing Sensor - Clean/Inspect ...... 86
Cooling System Coolant Level - Check ................ 70
Engine Air Cleaner Service Indicator - Inspect ..... 77 Every 4000 Service Hours
Engine Air Precleaner - Clean .............................. 78
Air Starting Motor Lubricator Bowl - Clean ........... 62
Engine Oil Level - Check ...................................... 85
Alternator - Inspect ............................................... 64
Fuel System Fuel Filter Differential Pressure -
Check .................................................................. 89 Crankcase Blowby - Measure/Record .................. 73
Cylinder Pressure - Measure/Record ................... 74
Jacket Water Heater - Check ................................ 93
Engine Mounts - Check ........................................ 79
Walk-Around Inspection ...................................... 102
Engine Protective Devices - Check ...................... 86
Exhaust Bypass - Inspect ..................................... 88
Every Week Starting Motor - Inspect ........................................ 99
Battery Charger - Check ....................................... 65 Water Pump - Inspect ......................................... 103
Electrical Connections - Check ............................. 75
Every 8000 Service Hours
Initial 250 Service Hours Cooling System Coolant Sample (Level 2) -
Valve Stem Projection - Measure/Record ........... 101 Obtain ................................................................. 71
Exhaust Manifold - Inspect ................................... 88
Every 250 Service Hours Turbocharger - Inspect ........................................ 100
Water Temperature Regulator - Replace ............ 103
Battery Electrolyte Level - Check .......................... 66
Engine Oil Sample - Obtain .................................. 85 Between 9000 and 16 000 Service Hours

Initial 1000 Service Hours Overhaul (Top End) ............................................... 95

Cooling System Coolant Sample (Level 1) - Every 24 000 Service Hours or 3 Years
Obtain ................................................................. 70
Cooling System Coolant (NGEC) - Change .......... 67
SEBU6355-03 59
Maintenance Section
Maintenance Interval Schedule

Between 45 000 and 80 000 Service Hours

Overhaul (Major) ................................................... 93
60 SEBU6355-03
Maintenance Section
Maintenance Interval Schedule

i02118527 Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 71
Maintenance Interval Schedule Engine Mounts - Check ........................................ 79
(Naturally Aspirated) Engine Speed/Timing Sensor - Clean/Inspect ...... 86
Valve Stem Projection - Measure/Record ........... 101
SMCS Code: 1000; 4450; 7500
Every 1000 Service Hours
Before performing any operation or maintenance
Belts - Inspect/Adjust/Replace .............................. 66
procedures, ensure that the safety information,
Carburetor Air/Fuel Ratio - Check/Adjust ............. 67
warnings, and instructions are read and
understood. Crankshaft Vibration Damper - Inspect ................. 73
Engine Crankcase Breather - Clean ..................... 78
Engine Oil - Change ............................................. 80
Failure to adhere to proper maintenance intervals
may result in the degradation of the engine’s Engine Oil Filter (Auxiliary) - Change ................... 81
Engine Oil Filter - Change .................................... 82
performance and/or the accelerated wear of the
Exhaust Piping - Inspect ....................................... 88
engine’s components.
Gas Pressure Regulator Condensation - Drain .... 89
Hoses and Clamps - Inspect/Replace .................. 89
Before each consecutive interval is performed, all
Ignition System Spark Plugs - Check/Adjust/
of the maintenance requirements from the previous
interval must be performed. Replace ............................................................... 90
Ignition System Timing - Check/Adjust ................. 93
Inlet Air System - Inspect ...................................... 93
When Required Radiator - Clean .................................................... 99
Batteries - Replace ............................................... 64
Engine Air Cleaner Element - Replace ................. 75 Every 2000 Service Hours
Engine Oil Filter - Change .................................... 82
Overhaul Considerations ...................................... 97 Actuator Control Linkage - Lubricate .................... 62
Cooling System Coolant Sample (Level 1) -
Valve Stem Projection - Measure/Record ........... 101
Obtain ................................................................. 70
Cooling System Supplemental Coolant Additive
Daily (SCA) - Test/Add ................................................. 71
Air Starting Motor Lubricator Oil Level - Check .... 63 Engine Speed/Timing Sensor - Clean/Inspect ...... 86
Air Tank Moisture and Sediment - Drain ............... 64 Engine Valve Lash - Inspect/Adjust ...................... 87
Control Panel - Inspect ......................................... 67
Cooling System Coolant Level - Check ................ 70 Every 4000 Service Hours
Engine Air Cleaner Service Indicator - Inspect ..... 77
Engine Air Precleaner - Clean .............................. 78 Air Starting Motor Lubricator Bowl - Clean ........... 62
Alternator - Inspect ............................................... 64
Engine Oil Level - Check ...................................... 85
Crankcase Blowby - Measure/Record .................. 73
Fuel System Fuel Filter Differential Pressure -
Check .................................................................. 89 Cylinder Pressure - Measure/Record ................... 74
Engine Mounts - Check ........................................ 79
Jacket Water Heater - Check ................................ 93
Engine Protective Devices - Check ...................... 86
Walk-Around Inspection ...................................... 102
Exhaust Bypass - Inspect ..................................... 88
Starting Motor - Inspect ........................................ 99
Every Week Water Pump - Inspect ......................................... 103
Battery Charger - Check ....................................... 65
Electrical Connections - Check ............................. 75 Every 8000 Service Hours
Cooling System Coolant Sample (Level 2) -
Initial 250 Service Hours Obtain ................................................................. 71
Valve Stem Projection - Measure/Record ........... 101 Exhaust Manifold - Inspect ................................... 88
Water Temperature Regulator - Replace ............ 103
Every 250 Service Hours
Between 8000 and 10 000 Service Hours
Battery Electrolyte Level - Check .......................... 66
Engine Oil Sample - Obtain .................................. 85 Overhaul (Top End) ............................................... 95

Initial 1000 Service Hours Every 24 000 Service Hours or 3 Years

Cooling System Coolant Sample (Level 1) - Cooling System Coolant (NGEC) - Change .......... 67
Obtain ................................................................. 70
SEBU6355-03 61
Maintenance Section
Maintenance Interval Schedule

Between 64 000 and 80 000 Service Hours

Overhaul (Major) ................................................... 93
62 SEBU6355-03
Maintenance Section
Actuator Control Linkage - Lubricate

i01516282

Actuator Control Linkage -

Lubricate
SMCS Code: 1265-086

g00786820
Illustration 43
(1) Plug

Remove plug (1). Drain the moisture into a suitable

container. Install the plug.

i02208941

Air Starting Motor Lubricator

Bowl - Clean
g00786805
SMCS Code: 1451-070
Illustration 42
Grease fittings on the linkage If the engine is equipped with an air starting motor,
use the following procedure:
Apply grease to the grease fittings. Use a hand
grease gun and lubricate the grease fittings with
MPGM.
Personal injury can result from removing hoses or
i01516337 fittings in a pressure system.
Aftercooler Condensation - Failure to relieve pressure can cause personal in-
Drain jury.

SMCS Code: 1063 Do not disconnect or remove hoses or fittings un-

til all pressure in the system has been relieved.
The aftercooler cools the compressed air/fuel mixture
from the turbocharger. Coolant passes through the 1. Ensure that the air supply to the lubricator is OFF.
tubes in the aftercooler core. The air/fuel mixture
that is compressed and warmed by the turbocharger
compressor is directed through the aftercooler core.
The air/fuel mixture is cooled in the aftercooler.

Condensation can form in the housing of the

aftercooler. A drain plug is provided for draining the
condensation.

Note: An automatic drain is available for use with

32 °C (90 °F) separate circuit aftercoolers. Consult
your Caterpillar dealer for details.
SEBU6355-03 63
Maintenance Section
Air Starting Motor Lubricator Oil Level - Check

i01924142

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.

g00745554
Illustration 44
(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 g00745561
collect the fluid with suitable containers before open- Illustration 45
ing any compartment or disassembling any compo-
nent containing fluids. 1. Observe the oil level in sight gauge (3). If the oil
level is less than 1/2, add oil to the lubricator bowl.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products. Personal injury can result from removing hoses or
fittings in a pressure system.
Dispose of all fluids according to local regulations and
mandates. Failure to relieve pressure can cause personal in-
jury.
3. Place a suitable container under bowl (2) and
open drain valve (3) in order to drain the oil from Do not disconnect or remove hoses or fittings un-
the bowl. til all pressure in the system has been relieved.

4. Remove bowl (2). Clean the bowl with warm water. 2. Ensure that the air supply to the lubricator is OFF.
Slowly loosen filler plug (4) in order to release
5. Dry the bowl. Inspect the bowl for cracks. If the pressure from the lubricator bowl.
bowl is cracked, replace the damaged bowl with
a new bowl. Inspect the gasket. If the gasket is 3. Remove filler plug (4). Pour oil into the lubricator
damaged, replace the gasket. bowl. Use nondetergent “10W” oil for temperatures
that are greater than 0 °C (32 °F). Use air tool oil
6. Install the bowl. for temperatures that are below 0 °C (32 °F).
7. Make sure that drain valve (3) is closed. 4. Install filler plug (4).
8. For instructions on filling the lubricator, see this
Operation and Maintenance Manual, “Air Starting Adjust the Lubricator
Motor Lubricator Oil Level - Check” topic.
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.
64 SEBU6355-03
Maintenance Section
Air Tank Moisture and Sediment - Drain

1. Ensure that the fuel supply to the engine is OFF. • Clean ports for cooling airflow

NOTICE • Proper charging of the battery

Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two Observe the ammeter during engine operation in
minutes before cranking the engine again. order to ensure proper battery performance and/or
proper performance of the electrical system.

2. Operate the air starting motor. Observe the drops Make repairs, if necessary. See the Service Manual
of oil that are released in dome (1). for service procedures. Consult your Caterpillar
dealer for assistance.
Note: Some lubricators have an adjustment screw
rather than a knob.
i01041029

3. If necessary, adjust the lubricator in order

to release from one to three drops of oil per
Batteries - Replace
second. To increase the rate, turn knob (2) SMCS Code: 1401-510
counterclockwise. To decrease the rate, turn the
knob clockwise.

i00351324 Batteries give off combustible gases which can

explode. A spark can cause the combustible gas-
Air Tank Moisture and es to ignite. This can result in severe personal in-
Sediment - Drain jury or death.

SMCS Code: 1466-543-M&S Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
Moisture and sediment in the air starting system can der to help prevent electrical arcs and/or sparks
cause the following conditions: near batteries. Do not smoke when batteries are
serviced.
• Freezing
1. Turn the key start switch to the OFF position.
• Corrosion of internal parts Remove the key and all electrical loads.
• Malfunction of the air starting system 2. Turn OFF the battery charger. Disconnect the
charger.

3. The NEGATIVE “-” cable connects the NEGATIVE

When opening the drain valve, wear protective “-” battery terminal to the ground plane. Disconnect
gloves, a protective face shield, protective cloth- the cable from the NEGATIVE “-” battery terminal.
ing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal 4. The POSITIVE “+” cable connects the POSITIVE
injury. “+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+”
battery terminal.
1. Open the drain valve that is on the bottom of the
air tank. Allow the moisture and sediment to drain. Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
2. Close the drain valve. recycling facility.

i02084374
5. Remove the used battery.

Alternator - Inspect 6. Install the new battery.

SMCS Code: 1405-040 Note: Before connecting the cables, ensure that the
key start switch is OFF.
Inspect the alternator for the following conditions:
7. Connect the cable from the starting motor to the
• Proper connections POSITIVE “+” battery terminal.
SEBU6355-03 65
Maintenance Section
Battery Charger - Check

8. Connect the cable from the ground plane to the • A strong odor of acid is present.
NEGATIVE “-” battery terminal.
• The battery emits smoke or a dense vapor (gas).
i01039758
Perform one of the following procedures if the battery
Battery Charger - Check shows symptoms of overcharging:

SMCS Code: 1401-535 • Reduce the rate of charging by a significant

amount. Complete the charging at the reduced
rate.
Checking Before Start-Up
• Turn OFF the charger.
Check the battery charger for proper operation. If
the batteries are properly charged, the needle of the Table 17 describes the effects of overcharging on
ammeter will register near “0” (zero). different types of batteries.

The battery charger must not produce excessive Table 17

current during start-up. Alternatively, the charger Effects of Overcharging Batteries
must be automatically disconnected for start-up.
If the engine has an alternator, the charger must Type of Battery Effect
be automatically disconnected during start-up and
during engine operation.
Caterpillar General Service All of the battery cells have
Batteries a low level of electrolyte.
Charging the Battery Caterpillar Premium High
Output Batteries

Never disconnect any charging unit circuit or bat-

When the plates of the
tery circuit cable from the battery when the charg- battery are inspected
ing unit is operated. A spark can cause an explo- through the filler holes, the
sion from the flammable vapor mixture of hydro- plates may appear to be
gen and oxygen that is released from the elec- warped. This is caused by
trolyte through the battery outlets. Injury to per- an excessive temperature.
sonnel can be the result.
The battery may not pass
a load test.
Perform the following procedure to charge the Caterpillar Maintenance The battery may not accept
battery: Free Batteries a charging current.

1. Ensure that the charger is turned OFF. The battery may not pass
a load test.
2. Adjust the voltage of the charger in order to match
the voltage of the battery.
Checking After Stopping
3. Connect the POSITIVE “+” lead of the charger
to the POSITIVE “+” battery terminal. Connect Ensure that the battery charger is connected
the NEGATIVE “-” lead of the charger to the properly. Observe the meter of the charger. Record
NEGATIVE “-” battery terminal. the amperage.

4. Turn ON the battery charger.

Overcharging of Batteries

Overcharging reduces the service life of batteries.

Use a battery charger that will not overcharge the
battery. DO NOT charge the battery if the meter of
the battery charger is in the RED zone.

Overcharging is indicated by the following symptoms:

• The battery is very warm to the touch.

66 SEBU6355-03
Maintenance Section
Battery Electrolyte Level - Check

i01639002 i02154849

Battery Electrolyte Level - Belts - Inspect/Adjust/Replace

Check SMCS Code: 1357-025; 1357-040; 1357-510
SMCS Code: 1401-535-FLV
Inspection
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries Inspect the alternator belt and the fan drive belts for
may not fully recharge. Ensure a full charge in order wear and for cracking. Replace the belts if the belts
to help prevent the battery from freezing. If batteries are not in good condition.
are properly charged, ammeter reading should be
very near zero. Check the belt tension according to the information in
the Service Manual, “Specifications”.

Slippage of loose belts can reduce the efficiency

of the driven components. Vibration of loose belts
All lead-acid batteries contain sulfuric acid which can cause unnecessary wear on the following
can burn the skin and clothing. Always wear a face components:
shield and protective clothing when working on or
near batteries. • Belts
1. Remove the filler caps. Maintain the electrolyte • Pulleys
level to the “FULL” mark on the battery.
• Bearings
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean If the belts are too tight, unnecessary stress is placed
water that is low in minerals. Do not use artificially on the components. This reduces the service life of
softened water. the components.

2. Check the condition of the electrolyte with the Adjusting the Alternator Belt
1U-7298 Coolant/Battery Tester (°C) or the
1U-7297 Coolant/Battery Tester (°F).

3. Keep the batteries clean.

Clean the battery case with one of the following

cleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and

1 L (1 qt) of clean water

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L

(1 qt) of clean water

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean the

terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit
properly. Coat the clamps and the terminals with g01092641
5N-5561 Silicone Lubricant, petroleum jelly or Illustration 46
MPGM grease. (1) Mounting bolt
(2) Adjusting nuts
(3) Mounting bolt

1. Remove the drive belt guard.

SEBU6355-03 67
Maintenance Section
Carburetor Air/Fuel Ratio - Check/Adjust

2. Loosen mounting bolt (1), adjusting nuts (2) and i01762721

mounting bolt (3).
Control Panel - Inspect
3. Turn adjusting nuts (2) in order to increase or
decrease the drive belt tension. SMCS Code: 4490-040; 7451-040

4. Tighten adjusting nuts (2). Tighten mounting bolt Inspect the condition of the panel. If a component is
(3). Tighten mounting bolt (1). For the proper damaged, ensure that the component is repaired or
torque, see the Service Manual, “Specifications” that the component is replaced. If equipped, ensure
module. that the electronic displays are operating properly.

5. Reinstall the drive belt guard. Inspect the wiring for good condition. Ensure that the
wiring connections are secure.
If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation at Record the Data and Review the
the rated rpm.
Data
Adjusting the Fan Drive Belt If equipped, check the gauges and check the
indicators frequently during normal operation. Record
1. Loosen the mounting bolt for the pulley. the data in a log. Compare the new data to the data
that was previously recorded. Comparing the new
2. Loosen the adjusting nut for the pulley. data to the recorded data will establish the normal
gauge readings for the engine. A gauge reading that
3. Move the pulley in order to adjust the belt tension. is abnormal may indicate a problem with operation
or with the gauge.
4. Tighten the adjusting nut.

5. Tighten the mounting bolt. i02209116

Cooling System Coolant

Replacement
(NGEC) - Change
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing SMCS Code: 1350-044
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive Clean the cooling system before the recommended
belts are stretched. The additional load on the new maintenance interval if the following conditions exist:
drive belt could cause the new drive belt to fail.
• The engine overheats frequently.
i01005891 • Foaming is observed.
Carburetor Air/Fuel Ratio - • Engine oil has entered the cooling system and the
Check/Adjust coolant is contaminated.

SMCS Code: 1266-535; 1266 NOTICE

Use of commercially available cooling system clean-
An engine failure may occur if the air/fuel ratio is ers may cause damage to cooling system compo-
not appropriate for the fuel and for the operating nents. Use only cooling system cleaners that are ap-
conditions. The service life of the turbocharger, of the proved for Caterpillar engines.
valves, and of the other components may be reduced.

Ensure that the carburetor is adjusted properly so Drain the Cooling System
that the air/fuel ratio is correct.
1. Stop the engine and allow the engine to cool.
For information on adjusting the carburetor, refer to Ensure that the engine will not start when the
the Service Manual, “Systems Operation/Testing cooling system is drained.
and Adjusting”, or refer to the Special Instruction,
“Installation and Initial Start-Up Procedure”. 2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
68 SEBU6355-03
Maintenance Section
Cooling System Coolant (NGEC) - Change

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.

g00786868
Illustration 47
NOTICE
Locations of the drain plugs
If the aftercooler circuit has been drained, the vent
(1) Jacket water pump plug must be opened to allow the aftercooler to fill
(2) Cylinder block
(3) Auxiliary water pump
properly. Failure to do this will cause an air lock re-
sulting in engine damage.
3. Open the cooling system drain valves (if
equipped). If the cooling system is not equipped
with drain valves, remove drain plugs (1), (2), and
(3). Drain all of the cooling system components:

• Expansion tank or radiator

• Water pumps
• Aftercooler
• Thermostatic valve
• Engine block
g00786870
• All coolant lines Illustration 48
Vent plug
4. Inspect the cooling system lines that run from the The vent line of the ebullient cooled engine will be installed by
engine to the expansion tank. Ensure that the the customer.
lines maintain a constant upward slope from the If a customer has not installed the vent lines, loosen the vent
engine to the tank. cap from the tee.

NOTICE 3. Remove vent plug (4) for the aftercooler.

Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used 4. Fill the cooling system with a mixture of clean
coolant for reuse in engine cooling systems. The full water and Caterpillar Fast Acting Cooling System
distillation procedure is the only method acceptable by Cleaner. Add .5 L (1 pint) of cleaner per 15 L
Caterpillar to reclaim the used coolant. (4 US gal) of the cooling system capacity. Install
the cooling system filler cap. Install vent plug (4).

For information regarding the disposal and the 5. Start the engine. Operate the engine for a
recycling of used coolant, consult your Caterpillar minimum of 30 minutes with a coolant temperature
dealer or consult Caterpillar Dealer Service Tools: of at least 82 °C (180 °F).

Outside Illinois: 1-800-542-TOOL 6. Stop the engine and allow the engine to cool.
Inside Illinois: 1-800-541-TOOL Loosen the cooling system filler cap slowly in
Canada: 1-800-523-TOOL order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valves (if equipped) or remove drain plugs (1), (2),
and (3). See Illustration 47.
SEBU6355-03 69
Maintenance Section
Cooling System Coolant (NGEC) - Change

6. Stop the engine and allow the engine to cool.

NOTICE Loosen the cooling system filler cap slowly in
Improper or incomplete rinsing of the cooling system order to relieve any pressure. Remove the cooling
can result in damage to copper and other metal com- system filler cap. Open the cooling system drain
ponents. valves (if equipped) or remove drain plugs (1),
(2), and (3). See Illustration 47. Allow the water
To avoid damage to the cooling system, make sure to drain.
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the NOTICE
cleaning agent are gone. Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
Note: The cleaner has a smell of ammonia. Continue
to flush the cooling system until the smell is gone.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
7. Allow the water to drain. Flush the cooling system ter. Continue to flush the system until all signs of the
with clean water until the water that drains is
cleaning agent are gone.
clean. Close the cooling system drain valves (if
equipped). Clean the drain plugs and install the
drain plugs. Note: The cleaner has a smell of ammonia. Continue
to flush the cooling system until the smell is gone.
Cleaning a Cooling System that 7. Flush the cooling system with clean water until
has Heavy Deposits or Plugging the water that drains is clean. Close the cooling
system drain valves (if equipped). Clean the drain
Note: For the following procedure to be effective, plugs and install the drain plugs.
there must be an active flow through the cooling
system components.
Fill the Cooling System
1. After the cooling system has been drained, flush
the cooling system with clean water in order to NOTICE
remove any debris. Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
2. Close the cooling system drain valves (if
equipped). Clean drain plugs and install drain
plugs (1), (2), and (3). See Illustration 47. Note: For information about the proper coolant to
use, and for the capacity of the cooling system,
see this Operation and Maintenance Manual, “Refill
NOTICE Capacities and Recommendations” (Maintenance
Fill the cooling system no faster than 19 L (5 US gal) Section).
per minute to avoid air locks.
1. Remove vent plug (4) for the aftercooler. See
Illustration 48.
NOTICE
If the aftercooler circuit has been drained, the vent 2. Fill the cooling system with coolant/antifreeze.
plug must be opened to allow the aftercooler to fill Install vent plug (4). Do not install the cooling
properly. Failure to do this will cause an air lock re- system filler cap.
sulting in engine damage.
3. Start the engine. Operate the engine in order to
3. Remove vent plug (4) for the aftercooler. See purge the air from the cavities of the engine block.
Illustration 48. Allow the coolant to warm and allow the coolant
level to stabilize. Stop the engine.
4. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System 4. Check the coolant level. Maintain the coolant to
Cleaner. Add .5 L (1 pint) of cleaner per 7.5 L the proper level on the sight gauge (if equipped).
(2 US gal) of the cooling system capacity. Install If a sight gauge is not equipped, maintain the
the cooling system filler cap. Install vent plug (4). coolant within 13 mm (.5 inch) below the bottom of
the filler pipe.
5. Start the engine. Operate the engine for a
minimum of 90 minutes with a coolant temperature
of at least 82 °C (180 °F).
70 SEBU6355-03
Maintenance Section
Cooling System Coolant Level - Check

5. Clean the cooling system filler cap. Inspect the Observe the coolant level in the sight gauge (if
gaskets of the cooling system filler cap. If the equipped). When the engine is running at normal
gaskets of the cooling system filler cap are operating temperature, the coolant should be in the
damaged, discard the old cooling system filler cap upper half of the sight gauge. If the coolant level is
and install a new cooling system filler cap. If the low, add the proper coolant mixture.
gaskets of the cooling system filler cap are not
damaged, use a 9S-8140 Pressurizing Pump in Add Coolant
order to pressure test the cooling system filler cap.
The correct pressure is stamped on the face of
Note: For the proper coolant mixture to use, see
the cooling system filler cap. If the cooling system this Operation and Maintenance Manual, “Refill
filler cap does not maintain the correct pressure,
Capacities and Recommendations” topic.
install a new cooling system filler cap.
1. Stop the engine. Allow the engine to cool.
6. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
2. Remove the cooling system filler cap slowly in
order to relieve any pressure. Pour the proper
i02017615 coolant mixture into the filler pipe.

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.

NOTICE Illustration 50
g00103639
Overfilling the overflow tank (if equipped) will result in Filler cap gaskets
damage to the cooling system.
3. Clean the cooling system filler cap. Inspect the
If the cooling system has an overflow tank, maintain gaskets of the cooling system filler cap. If the
the coolant level in the tank below 1/2 full in order to gaskets are damaged, replace the old cooling
avoid damage to the cooling system. 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.

i02064894

Cooling System Coolant

Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542

NOTICE
g00760290 Always use a designated pump for oil sampling, and
Illustration 49
use a separate designated pump for coolant sampling.
Normal position of the coolant in the sight gauge during rated Using the same pump for both types of samples may
operation
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.
SEBU6355-03 71
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

For conventional heavy-duty coolant/antifreeze, i02168823

check the concentration of supplemental coolant
additive (SCA) regularly. The concentration of SCA Cooling System Coolant
can be checked with an S·O·S coolant analysis
(Level 1).
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
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 NOTICE
must establish a consistent trend of data. In order Always use a designated pump for oil sampling, and
to establish a pertinent history of data, perform use a separate designated pump for coolant sampling.
consistent samplings that are evenly spaced. Using the same pump for both types of samples may
Supplies for collecting samples can be obtained from contaminate the samples that are being drawn. This
your Caterpillar dealer. contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
Use the following guidelines for proper sampling of dealers and customers.
the coolant:
Obtain the sample of the coolant as close as possible
• Never collect samples from expansion bottles. to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
• Never collect samples from the drain for a system. Caterpillar dealer.

• Keep the unused sampling bottles stored in plastic Refer to this Operation and Maintenance Manual,
bags. “Cooling System Coolant Sample (Level 1) - Obtain”
(Maintenance Section) for the guidelines for proper
• Keep the lids on empty sampling bottles until you sampling of the coolant.
are ready to collect the sample.
Submit the sample for Level 2 analysis.
• Complete the information on the label for the
sampling bottle before you begin to take the For additional information about coolant analysis,
samples. see the Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel, and Coolant
• Obtain coolant samples directly from the coolant Recommendations” or consult your Caterpillar dealer.
sample port. You should not obtain the samples
from any other location.
i02017557

• In order to avoid contamination, immediately place

the sample in the tube that is provided for mailing.
Cooling System Supplemental
Coolant Additive (SCA) -
Submit the sample for Level 1 analysis.
Test/Add
Note: Level 1 results may indicate a need for
SMCS Code: 1352-045; 1395-081
Level 2 Analysis.

For additional information about coolant analysis,

see the Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel and Coolant Cooling system coolant additive contains alkali.
Recommendations” or consult your Caterpillar dealer. 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).
72 SEBU6355-03
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Test the Concentration of the SCA Table 18

Number of Concentration Maintenance
Coolant/Antifreeze and SCA Drops of SCA Required
Less than 25 Less than the Add SCA.
NOTICE recommended Retest the
Do not exceed the recommended six percent supple- concentration of coolant.
mental coolant additive concentration. SCA
25 to 30 The None
Test the concentration of the SCA with the 8T-5296 recommended
Coolant Conditioner Test Kit. Follow the instructions concentration of
that are provided in the kit. SCA
More than 30 More than the Remove the
Water and SCA recommended coolant.
concentration of Replace with
SCA water only
NOTICE
Retest the
Do not exceed the recommended eight percent sup- coolant.
plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296 Add the SCA, If Necessary
Coolant Conditioner Test Kit. Use the instructions
that follow:

1. Fill the syringe to the “1.0 ml” mark with the Pressurized System: Hot coolant can cause seri-
coolant. ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
2. Dispense the 1.0 mL coolant sample from the components are cool. Loosen the cooling system
syringe into the empty mixing bottle. pressure cap slowly in order to relieve the pres-
sure.
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. 1. Remove the cooling system filler cap slowly.

4. Add 2 to 3 drops of the “NITRITE INDICATOR Note: Always dispose of fluids according to local
SOLUTION B” to the mixing bottle. Move the bottle regulations.
in a circular motion in order to mix the solution.
2. If necessary, drain some coolant in order to allow
5. Add 1 drop of “NITRITE TEST SOLUTION A” to space for the addition of the SCA.
the mixing bottle. Move the bottle in a circular
motion in order to mix the solution. NOTICE
Excessive supplemental coolant additive concentra-
6. Repeat 5 until the solution changes color from red tion can form deposits on the higher temperature sur-
to light gray, green, or blue. Record the number of faces of the cooling system, reducing the engine’s
drops of “NITRITE TEST SOLUTION A” that were heat transfer characteristics. Reduced heat transfer
required to cause the color change. could cause cracking of the cylinder head and other
high temperature components.
7. Use Table 18 to interpret the results.
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. The concentration

of the SCA depends on the type of coolant that
is used. To determine the proper amount, see
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” topic.
SEBU6355-03 73
Maintenance Section
Crankcase Blowby - Measure/Record

4. Clean the cooling system filler cap. Install the Excessive blowby may indicate the need for an
cooling system filler cap. overhaul. By keeping a record of the results, a
gradual increase in the amount of the blowby will be
noted until the amount has become excessive.
i02026805

Crankcase Blowby - To measure the blowby, use the 8T-2700 Blowby/Air

Flow Indicator. Refer to Special Instruction,
Measure/Record SEHS8712, “Using the 8T-2700 Blowby/Airflow
Indicator Group”. The instruction is provided with the
SMCS Code: 1317 tool.

Note: For a G3500 Engine that is rated at 1500 Keep a record of the results.
rpm with 1500 service hours, the crankcase
blowby typically has a range of 259 to 283 L/min For assistance, consult your Caterpillar dealer.
(550 to 600 ft3/hr).

Measure the crankcase blowby of new engines. i01949731

Record the data. Continue to periodically measure

the blowby. Comparing the recorded data to the new
Crankshaft Vibration Damper
data provides information about the condition of the - Inspect
engine.
SMCS Code: 1205-040
Note: Crankcase blowby is one of the three factors
that help to determine the in-frame overhaul interval. The crankshaft vibration damper limits the torsional
For more information, see this Operation and vibration of the crankshaft. The visconic damper has
Maintenance manual, “Overhaul (In-Frame)” topic a weight that is located inside a fluid filled case.
(Maintenance Section).
Damage to the crankshaft vibration damper or failure
After a new engine is used for a short time, the of the damper can increase torsional vibrations. This
blowby can decrease as the piston rings are seated. can result in damage to the crankshaft and to other
The blowby will gradually increase as the following engine components. A deteriorating damper can
components show wear: cause excessive gear train noise at variable points
in the speed range.
• piston rings
A damper that is hot is due to excessive torsional
• cylinder liners vibration. Monitor the temperature of the damper
during operation.
Note: A problem with the piston rings causes the
oil to deteriorate rapidly. Information regarding the The 8T-2821 Temperature Indicator or the 8T-2822
condition of the piston rings can be obtained from Temperature Indicator are recommended for
the measurement of the blowby and the results of monitoring the temperature of the damper. Evenly
oil analysis. space four of the adhesive indicators around the
outer diameter of the damper.
The blowby of a worn engine may exceed the blowby
of a new engine by two times or more. Note: If you use an infrared thermometer to monitor
the temperature of the damper, use the thermometer
A sudden increase in blowby could indicate a broken during operation with similar loads and speeds. Keep
piston ring. The following conditions are other a record of the data. If the temperature begins to rise,
potential sources of blowby: reduce the interval for inspecting the damper.

• Worn valve guides If the temperature of the damper reaches 110 °C

(230 °F), consult your Caterpillar dealer.
• A turbocharger seal that leaks
Inspect the damper for evidence of dents, cracks,
A rebuilt engine can have a high blowby due to the and leaks of the fluid.
following factors:
If a fluid leak is found, repair the damper or
• The piston rings are not seated properly. replace the damper. The fluid in the damper is
silicone. Silicone has the following characteristics:
• Worn parts such as valve guides were not replaced. transparent, viscous, smooth, and sticky.
74 SEBU6355-03
Maintenance Section
Cylinder Pressure - Measure/Record

Inspect the damper and repair or replace the damper • A broken piston ring
for any of the following reasons.
• Worn piston rings
• The damper is dented, cracked, or leaking.
• Worn cylinder liners
• The paint on the damper is discolored from heat.
If the cylinder pressure has risen by one or more
• The engine has had a failure because of a broken compression ratios, the engine needs a top end
crankshaft. overhaul in order to remove deposits. Failure to
remove the deposits will increase the chance for
• An analysis of the oil has revealed that the front detonation. Severe guttering of the valves will occur.
bearing of the crankshaft is badly worn.
To measure the cylinder pressure, use the 193-5859
• There is a large amount of gear train wear that is Cylinder Pressure Gauge Gp. Follow the procedure
not caused by a lack of oil. in the Special Instruction, NEHS0798 that is included
with the gauge group. Record the pressure for
each cylinder. Use the Operation and Maintenance
Removal and Installation Manual, “Valve Data Sheet” (Reference Materials
Refer to the Service Manual, “Disassembly and Section).
Assembly” or consult your Caterpillar dealer for
Illustration 51 is a graph of typical cylinder pressures
information about damper replacement.
for engines with different compression ratios.

i01664707

Cylinder Pressure -
Measure/Record
SMCS Code: 1223-082-CC; 1223; 7450-082

Measure the cylinder pressure of new engines.

Record the data. Continue to periodically measure
the cylinder pressure. Comparing the recorded data
to the new data provides information about the
condition of the engine.

Cylinder pressure can be measured during inspection

of the spark plugs. Use the following guidelines for
checking the cylinder pressure:

• Remove all of the spark plugs.

• Fully open the throttle plate.
• Minimize the cranking time to 3 or 4 revolutions.
This will enable a maximum consistent cranking
speed for the check. Also, the battery power will
be conserved.

A loss of cylinder pressure or a change of pressure g00828960

in one or more cylinders may indicate the following Illustration 51
conditions. These conditions may indicate a problem (Y) Cylinder pressure in kPa
with lubrication: (X) Compression ratio
(1) Normal range for cylinder pressure

• Excessive deposits
• Guttering of valves
• A broken valve
• A piston ring that sticks
SEBU6355-03 75
Maintenance Section
Electrical Connections - Check

i01217164 • Operating conditions (dust, dirt and debris) may

require more frequent service of the air cleaner
Electrical Connections - Check element.
SMCS Code: 4459-535 • The air cleaner element may be cleaned up to
six times if the element is properly cleaned and
Check all exposed electrical connections for inspected.
tightness.
• The air cleaner element should be replaced at least
Check the following devices for loose mounting or one time per year. This replacement should be
physical damage: performed regardless of the number of cleanings.

• transformers Replace the dirty paper elements with clean

elements. Before installation, thoroughly inspect the
• fuses element for tears and/or holes in the filter material.
Inspect the gasket or the seal of the element for
• capacitors damage. Maintain a supply of suitable elements for
replacement purposes.
• lightning arrestors
Check all lead wires and electrical connections for
proper clearance.

i01749609

Engine Air Cleaner Element -

Replace
SMCS Code: 1051-510; 1054-510

NOTICE
Never run the engine without an air cleaner element
g00317608
installed. Never run the engine with a damaged air Illustration 52
cleaner element. Do not use air cleaner elements with Fasteners for the air cleaner cover
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.
g00781084
Unfiltered air will drastically accelerate internal Illustration 53
engine wear. Your Caterpillar dealer has the proper (1) Cover
air cleaner elements for your application. (2) Element
(3) Air inlet
The air cleaner may be mounted high above the
engine. If necessary, use a ladder or a platform to 1. Release the fasteners for cover (1).
reach the air cleaner.
2. Remove the cover and element (2).
• Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt 3. Cover air inlet (3) with tape in order to keep dirt
and debris, as needed. out.
76 SEBU6355-03
Maintenance Section
Engine Air Cleaner Element - Replace

4. Clean the inside of the cover and the body with Note: When the elements are cleaned, always begin
a clean, dry cloth. with the clean side (inside) in order to force dirt
particles toward the dirty side (outside).
5. Remove the tape for the air inlet. Install a new
element or a clean element. Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
6. Install the cover. damage to the paper pleats. Do not aim the stream
of air directly at the primary air cleaner element. Dirt
7. If necessary, reset the air cleaner service indicator. could be forced into the pleats.

Note: Refer to “Inspecting the Primary Air Cleaner

Cleaning the Primary Air Cleaner Elements”.
Elements
Vacuum Cleaning
The primary air cleaner element can be used up
to six times if the element is properly cleaned and Vacuum cleaning is a good method for cleaning
inspected. When the element is cleaned, check the elements which require daily cleaning because of a
filter material for rips or tears. Replace the element dry, dusty environment. Cleaning with pressurized air
at least one time per year regardless of the number is recommended prior to vacuum cleaning. Vacuum
of cleanings. cleaning will not remove deposits of carbon and oil.
Use clean elements while dirty elements are being Note: Refer to “Inspecting the Primary Air Cleaner
cleaned. Elements”.

NOTICE Inspecting the Primary Air Cleaner

Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use el- Elements
ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.

Visually inspect the elements before cleaning. Inspect

the elements for damage to the seal, the gaskets,
and the outer cover. Discard any damaged elements.

Air cleaner elements can be cleaned with pressurized

air and with a vacuum.

Pressurized Air
Pressurized air can be used to clean elements g00281693
Illustration 55
that have not been cleaned more than two times.
Pressurized air will not remove deposits of carbon
Inspect the clean, dry element. Use a 60 watt blue
and oil. Use filtered, dry air with a maximum pressure
light in a dark room or in a similar facility. Place
of 207 kPa (30 psi).
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 part 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 Primary Air Cleaner Elements

If an element that passes inspection will not be used
g00281692 immediately, store the element for future use.
Illustration 54
SEBU6355-03 77
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

g00281694 g00760342
Illustration 56 Illustration 57
Service indicator
Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. Restricted air flow Some engines may be equipped with a different
may result. To protect against dirt and damage, wrap service indicator.
the elements in Volatile Corrosion Inhibited (VCI)
paper. Observe the service indicator. Clean the air cleaner
element or replace the element when any of the
Place the element into a cardboard box for storage. following conditions occur:
For identification, mark the outside of the container
and mark the element. Include the following • The yellow diaphragm enters the red zone.
information:
• The red piston locks in the visible position.
• Date of cleaning
• The air restriction reaches 3.75 kPa
• Number of cleanings (15 inch of H2O).

Store the container in a dry location.

For more detailed information on cleaning the primary

air cleaner element, refer to Special Publication,
SEBF8062, “Procedure to Inspect and Clean Air
Filters”.

i01665086

Engine Air Cleaner Service

Indicator - Inspect
SMCS Code: 7452-040
g00760341
Illustration 58
A service indicator may be mounted on the air Service indicator on an air cleaner for crankcase ventilation
cleaner element or in a remote location.
Some engines are equipped with an air cleaner for
crankcase ventilation. The air cleaner is mounted
on a camshaft cover. Clean the air cleaner element
or replace the element when any of the following
conditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.
• The air restriction reaches 0.25 kPa (1 inch of H2O).
• The air cleaner is saturated with oil.
78 SEBU6355-03
Maintenance Section
Engine Air Precleaner - Clean

Inspect the service indicator daily for cracks, holes, or i01397717

loose fittings. If any of these conditions are present,
replace the service indicator. Engine Air Precleaner - Clean
SMCS Code: 1055-070
Test the Service Indicator
Service indicators are important instruments.

• Apply vacuum (suction) to the service indicator.

• Reset the service indicator.
If the yellow core does not latch at the greatest
vacuum, or if service indicator does not reset easily,
obtain a new service indicator. If the new service
indicator will not reset, the fitting for the service
indicator may be plugged.

g00736588
Illustration 60
Typical precleaner
(1) Wing nut
(2) Cover
(3) Body

Remove wing nut (1) and cover (2). Check for an

accumulation of dirt and debris in body (3). Clean the
body, if necessary.

After cleaning the precleaner, install cover (2) and

wing nut (1).
g00351792
Illustration 59 Note: When the engine is operated in dusty
Porous filter applications, more frequent cleaning is required.

A porous filter is part of the fitting that is used for

i01225429
mounting of the service indicator. Inspect the filter
for cleanliness. Clean the filter, if necessary. Use
compressed air or a clean, nonflammable solvent.
Engine Crankcase Breather -
Clean
Note: When service indicator is installed, excessive
tightening may crack the top of the service indicator. SMCS Code: 1317-070
Tighten the service indicator to a torque of 2 N·m
(18 lb in). If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become
Replace the service indicator annually regardless of plugged. A plugged crankcase breather will cause
the operating conditions. excessive crankcase pressure that may cause
crankshaft seal leakage.
SEBU6355-03 79
Maintenance Section
Engine Mounts - Check

Inspect the hose tee for cracks. If the tee is

cracked, discard the old tee and obtain a new tee
for installation.

5. Turn the breathers upside-down in order to inspect

the condition of the breather elements.

Clean the breather elements with clean,

nonflammable solvent. If the breather elements
remain contaminated after the cleaning, discard
the breathers and obtain new breathers. Do not
attempt to disassemble the breathers.

Allow the breather elements to dry before

g00597463
installation.
Illustration 61
Note: Coat the rubber parts with clean engine oil or
1. Loosen clamp (1). Slide the clamp down on tube petroleum jelly in order to make installation easier.
(2).
6. Place clamps (6) over the parts of hose tee (7)
2. Loosen clamps (3). Remove both breathers as a that will receive breathers (5). Install the breathers
unit. into the tee. Tighten the clamps to the torque that
is listed in the Service Manual, “Specifications”.

7. Coat O-ring seals (4) with clean engine oil. Place

the O-ring seals on the valve covers.

8. Place clamps (3) around the parts of the breathers

that will be attached to the valve covers. Install
both breathers as a unit. Tighten the clamps.

9. Place clamp (1) on the part of the hose tee that

will receive tube (2). Install the tube into the hose
tee. Tighten the clamp to the torque that is listed
in the Service Manual, “Specifications”.

g00597465
Illustration 62 i02017664

3. Remove O-ring seals (4) from the valve covers. Engine Mounts - Check
Inspect the O-ring seals for good condition. Obtain
new O-ring seals, if necessary. SMCS Code: 1152-535

g00736591
Illustration 64
(1) Mounting bolts for the engine
(2) Mounting bolts for the generator
(3) Levelling bolts for the isolators

Misalignment of the engine and the driven equipment

will cause extensive damage. Excessive vibration
g00597466
Illustration 63 can lead to misalignment. Excessive vibration of the
engine and the driven equipment can be caused by
4. Remove two clamps (6). Remove both breathers the following conditions:
(5) from hose tee (7).
• Improper mounting
80 SEBU6355-03
Maintenance Section
Engine Oil - Change

• Loose bolts Note: If a suction device is used in order to remove

the oil from the oil pan, ensure that the suction device
• Deterioration of the isolators is clean. This will prevent dirt from entering into the
oil pan. Be careful not to strike the engine oil suction
Ensure that the mounting bolts are tightened tubes or the piston cooling jets.
to the proper torque. For standard torques, see
Specifications, SENR3130, “Torque Specifications”. a. If the engine has an oil drain valve, open the
valve in order to drain the oil. After the oil has
Ensure that the isolators are free of oil and drained, close the valve.
contamination. Inspect the isolators for deterioration.
Ensure that the bolts for the isolators are tightened to b. If the engine has a pump for removing dirty
the proper torque. oil, connect a hose to the outlet of the pump.
Place the hose in a suitable container. Open
Replace any isolator that shows deterioration. For the valve for the drain line. Operate the pump
more information, see the literature that is provided until the crankcase is empty. Close the valve to
by the OEM of the isolators. Also see the Application the drain line. Disconnect the hose.
and Installation Guide for the engine. Consult your
Caterpillar dealer for assistance. c. If the oil drain valve has a “quick connect”
coupling, attach the coupling. Open the drain
valve in order to drain the crankcase. After
i02017618
the oil has drained, close the drain valve.
Engine Oil - Change Disconnect the coupling.

SMCS Code: 1348-044; 1348 d. If the engine does not have a drain valve or a
pump, remove an oil drain plug. Allow the oil to
drain. After the oil has drained, clean the drain
plug and clean the fitting for the drain plug.
Install the drain plug. Tighten the drain plug to
Hot oil and components can cause personal in- 145 ± 15 N·m (105 ± 10 lb ft).
jury.
Note: Ensure that the dirty oil is thoroughly drained
Do not allow hot oil or components to contact from the pan. Caterpillar recommends a thorough
skin. cleaning of the oil pan with a vacuum and with rags
in order to completely remove all of the old oil. This
will help prevent inaccurate oil analysis results and/or
NOTICE shortened life of the oil.
Ensure that the engine is stopped before performing
this procedure. Attach a DO NOT OPERATE tag to the 3. Replace the engine oil filter elements before filling
starting controls. the crankcase with new oil.

Do not drain the oil when the engine is cold. As the oil a. For the procedure to change the engine oil
cools, suspended waste particles settle on the bottom filters, refer to the Operation and Maintenance
of the oil pan. The waste particles are not removed Manual, “Engine Oil Filter - Change” topic
when the cold oil is drained. Drain the crankcase with (Maintenance Section).
the oil warm, immediately after the engine is stopped.
This draining method allows the waste particles
that are suspended in the oil to be drained properly.
Failure to follow this recommended procedure will
allow the waste particles to be recirculated through
the engine lubrication system with the new oil.

1. After the engine has been operated at normal

operating temperature, STOP the engine.

Note: Drain the oil into a suitable container. Dispose

of fluids according to local regulations.

2. Drain the oil by using one of the following

methods. Use the method that corresponds to the
equipment on the engine.
SEBU6355-03 81
Maintenance Section
Engine Oil Filter (Auxiliary) - Change

i02017678
NOTICE
Engine damage can occur if the crankcase is filled
Engine Oil Filter (Auxiliary) -
above the “FULL” mark on the oil level gauge (dip- Change
stick).
SMCS Code: 1318
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel- Note: An auxiliary oil filter system enables the oil
oped and also force air bubbles into the oil. These capacity of the engine to be increased. Use of the
bubbles (foam) can cause the following problems: re- auxiliary oil filter elements is not recommended.
duction of the oil’s ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the Perform this procedure after the oil has been drained
crankcase breathers, and excessive oil consumption. from the auxiliary oil filter housing.

Excessive oil consumption will cause deposits to form

on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately.

Note: For the appropriate oil to use, and for

the amount of oil to use, refer to this Operation
and Maintenance Manual, “Refill Capacities and
Recommendations” article (Maintenance Section).
g00787079
Illustration 65
4. Remove the oil filler cap. Fill the crankcase
Auxiliary oil filter housing
through the oil filler tube only. Clean the oil filler
cap. Install the oil filler cap. (1) Vent plug
(2) Drain plug

NOTICE 1. If the engine is equipped with an auxiliary oil filter

To prevent crankshaft damage and to prevent bearing system, remove vent plug (1). Remove drain plug
damage, manually operate the prelube pump or crank (2). Allow the oil to drain. After the oil has drained,
the engine with the fuel supply line closed for 15 to 30 clean the drain plug.
seconds. This will ensure that all of the oil filters are
filled with oil before the engine is started.

5. Close the fuel supply line. Crank the engine until

the oil pressure gauge indicates 70 kPa (10 psi).
Open the fuel supply line. Allow the starting motor
to cool for two minutes before cranking again.

6. Follow this Operation and Maintenance Manual,

“Starting The Engine” procedure (Operation
Section). Operate the engine at low idle for two
minutes. This will ensure that the lubrication
system and the oil filters are filled with oil. Inspect
the engine for oil leaks. Ensure that the oil level is
between the “ADD” and the “FULL” marks on the
“LOW IDLE” side of the oil level gauge.

7. Stop the engine and allow the oil to drain back into
the sump for a minimum of ten minutes.

8. Remove the oil level gauge and check the oil level.
Maintain the oil level between the “ADD” and the
“FULL” marks on the “ENGINE STOPPED” side of
the oil level gauge.
82 SEBU6355-03
Maintenance Section
Engine Oil Filter - Change

4. Remove bolt (12). Remove washer (13) and

spider (14). Remove plate (15).

5. Remove the oil filter elements if the oil filters have

been installed. Clean the inside of the oil filter
housing.

Inspect the oil filter elements if the oil filters have

been installed. For instructions on inspecting
the oil filter elements, refer to the Operation and
Maintenance Manual, “Engine Oil Filter - Change”
topic (Maintenance Section).

6. Ensure that plug (5) is tight.

7. Install drain plug (2). Tighten the drain plug to

70 ± 14 N·m (50 ± 10 lb ft).

Note: Use of the auxiliary oil filter elements is not

required.

8. If the use of auxiliary oil filter elements is desired,

install new elements.

9. Install plate (15), spider (14), washer (13), and

bolt (12).

10. Install spring (11) on spider (14). Install spring

g00787105
Illustration 66 retainer (10) and nut (9) on bolt (12).
(1) Vent plug
(2) Drain plug 11. Tighten nut (9) in order to compress spring (11)
(3) Nut until the spring retainer bottoms out on bolt (12).
(4) Washer
(5) Plug Do not overtighten the nut.
(6) Bolt
(7) Cover 12. Fill the oil filter housing with oil. For the correct
(8) Cover gasket amount of oil, refer to the Operation and
(9) Nut
(10) Spring retainer
Maintenance Manual, “Refill Capacities and
(11) Spring Recommendations” topic (Maintenance Section).
(12) Bolt
(13) Washer 13. Inspect cover gasket (8) for tears, breaks, or other
(14) Spider damage. If the cover gasket is damaged, replace
(15) Plate
the old cover gasket with a new cover gasket.
Install cover gasket (8). Install cover (7).
1. Remove 12 nuts (3), washers (4), and bolts (6).
14. Install twelve bolts (6), washers (4), and nuts
2. Remove cover (7) and gasket (8). Do not damage
(3). Tighten nuts sequentially around the cover
the gasket.
until the nuts are snug. Tighten the nuts to
100 ± 15 N·m (75 ± 11 lb ft).

15. Install vent plug (1).

Possible injury can occur during the removal of
the nut, the spring retainer, and the spring. Spring
i02154624
force will be released when the nut and the spring
retainer are removed. Be prepared to hold the
spring retainer as the nut is loosened.
Engine Oil Filter - Change
SMCS Code: 1308-510; 1308
3. Remove nut (9), spring retainer (10), and spring
(11). Hold spring retainer (10) as nut (9) is Replace the engine oil filters when any of the
loosened. following conditions are met:

• Every oil change

SEBU6355-03 83
Maintenance Section
Engine Oil Filter - Change

• The engine oil filter differential pressure reaches Note: Some oil will remain in the housing after the oil
100 kPa (15 psi). has been drained. This oil will pour out of the housing
when cover (5) is removed. Prepare to catch the oil
• The engine oil filters have been used for 1500 in a suitable container. Clean up any spilled oil with
operating hours. absorbent pillows or towels. DO NOT use absorbent
particles to clean up the oil.
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 Personal injury can result from parts and/or cov-
procedure. ers under spring pressure.

Spring force will be released when covers are re-

Replacing the Engine Oil Filters moved.
With the Engine Stopped
Be prepared to hold spring loaded covers as the
bolts are loosened.

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.

g00760382
Illustration 68
Section view
(4) Bolt
(5) Cover
(6) O-ring seal
(7) Oil filter element

3. Be alert to the spring force. Gradually loosen but

do not remove bolts (4). Before removing bolts (4),
pry cover (5) loose or tap the cover with a rubber
Illustration 67
g01092449 mallet in order to relieve any spring pressure.
(1) Plug
(2) Drain valve 4. Remove bolts (4) and the washers in order to
(3) Drain remove cover (5) and O-ring seal (6). Remove oil
(4) Bolt filter elements (7).
(5) Cover
5. Clean cover (5), O-ring seal (6), and the inside
1. Connect a hose to drain (3). Place the other end of the oil filter housing.
of the hose into a suitable container in order to
collect the oil.
NOTICE
2. Open drain valve (2). Remove plug (1). Allow the Caterpillar oil filters are built to Caterpillar speci-
oil to drain. Clean the plug and install the plug. fications. Use of an oil filter not recommended by
Close the drain valve. Remove the hose from the Caterpillar could result in severe engine damage to
drain. 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.
84 SEBU6355-03
Maintenance Section
Engine Oil Filter - Change

6. Ensure that the new oil filter elements are in good If the engine is equipped with duplex oil filters, the
condition. Install the new oil filter elements. engine oil filter elements can be changed while the
engine is operation. This is useful if the oil filter
7. Inspect O-ring seal (6). Ensure that the surfaces elements require more frequent replacement than
for the O-ring seal are clean. Install a new the engine oil.
O-ring seal if the old O-ring seal is damaged or
deteriorated. 1. Move the control valve to the “AUX RUN” position
in order to change the main oil filter elements.
8. Install O-ring seal (6) and cover (5). Ensure that Move the selector valve to the “MAIN RUN”
the cover’s retainer is properly seated. position in order to change the auxiliary oil filter
elements.
9. Close drain valve (2).
2. Allow the oil pressure gauge for the oil filter that
10. Install plug (1). is being changed to reach a “ZERO” pressure
reading.
11. Start the engine. Check for oil leaks.
3. Perform Step 1 through Step 12 of “Replacing the
12. Check the oil level on the “LOW IDLE” side of the Engine Oil Filters With the Engine Stopped”.
oil level gauge. Maintain the oil level between the
“ADD” and “FULL” marks on the “LOW IDLE” side 4. Open the “FILL” valve for a minimum of five
of oil level gauge. minutes in order to fill the new oil filter elements.

5. Close the “FILL” valve. Rotate the control valve

Replacing the Engine Oil Filters to the “RUN” position for the oil filter that was
During Engine Operation serviced.

Inspect the Used Oil Filter Elements

Filter contains hot pressurized fluid when engine Cut the used oil filter element open with a utility knife.
is running. Cut the filter element free from the end caps. Spread
apart the pleats and inspect the element for metal
Follow instructions on control valve to avoid per- debris. An excessive amount of debris in the element
sonal injury. may indicate early wear or a pending failure.

If rapid air movement exists to blow fluid, Stop the Use a magnet to differentiate between the ferrous
engine to avoid fire. metals and the nonferrous metals that are found
in the element. Ferrous metals may indicate wear
on the steel and the cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, the brass parts, or the bronze parts
of the engine. Parts that may be affected include the
following components: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.

Aluminum debris may indicate problems with the

bearings of the front gears. If an excessive amount
of 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.

g00850266
Illustration 69
SEBU6355-03 85
Maintenance Section
Engine Oil Level - Check

i02017693 b. If the engine is operating, reduce the engine

speed to low idle. Remove the engine oil level
Engine Oil Level - Check gauge and observe the engine oil level on
“ENGINE AT LOW IDLE WITH WARM OIL”
SMCS Code: 1348-535-FLV side (4).
The most accurate check of the engine oil level is The engine oil level should be between “ADD”
obtained when the engine is stopped. mark (5) and “FULL” mark (6).

NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip-
stick).

An overfull crankcase can 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.

Illustration 70
g00760401 Excessive oil consumption will cause deposits to form
(1) Engine oil level gauge (dipstick)
on the pistons and in the combustion chamber. De-
(2) Filler cap posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
1. Remove filler cap (2) in order to ensure that the under the piston rings, and wear of the cylinder liner.
crankcase pressure is equal to the atmospheric
pressure. If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately.
Excess pressure or a slight vacuum will affect
engine oil level that is measured. 3. If necessary, add engine oil. For the correct
engine oil to use, refer to this Operation and
2. Ensure that engine oil level gauge (1) is seated. Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section).
Do not fill the crankcase above the “FULL” mark
on the engine oil level gauge. Clean the filler cap
(2). Install the filler cap.

4. Record the amount of engine oil that is added. For

the next engine oil sample and analysis, include
the total amount of engine oil that has been added
since the previous oil change. This will help to
provide the most accurate analysis.

i01935337

Engine Oil Sample - Obtain

g00735162
Illustration 71
(3) “ENGINE STOPPED WITH OIL COLD” side
SMCS Code: 1348-554-SM
(4) “ENGINE AT LOW IDLE WITH WARM OIL” side
(5) “ADD” mark In addition to a good preventive maintenance
(6) “FULL” mark program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order
a. If the engine is stopped, remove the engine oil to monitor the condition of the engine and the
level gauge. Observe the engine oil level on maintenance requirements of the engine. S·O·S oil
“ENGINE STOPPED WITH OIL COLD” side analysis provides infrared analysis, which is required
(3). for determining nitration and oxidation levels.
86 SEBU6355-03
Maintenance Section
Engine Protective Devices - Check

Obtain the Sample and the Analysis 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.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin. i00626013

Engine Protective Devices -

Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order Check
to help obtain the most accurate analysis, provide
the following information: SMCS Code: 7400-535

• Engine model Alarms and shutoffs must function properly. Alarms

provide timely warning to the operator. Shutoffs help
• Service hours on the engine to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
• The number of hours that have accumulated since in good working order during normal operation.
the last oil change Malfunctions must be simulated in order to test the
engine protective devices.
• The amount of oil that has been added since the
last oil change A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate
To ensure that the sample is representative of the at the setpoints. Ensure that the engine protective
oil in the crankcase, obtain a warm, well mixed oil devices are functioning properly.
sample.
NOTICE
To avoid contamination of the oil samples, the tools During testing, abnormal operating conditions must be
and the supplies that are used for obtaining oil simulated.
samples must be clean.
The tests must be performed correctly in order to pre-
Caterpillar recommends using the sampling valve vent possible damage to the engine.
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling To prevent damage to the engine, only authorized
valve allows oil that is flowing under pressure to be service personnel or your Caterpillar dealer should
obtained during normal engine operation. perform the tests.

The 169-8373 Fluid Sampling Bottle is Visual Inspection

recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are Visually check the condition of all gauges, sensors
needed for obtaining oil samples. Instructions are and wiring. Look for wiring and components that
also provided. are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
NOTICE immediately.
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling. i02209352
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This Engine Speed/Timing Sensor -
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both Clean/Inspect
dealers and customers.
SMCS Code: 1905-040; 1905-070; 1907-040;
1907-070
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is An engine speed/timing sensor is mounted in the
designed to accept sampling bottles. Disposable flywheel housing. The speed/timing sensor provides
tubing must be attached to the pump for insertion information about engine speed and the position of
into the sump. the crankshaft to the ECM.
SEBU6355-03 87
Maintenance Section
Engine Valve Lash - Inspect/Adjust

c. Coat the threads of the sensor with 4C-5597

Anti-Seize Compound.

Note: The sliphead is designed to contact a tooth

during the first revolution of the speed-timing wheel.
For the maximum allowable clearance between
the sliphead and the tooth, refer to the engine’s
Specifications manual.

d. Install the sensor. Tighten the locknut to

40 ± 5 N·m (30 ± 4 lb ft).

i02100013

Illustration 72
g00760464 Engine Valve Lash -
Inspect/Adjust
1. Remove engine speed/timing sensor (1). Inspect
the condition of the end of the magnet. Look for SMCS Code: 1102-025
signs of wear and contaminants.
Note: For procedures on adjusting the valve lash and
2. Clean any debris from the face of the magnet. adjusting the valve bridge, see Testing and Adjusting,
“Valve Lash and Valve Bridge Adjustment”. Consult
your Caterpillar dealer for assistance.

Valve Bridge
Check the valve bridge and adjust the valve bridge,
if necessary. Perform the procedure for both valve
g01115363 bridges for each cylinder. After the valve bridge is
Illustration 73 checked for each cylinder, proceed with the valve
lash adjustment, if necessary.
3. Check the tension of the sliphead. Gently extend
sliphead (2) for a minimum of 4 mm (0.16 inch).
Then push back the sliphead. Engine Valve Lash
When the sliphead has the correct tension, at NOTICE
least 22 N (5 lb) of force is required to push in the Only qualified service personnel should perform this
sliphead from the extended position. maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
NOTICE ment procedure.
The sliphead must be fully extended when the speed/
timing sensor is installed so that the sensor maintains Operation of Caterpillar engines with improper valve
the correct clearance with the speed-timing wheel. adjustments can reduce engine efficiency. This re-
If the correct clearance is not maintained, the signal duced efficiency could result in excessive fuel usage
from the sensor will not be generated. and/or shortened engine component life.

Do not install the sensor between the teeth of the

The valve bridge adjustment must be performed
speed-timing wheel. Damage to the sensor would re-
before making a valve lash adjustment. If the valve
sult. Before installing the sensor, ensure that a tooth
lash is within the tolerance, an adjustment of the
of the wheel is visible in the mounting hole for the sen-
valve lash is NOT necessary.
sor.
Perform the valve lash setting when the engine is
4. Install the engine speed/timing sensor. cold. After the engine has been shut down and the
valve covers are removed, the engine is considered
a. Ensure that a tooth on the speed-timing wheel cold. Before performing maintenance, prevent the
is visible in the mounting hole for the sensor. entry of foreign matter into the top of the cylinder
head and the valve mechanism. Thoroughly clean
b. Extend sliphead (2) by a minimum of 4 mm the area around the valve mechanism covers.
(0.16 inch).
88 SEBU6355-03
Maintenance Section
Exhaust Bypass - Inspect

For the valve lash setting, see this Operation and i02209321
Maintenance Manual, “Product Description” topic
(Product Information Section). Exhaust Manifold - Inspect
(Water Cooled Exhaust
i01505507 Manifolds)
Exhaust Bypass - Inspect SMCS Code: 1059-040
SMCS Code: 1057-040 Normally, water cooled exhaust manifolds do not
require maintenance unless excessive deposits build
For instructions on removal and installation, see the up in the exhaust passages. Buildup of deposits
Service Manual, “Disassembly and Assembly”. cause an increase in back pressure that will cause
the following conditions:
1. Remove the exhaust bypass valve.
• Increased fuel consumption
• Reduced boost pressure
The exhaust bypass valve cover is under spring
compression. To prevent personal injury, use cau- If excessive deposits build up in the exhaust
tion when removing the cover. passages, clean the passages in order to remove
the deposits.
2. Disassemble the valve.
Landfill Applications
In landfill applications, the composition of the gas can
corrode engine components such as the water cooled
manifold. Inspect the manifold. Repair the manifold or
replace the manifold if any of the following conditions
occur:

• Cracks in welds
• Cracks in the base material
• Coolant leaks

g00781274
• Exhaust leaks
Illustration 74
Exhaust bypass valve
i01003546
(1) Diaphragm
(2) Valve stem
(3) Breather
Exhaust Piping - Inspect
SMCS Code: 1061-040
3. Inspect diaphragm (1). If the diaphragm is worn or
cracked, replace the diaphragm.

4. Inspect valve stem (2) and the valve guide. If the

parts are excessively worn, replace the parts. Hot engine components can cause injury from
burns. Before performing maintenance on the
5. Clean breather (3). engine, allow the engine and the components to
cool.
6. Assemble the valve.
Inspect the components of the exhaust system.
7. Install the valve. Repair the components or replace the components
for any of the following conditions:

• Damage
• Cracks
SEBU6355-03 89
Maintenance Section
Fuel System Fuel Filter Differential Pressure - Check

• Leaks
• Loose connections
For information on removal and installation, see
the Service Manual, “Disassembly and Assembly”
module. Consult your Caterpillar dealer for
assistance.

i01505536

Fuel System Fuel Filter

Differential Pressure - Check
g00829869
SMCS Code: 1261-535 Illustration 75
(1) Cap on the drip leg for the balance line
A fuel filter differential pressure gauge must be (2) Cap on the drip leg for the gas supply line to the gas pressure
regulator
installed in order to determine when the fuel filter
requires service. This gauge and the fuel filter are
supplied by the customer. 1. Close the main gas supply valve.

A fuel filter differential pressure gauge indicates the 2. Remove caps (1) and (2) from the drip legs.
difference in fuel pressure between the inlet side
and the outlet side of the fuel filter. The differential 3. Allow the moisture to drain into a suitable
pressure increases as the fuel filter becomes container. Inspect the drip legs for debris. Clean
plugged. the drip legs, if necessary.

Operate the engine at the rated speed and at the 4. Clean the caps. Install the caps.
normal operating temperature. Check the fuel filter
differential pressure. Service of the fuel filter depends 5. Perform Step 2 through Step 4 for the drip leg on
on the pressure of the fuel system: the supply line to the gas shutoff valve.

6. Open the main gas supply valve.

• For low pressure gas fuel systems, service the
fuel filter when the fuel filter differential pressure
reaches 1.7 kPa (0.25 psi). i02121526

• For high pressure gas fuel systems, service the Hoses and Clamps -
fuel filter when the fuel filter differential pressure
reaches 34 kPa (5 psi).
Inspect/Replace
SMCS Code: 7554-040; 7554-510
For instructions, see Special Instruction, SEHS9298,
“Installation and Maintenance of Gaseous Fuel
Inspect all hoses for leaks that are caused by the
Filters”. Consult your Caterpillar dealer for assistance.
following conditions:

i01642256 • Cracking
Gas Pressure Regulator • Softness
Condensation - Drain • Loose clamps
SMCS Code: 1270-543
Replace hoses that are cracked or soft. Tighten any
To collect condensation, drip legs should be installed loose clamps.
in the following locations:

• Supply line for the gas pressure regulator

• Balance line for the gas pressure regulator
• Supply line to the gas shutoff valve
90 SEBU6355-03
Maintenance Section
Ignition System Spark Plugs - Check/Adjust/Replace

2. Loosen the cooling system filler cap slowly in

NOTICE order to relieve any pressure. Remove the cooling
Do not bend or strike high pressure lines. Do not in- system filler cap.
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and Note: Drain the coolant into a suitable, clean
hoses. Leaks can cause fires. Inspect all lines, tubes container. The coolant can be reused.
and hoses carefully. Tighten all connections to the rec-
ommended torque. 3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
Check for the following conditions: 4. Remove the hose clamps.

• End fittings that are damaged or leaking 5. Disconnect the old hose.

• Outer covering that is chafed or cut 6. Replace the old hose with a new hose.

• Exposed wire that is used for reinforcement 7. Install the hose clamps with a torque wrench.

• Outer covering that is ballooning locally Note: Refer to the Specifications, SENR3130,
“Torque Specifications” in order to locate the proper
• Flexible part of the hose that is kinked or crushed torques.

• Armoring that is embedded in the outer covering 8. Refill the cooling system.
A constant torque hose clamp can be used in place 9. Clean the cooling system filler cap. Inspect the
of any standard hose clamp. Ensure that the constant cooling system filler cap’s gaskets. Replace
torque hose clamp is the same size as the standard the cooling system filler cap if the gaskets are
clamp. damaged. Install the cooling system filler cap.
Due to extreme temperature changes, the hose will 10. Start the engine. Inspect the cooling system for
heat set. Heat setting causes hose clamps to loosen. leaks.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
i02125673
Each installation application can be different. The
differences depend on the following factors: Ignition System Spark Plugs -
Check/Adjust/Replace
• Type of hose
SMCS Code: 1555-535
• Type of fitting material
• Anticipated expansion and contraction of the hose
Ignition systems can cause electrical shocks.
• Anticipated expansion and contraction of the Avoid contacting the ignition system components
fittings
and wiring.

Replace the Hoses and the Clamps Do not attempt to remove the valve covers when
the engine is operating. The transformers are
grounded to the valve covers. Personal injury or
death may result and the ignition system will be
damaged if the valve covers are removed during
Pressurized System: Hot coolant can cause seri- engine operation. The engine will not operate
ous burns. To open the cooling system filler cap, without the valve covers.
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- Maintenance of the spark plugs is required in order
sure. to achieve the following benefits:

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

• Normal fuel consumption
• Normal level of emissions
SEBU6355-03 91
Maintenance Section
Ignition System Spark Plugs - Check/Adjust/Replace

• Maximum service life of the spark plugs If the spark plug resists removal by hand, apply
penetrating oil to the threads. Use the wrench and
The service life of the spark plugs is affected by apply steady pressure to the spark plug until the
fouling due to deposits from the oil and by peak spark plug is loose.
voltage. Maintenance of the ignition system is also
affected by voltage. Higher voltage is required by If the spark plug can not be removed by hand, clean
higher inlet manifold air pressure and a higher the threads with 9U-7511 Spark Plug Seat Cleaner.
compression ratio. Higher voltage reduces the This tool scrapes debris from the seat and from the
service life of components such as spark plugs, threads in the cylinder head. Be sure to clean any
wires, and transformers. debris from the cylinder.

Removing the Spark Plug Inspecting the Spark Plug

g00787368
Illustration 77
(1) Terminal post
(2) Insulator
(3) Shell
(4) Gasket
(5) Electrode

Illustration 76
g01081802 Inspect the spark plug closely for damage. The
condition of the spark plug can indicate the operating
1. Remove the three bolts (1) that hold transformer condition of the engine.
(2) to the valve cover. Leave the wiring attached.
Place the transformer out of the way. Do not pull Terminal post (1) must not move. If the terminal post
on the wires as damage to the wiring harness can be moved by hand, carefully tighten the post into
could result. the threads of the insulator. If the post cannot be
tightened, discard the spark plug.
2. Remove the spring loaded spark plug extension
(3) from the spark plug well. Inspect insulator (2) for cracks. If a crack is found,
discard the spark plug.
3. Use a 22.23 mm (0.875 inch), 4C-4601 Spark
Plug Socket and an extension to loosen spark Faint marks may extend from shell (3) onto the
plug (4). After the spark plug has been loosened, insulator. The marks may be a result of corona that
remove the spark plug by hand in order to detect forms at the top of the shell. The conductor will
problems with the threads. After the spark plug develop a corona when a very high voltage potential
has been removed, discard the used spark plug ionizes the air. This is a normal condition. This is not
gasket. an indication of leakage between the shell and the
insulator.
NOTICE
Inspect shell (3) for damage. Cracks can be caused
Do not use a thread tap. A thread tap will remove metal
by overtightening the spark plug. Overtightening can
unnecessarily. The threads could be stripped and the
also loosen the shell. Discard any spark plug that has
cylinder head could be damaged.
a shell that is cracked or loose.
92 SEBU6355-03
Maintenance Section
Ignition System Spark Plugs - Check/Adjust/Replace

Installing the Spark Plug

Note: Use the 9U-7516 Spark Plug Gauge to
measure the electrode gap. Do not use a flat feeler
gauge for measuring the electrode gap of used spark
plugs. A feeler gauge will incorrectly measure the
actual electrode gap because the used precious
metal tips are curved.

1. Before installing the spark plug, set the electrode

gap. The electrode gap depends on the engine’s
ignition system.

a. For engines with an Altronic ignition system,

g00787372 set the electrode gap to 0.4 mm (0.014 inch).
Illustration 78
(6) Precious metal tips on the electrode and the ground strap b. For other ignition systems, set the electrode
gap to 0.28 mm (0.011 inch).
Caterpillar spark plugs have precious metal tips (6)
on the electrode and the ground strap. This material Adjust the electrode gap, if necessary. Bend
will gradually erode. Use extreme care when you set the ground strap at the existing bend. Then
the electrode gap. Maintain even spacing and proper bend the strap near the weld in order to achieve
alignment between the two precious metal surfaces. proper alignment and even spacing between
the two precious metal surfaces. Measure the
Replace the spark plug if the precious metal is worn electrode gap after the alignment. Correct the
off. electrode gap, if necessary.

A light brown deposit or a beige deposit around the Note: Do not use anti-seize compound on spark
electrode is produced by normal operation. plugs. Most of the heat is transferred through the
threads and the seat area of the spark plug. The
Deposits that are gray or black may be caused by surfaces must be in contact in order to provide the
the following substances: heat transfer that is required.

• Excessive oil 2. Ensure that the spark plug is clean and free of
dirt and oil.
• Use of the wrong oil
3. Always use a new gasket when a spark plug is
• A substance that is introduced through the fuel installed. If a used spark plug is installed, place a
system or the air system new 9Y-6792 Spark Plug Gasket on the spark
plug. Orient the tabs of the gasket toward the
A spark plug can operate despite a buildup of ash. electrode. Otherwise, the gasket may not seat
However, a buildup of ash can cover the electrode properly. If a gasket for a spark plug is installed
gap. This will cause misfire. Large deposits may incorrectly, do not increase the torque on the spark
retain heat which can cause premature fuel ignition. plug in order to improve the seal. Do not reuse the
This can lead to uncontrollable detonation. gasket. Install a new gasket.

Cleaning the Spark Plug NOTICE

Do not overtighten the spark plugs. The shell can be
Thoroughly clean the spark plug. Do not use a wire cracked and the gasket can be deformed. The shell
brush. Glass beads are the preferred method for can be stretched. This will loosen the seal that is be-
cleaning. tween the shell and the insulator, allowing combustion
pressure to blow past the seal. Serious damage to the
Follow these guidelines for using glass beads: engine can occur.

• Always use clean glass beads. Use the proper torque.

• Use care in order to clean only the electrode and

the insulator near the electrode. 4. Install the spark plug by hand until the spark plug
bottoms out. Tighten the spark plug to 48 ± 4 N·m
• Do not use glass beads on the outside of the shell (35 ± 3 lb ft).
or on the upper part of the insulator.
SEBU6355-03 93
Maintenance Section
Ignition System Timing - Check/Adjust

5. Install the spark plug extension on the spark plug. Make repairs, if necessary. For information regarding
removal and installation of the components, see
6. Center the spark plug extension in the transformer the Service Manual, “Disassembly and Assembly”
and install the transformer. module. Consult your Caterpillar dealer for
assistance.
i00769368

Ignition System Timing -

i01042517

Check/Adjust Jacket Water Heater - Check

SMCS Code: 1383-535
SMCS Code: 1550-025; 1550-535
Jacket water heaters help to improve startability in
After maintenance has been performed on the
ambient temperatures that are below 21 °C (70 °F).
ignition system, check the timing of the ignition All installations that require automatic starting should
system. Adjust the timing, if necessary.
have jacket water heaters.
Ignition timing for gas engines varies with the gas Check the operation of the jacket water heater. For
chemistry and the inlet manifold air temperature
an ambient temperature of 0 °C (32 °F), the heater
(aftercooler condition).
should maintain the jacket water temperature at
approximately 32 °C (90 °F).
Use the Caterpillar Digital Diagnostic Tool (DDT)
to adjust the timing. Adjust the timing according to
the topic Preliminary Specifications in the Special i01642396
Instruction, SEHS9769, “Installation and Initial
Start-Up Procedures For G3500 Engines”. Consult Overhaul (Major)
your Caterpillar dealer for assistance.
SMCS Code: 7595-020-MJ

i01113853
Scheduling a Major Overhaul
Inlet Air System - Inspect
Note: For information on estimating operating hours
SMCS Code: 1058-040; 1071-040; 1087-040 before an overhaul, see Maintenance Management
Schedules, SEBU6127.
Inspect the components of the air inlet system for
the following conditions: Generally, a major overhaul is performed at the sixth
top end overhaul. The need for a major overhaul is
• Cracks determined by several factors. Some of those factors
are the same factors that determine the in-frame
• Leaks overhaul:

• Loose connections • An increase of oil consumption

Inspect the following components: • An increase of crankcase blowby
• Piping between the air cleaner and the turbocharger • A decrease and variation of cylinder compression
• Turbocharger Other factors must also be considered for determining
a major overhaul:
• Piping between the turbocharger and the
aftercooler • The service hours of the engine
• Aftercooler • The wear metal analysis of the lube oil
• Connection of the aftercooler to the air plenum • An increase in the levels of noise and vibration
• Connection of the air plenum to the cylinder head An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
Ensure that all of the connections are secure. Ensure need to be serviced. An increase in the levels of
that the components are in good condition. noise and vibration indicates that rotating parts
require service.
94 SEBU6355-03
Maintenance Section
Overhaul (Major)

Note: It is possible for oil analysis to indicate a • Main bearings

decrease of wear metals in the lube oil. The cylinder
liners may be worn so that polishing of the bore • Oil temperature regulators
occurs. Also, the increased use of lube oil will dilute
the wear metals. • Water temperature regulators
Monitor the engine as the engine accumulates • Wiring harnesses
service hours. Consult your Caterpillar dealer about
scheduling a major overhaul. Rebuilding or Replacing of Components
Note: The driven equipment may also require service Rebuild the following components during the major
when the engine is overhauled. Refer to the literature overhaul.
that is provided by the OEM of the driven equipment.
• Carburetor
Major Overhaul Information
• Crankshaft vibration damper 1.
A major overhaul includes all of the work that is done
for top end overhauls and in-frame overhauls. A • Exhaust bypass
major overhaul includes additional parts and labor.
Additional parts and labor are required in order to • Gas regulator
completely rebuild the engine. In some cases, the
engine is relocated for disassembly. • Prelube pump
For the major overhaul, all of the bearings, • Starting motor
seals, gaskets, and components that wear are
disassembled. The parts are cleaned and inspected. • Turbochargers
If necessary, the parts are replaced. The crankshaft
is measured for wear. The crankshaft may require • Water pumps
regrinding. Alternatively, the crankshaft may be
replaced with a Caterpillar replacement part. Note: 1. Replace the crankshaft vibration damper if
the damper cannot be rebuilt.
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure Inspecting Components
that the components are operating within the
appropriate specifications. Inspect the following components according to
the instructions that are in Caterpillar reusability
If you elect to perform an overhaul without the publications. Refer to Guidelines for Reusable
services of a Caterpillar dealer, be aware of the Parts and Salvage Operations, SEBF8029, “Index
following recommendations. of Publications on Reusability or Salvage of Used
Parts”.
Replacing of Components
• Aftercooler
Replace the following components during the major
overhaul. • Camshafts

• Camshaft bearings • Camshaft followers

• Connecting rod bearings • Connecting rods

• Coupling (tandem engines) • Crankshaft

• Cylinder liners • Gear train

• Piston rings • Governor

• Cylinder heads, gaskets, and bolts • Inlet air piping

• Gaskets and seals • Oil cooler

• Gear train bearings • Oil pump

SEBU6355-03 95
Maintenance Section
Overhaul (Top End)

• Pistons • Dial indicators

• Transformers • Accurate measurement tools

i02209546
• Cleaning equipment

Overhaul (Top End) • Rebuilding equipment

SMCS Code: 7595-020-TE Caterpillar dealers are equipped with these tools.
Caterpillar dealers can provide a flat rate price for
a top end overhaul.
Scheduling a Top End Overhaul
Unexpected problems may be found during a top
Top end overhauls are scheduled according to end overhaul. Plan to correct these problems, if
the recession of the exhaust valve stems. This necessary.
measurement provides an accurate indication of the
rate of valve wear. This measurement can be used to • Buildup in the cylinders from excessive oil
predict when a cylinder head requires replacement. consumption

Measure the projection of the exhaust valve stems • Buildup in the cylinders from contamination of the
within the first 250 service hours. This measurement fuel
is the baseline. The baseline is a reference for
subsequent measurements. Measure the projection • Plugging of the aftercooler from coolant that is
again at the initial 1000 service hour mark. Use poorly maintained
this measurement to determine when the next
measurement should be taken. • Plugging of the aftercooler from contamination of
the inlet air
The maximum limit for the increase in the valve stem
projection is 2.3 mm (0.09 inch). Plan for the top end • Degradation of the oil cooler from hydrogen sulfide
overhaul as the valve stem projection approaches in the fuel
70% of the maximum limit, or 1.6 mm (0.06 inch).
Perform the top end overhaul before the valve stem • Leaks in the internal coolant passages in water
projection has reached the 2.3 mm (0.09 inch) limit. cooled exhaust manifolds
Do not allow the projection of the exhaust valve
stems to exceed this limit. Inspect the following components according to
the instructions that are in Caterpillar reusability
Note: Generally, cylinder heads wear out at different publications. Refer to Guidelines for Reusable
rates. In some cases, servicing the cylinder heads at Parts and Salvage Operations, SEBF8029, “Index
different times may be the most economic decision. of Publications on Reusability or Salvage of Used
This depends on the valve stem projection of the Parts”.
individual cylinders. However, this decision must
include the costs of additional downtime that is Your Caterpillar dealer can provide these services
caused by this procedure. Perform an economic and components. Your Caterpillar dealer can ensure
analysis in order to determine if cylinder heads should that the components are operating within the
be serviced as a group or divided into smaller groups. appropriate specifications.

Note: The generator or the driven equipment may If you elect to perform an overhaul without the
also require service when the engine overhaul is services of a Caterpillar dealer, be aware of the
performed. following recommendations.

Top End Overhaul Information Replacing of Components

A top end overhaul involves servicing the cylinder Replace the following components during a top end
heads and turbochargers. Also, some other engine overhaul.
components are inspected.
• Cylinder heads and gaskets
Top end overhauls require more tools than preventive
maintenance. The following tools are needed for • Oil temperature regulators
restoring the engine to factory specifications:
• Water temperature regulators
• Torque wrenches
96 SEBU6355-03
Maintenance Section
Overhaul (Top End)

Rebuilding of Components Caterpillar recommends the use of Hydrosolv

liquid cleaner. Hydrosolv liquid cleaners are
Rebuild the following components during a top end available from your Caterpillar dealer.
overhaul:
Use a two to five percent concentration of the
• Carburetor cleaner at temperatures up to 93 °C (200 °F).
Refer to Application Guide, NEHS0526 or consult
• Exhaust bypass your Caterpillar dealer for more information.

• Gas regulator 4. Steam clean the core in order to remove any

residue. Flush the fins of the core. Remove any
• Prelube pump other trapped debris.

• Starting motor 5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
• Turbochargers
• Water pumps
Note: Periodic inspection of the turbocharger is Personal injury can result from air pressure.
recommended for determining when the turbocharger
will require an overhaul. In a few applications, the Personal injury can result without following prop-
turbocharger may require rebuilding prior to the top er procedure. When using pressure air, wear a pro-
end overhaul. An example is an application with tective face shield and protective clothing.
loads that vary frequently. In these cases, rebuilding
the turbocharger normally occurs separately from Maximum air pressure at the nozzle must be less
rebuilding the cylinder heads. Some applications than 205 kPa (30 psi) for cleaning purposes.
can operate longer before the turbocharger requires
rebuilding. Only experience can determine the actual 6. Dry the core with compressed air. Direct the air in
need. the reverse direction of the normal flow.

Inspecting of Components Note: The test pressure for the oil cooler is 790 kPa
(115 psi). The maximum differential pressure of water
Clean the aftercooler core and the oil cooler for the aftercooler is 44 kPa (6 psi). The maximum
core. Pressure test the components. Replace the differential pressure of air for the aftercooler is
components. 5.1 kPa (0.74 psi).

Note: It is difficult to clean the aftercooler core when 7. Inspect the core in order to ensure cleanliness.
proper maintenance is not performed . The tank that Pressure test the core. Many shops that service
is opposite of the inlet port and the outlet port can not radiators are equipped to perform pressure tests.
be removed for cleaning. If necessary, repair the core.

Note: This procedure may be used for cleaning both 8. Install the core. For the procedure, see the Service
the aftercooler core and the oil cooler core. Manual, “Disassembly and Assembly” module.

1. Remove the core. For the procedure, see the For more information on cleaning the cores, consult
Service Manual, “Disassembly and Assembly” your Caterpillar dealer.
module.
Coupling
2. Turn the core upside-down in order to remove
debris. For tandem engine arrangements, inspect the
coupling for the engines according to the information
NOTICE that is provided by the OEM of the coupling. Check
Do not use a high concentration of caustic cleaner to the bolts for proper torque.
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause Governor
leakage. Only use the recommended concentration of
cleaner. Inspect the governor for proper operation. Make any
repairs that are necessary.
3. Back flush the core with cleaner.
SEBU6355-03 97
Maintenance Section
Overhaul Considerations

Transformers

g00787412
Illustration 80
(1) Cover
(2) O-ring seal
(3) Screen assembly

Note: Approximately 1 L (1 qt) of oil will remain in the

housing after the sump has been completely drained.
g00850303
This oil will pour out of the housing when cover (1) is
Illustration 79 removed. Prepare to catch the oil in a pan. Clean up
any spilled oil with absorbent pillows or towels. DO
The transformers produce a voltage increase. For NOT use absorbent particles to clean up the oil.
good operation, the connections must be clean and
secure. Inspect the transformers for the following 1. Loosen the bolts from cover (1). Remove cover
conditions: (1) and O-ring seal (2). Discard the seal. Remove
screen assembly (3).
• 1. Damaged connector
2. Wash screen assembly (3) in clean nonflammable
• 2. Damaged O-rings solvent. Allow the screen assembly to dry before
installation.
• 3. Dirty insulator
3. Remove the side covers from the engine block
• 4. Loose connections and clean the inside of the oil pan. Install the side
covers.
• 5. Loose screws in the top ground spring
4. Inspect screen assembly (3) for good condition.
• Moisture Obtain a new screen assembly, if necessary.
Install the screen assembly. Install a new O-ring
Test the resistance of the transformers according seal (2). Install cover (1).
to the Electronic Troubleshooting, SENR6413,
“G3500 Engines”. Consult your Caterpillar dealer for
assistance. i01950926

Oil Suction Screen Overhaul Considerations

SMCS Code: 7595-043

Hot oil and components can cause personal in- Overhaul Information
jury.
An overhaul is replacing the major worn components
Do not allow hot oil or components to contact of the engine. An overhaul is a maintenance interval
skin. that is planned. The engine is rebuilt with certain
rebuilt parts or new parts that replace the worn parts.

Clean the oil suction screen after the oil has been An overhaul also includes the following maintenance:
drained.
• Inspection of all the parts that are visible during
the disassembly
98 SEBU6355-03
Maintenance Section
Overhaul Considerations

• Replacement of the seals and gaskets that are Generally, engines that are operated at a reduced
removed load and/or speed achieve more service life before
an overhaul. However, this is for engines that are
• Cleaning of the internal passages of the engine properly operated and maintained.
and the engine block
Overhaul Inspection
Most owners will save money by overhauling the
engine at the intervals that are recommended in Refer to the Service Manual for the disassembly and
the Operation and Maintenance Manual. It is not assembly procedures that are necessary in order
practical to wait until the engine exhibits symptoms to perform the required maintenance on the items
of excessive wear or failure. It is not less costly to that are listed. Consult your Caterpillar dealer for
wait. A planned overhaul before failure may be the assistance.
best value for the following reasons:
To determine the reusability publications that are
• Costly unplanned downtime can be avoided. needed to inspect the engine, refer to Guidelines for
Reusable Parts and Salvage Operations, SEBF8029,
• Many original parts can be reused according to the “Index of Publications on Reusability or Salvage of
guidelines for reusable parts. Used Parts”.

• The service life of the engine can be extended The Guidelines For Reusable Parts and Salvage
without the risk of a major catastrophe due to Operations is part of an established Caterpillar
engine failure. parts reusability program. These guidelines were
developed in order to assist Caterpillar dealers and
• Achieve the best cost/value relationship per hour customers reduce costs by avoiding unnecessary
of extended service life. expenditures for new parts. If the engine parts comply
with the established inspection specifications, the
Overhaul Intervals parts can be reused. New parts are not necessary if
the old parts can be reused, repaired, or salvaged.
Top end overhauls are determined by the projection
of exhaust valve stems. In-frame overhauls are If the parts are not within the inspection specifications,
determined by cylinder compression, crankcase the parts should be salvaged, repaired, replaced,
blowby, and oil consumption. Major overhauls are or exchanged. The use of out-of-spec parts could
determined by the in-frame tests, and by results of result in unscheduled downtime and/or costly repairs.
S·O·S oil analysis. The use of out-of-spec parts can also contribute to
increased fuel consumption and reduction of engine
Some other factors that are important for determining efficiency.
the overhaul intervals include the following
considerations: Your Caterpillar dealer can provide the parts that are
needed to rebuild the engine at the least possible
• Performance of preventive maintenance cost.

• Use of recommended lubricants Overhaul Programs

• Use of recommended coolants An economical way to obtain most of the parts
that are needed for overhauls is to use Caterpillar
• Use of recommended fuels remanufactured parts. Caterpillar remanufactured
parts are available at a fraction of the cost of new
• Proper installation parts. These parts have been rebuilt by Caterpillar
and certified for use. The following components are
• Operating conditions examples of the remanufactured parts:

• Operation within acceptable limits • Alternators

• Engine load • Connecting rods
• Engine speed • Crankshafts
Note: To avoid oil problems, engines that are • Cylinder heads
turbocharged and aftercooled must be operated at a
minimum of 60 percent of rated load. • Oil Pumps
SEBU6355-03 99
Maintenance Section
Radiator - Clean

• Starting motors Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction
• Turbochargers of the fan’s air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move the
• Water pumps air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.
Consult your Caterpillar dealer for details and for a
list of the remanufactured parts that are available. Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
Your Caterpillar dealer may be offering a variety of must be less than 275 kPa (40 psi). Use pressurized
overhaul options. water in order to soften mud. Clean the core from
both sides.
A Flat Rate Overhaul guarantees the maximum price
that you will pay for an overhaul. Flat rate prices on Use a degreaser and steam for removal of oil and
preventive maintenance programs or major repair grease. Clean both sides of the core. Wash the core
options are available from many servicing dealers with detergent and hot water. Thoroughly rinse the
for all Caterpillar Engines. Consult your Caterpillar core with clean water.
dealer in order to schedule a before failure overhaul.
After cleaning, start the engine and accelerate the
Overhaul Recommendation engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Caterpillar recommends a scheduled overhaul in Use a light bulb behind the core in order to inspect
order to minimize downtime. A scheduled overhaul the core for cleanliness. Repeat the cleaning, if
will provide the lowest cost and the greatest value. necessary.
Schedule an overhaul with your Caterpillar dealer.
Inspect the fins for damage. Bent fins may be opened
Overhaul programs vary between dealers. To obtain with a “comb”. Inspect these items for good condition:
specific information about the types of overhaul welds, mounting brackets, air lines, connections,
programs and services, consult your Caterpillar clamps, and seals. Make repairs, if necessary.
dealer.
For more detailed information on cleaning and
inspection, refer to Special Publication, SEBD0518,
i01604510
“Know Your Cooling System”.
Radiator - Clean
i01113939
SMCS Code: 1353-070
Starting Motor - Inspect
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. SMCS Code: 1451-040; 1453-040

Inspect the radiator for these items: damaged fins, If the starting motor fails, the engine may not start in
corrosion, dirt, grease, insects, leaves, oil, and other an emergency situation. A scheduled inspection of
debris. Clean the radiator, if necessary. the starting motor is recommended.

The starting motor pinion and the flywheel ring gear

must be in good condition in order for the engine
to start properly. The engine will not start if the
Personal injury can result from air pressure. starting motor pinion does not engage the flywheel
ring gear. The teeth of the starting motor pinion and
Personal injury can result without following prop- the flywheel ring gear can be damaged because of
er procedure. When using pressure air, wear a pro- irregular engagement.
tective face shield and protective clothing.
Inspect the starting motor for proper operation. Listen
Maximum air pressure at the nozzle must be less for grinding when the engine is started. Inspect the
than 205 kPa (30 psi) for cleaning purposes. 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.
100 SEBU6355-03
Maintenance Section
Turbocharger - Inspect

Electric Starting Motor i01454354

Note: Problems with the electric starting motor can Turbocharger - Inspect
be caused by the following conditions: malfunction of
the solenoid and malfunction of the electric starting SMCS Code: 1052-040
system.
Periodic inspection and cleaning is recommended for
Inspect the electrical system for the following the turbocharger. Fouling of the turbine wheels can
conditions: contribute to loss of engine power and overall loss
of engine efficiency.
• Loose connections
If the turbocharger fails during engine operation,
• Corrosion damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
• Wires that are worn or frayed turbocharger compressor wheel could allow parts
from the compressor wheel to enter an engine
• Cleanliness cylinder. This can cause additional damage to the
pistons, the valves, and the cylinder head.
Make repairs, if necessary.
NOTICE
Air Starting Motor Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.

Personal injury or death can result from improp- Minor leakage of a turbocharger housing under ex-
erly checking for a leak. tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc-
Always use a board or cardboard when checking curred.
for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tis- When a turbocharger bearing failure is accompanied
sue causing serious injury, and possible death. by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
If fluid is injected into your skin, it must be treated engine operation until the turbocharger is repaired or
immediately by a doctor familiar with this type of replaced.
injury.
An inspection of the turbocharger can minimize
Inspect all of the components in the air circuit for unscheduled downtime. Also, the chance for potential
the starting motor. Inspect all of the air lines and damage to other engine parts is reduced.
connections for leaks.
Note: Turbocharger components require clearances
If the teeth of the starting motor pinion and/or the that are precise. The turbocharger cartridge must be
flywheel ring gear are damaged, the air circuit for balanced due to high rpm.
the starting motor must be examined in order to
determine the cause of the problem. The following conditions can cause the turbocharger
to be out-of-balance:
Removal and Installation of the
• The buildup of deposits
Starting Motor
• Chipping and/or flaking of deposits
Refer to the Service Manual, “Disassembly and
Assembly” module for information on removing the If the turbocharger must be removed for inspection,
starting motor and installing the starting motor. use caution. Do not break deposits from the turbine
wheel. Do not attempt to clean the turbine wheel. For
Consult your Caterpillar dealer for assistance. options regarding removal, installation, repair and
replacement, see the Service Manual or consult your
Caterpillar dealer.

1. Remove the exhaust outlet piping and remove

the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil.
SEBU6355-03 101
Maintenance Section
Valve Stem Projection - Measure/Record

2. Turn the compressor wheel and the turbine wheel i02209685

by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for Valve Stem Projection -
contact with the turbocharger housing. There
should not be any visible signs of contact between
Measure/Record
the turbine wheel or compressor wheel and the SMCS Code: 1105-082
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the Valve Recession – The valves and the valve seats
compressor wheel and the turbocharger housing, are worn over time. This causes the valves to recede
the turbocharger should be reconditioned. into the cylinder head. This condition is called “valve
recession”.
3. Check the compressor wheel for cleanliness.
If only the inlet side of the wheel is dirty, dirt The top end overhaul is scheduled according to
and/or moisture is passing through the air filtering the recession of the exhaust valves. However, it is
system. If oil is found only on the back side of the difficult to measure the actual valve recession in the
wheel, there is a possibility of a failed turbocharger cylinder head. A simpler method is used to determine
oil seal. the valve recession:
The presence of oil may be the result of extended • Measure the projection of the valve rotator above
engine operation at low idle. The presence of oil the cylinder head. It is not necessary to remove the
may also result from restriction of the inlet air rocker arms in order to obtain this measurement.
(plugged air filters). This causes oil to leak past
the seal for the turbocharger compressor. Measure the projection of the exhaust valve rotators
with a 155-1536 Valve Recession Tool Group.
If oil is found on the compressor wheel and/or Follow the instructions that are provided with the tool
at the air inlet, the source of the oil is the fuel group.
compressor or the PCV system.
Record the measurements on the Operation and
Note: Deposits of ash and silicone can accumulate Maintenance Manual, “Valve Data Sheet” (Reference
on the turbine wheel. Turbine wheel will become Materials Section).
unbalanced when the deposits flake off. The
turbocharger cartridge must be replaced when this • Measure the projection of the exhaust valve
occurs. However, remove deposits from the housing. rotators after 250 service hours. This measurement
This will prevent wear on the blades of the new is the baseline. The baseline is a reference for
turbine wheel. subsequent measurements.
4. Inspect the turbine wheel and the nozzle for • Measure the projection of the exhaust valve
deposits of ash and silicone. If deposits of 1.6 mm rotators at the first 1000 service hours.
(0.06 inch) thickness are found or if the turbine is
in contact with the housing, the turbocharger must • Illustration 81 shows schedules for determining
be disassembled and cleaned. Removal of the subsequent intervals. After determining the
deposits can be difficult. increase in the valve stem projection from 250
service hours to 1000 service hours, find the
5. Inspect the bore of the turbine housing for schedule that best fits the measured increase in
corrosion and deposits. the valve stem projection.
6. Clean the turbocharger compressor housing with • After 70 percent of the maximum limit has been
standard shop solvents and a soft bristle brush. reached, measure the projection of the exhaust
valve rotators at every 1000 hours of operation.
7. Fasten the air inlet piping and the exhaust outlet The 70 percent is 1.60 mm (0.063 inch).
piping to the turbocharger housing.
• Plan for the top end overhaul as the projection of
the valve rotator approaches the maximum limit.
Perform the top end overhaul when the projection
of the valve rotator has increased by a total of
2.3 mm (0.09 inch). Do not allow the recession
of the exhaust valves to exceed this limit. The
valve head can break. This will cause severe
damage in the combustion chamber.
102 SEBU6355-03
Maintenance Section
Walk-Around Inspection

g01115573
Illustration 81
(A) Schedule (Y) Valve recession in millimeters (inches) (2) 0.218 mm (0.0086 inch)
(B) Schedule (X) Hours of operation (3) 0.152 mm (0.0060 inch)
(C) Schedule (1) 0.254 mm (0.0100 inch)

To determine intervals, use the point on the graph in i01492446

Illustration 81 that is closest to the measurement for
each cylinder. Walk-Around Inspection
For example, the “Valve Data Sheet” (reference SMCS Code: 1000-040
section) shows that the increase in the valve
stem projection at the initial 1000 service hour Inspect the Engine for Leaks and
measurement shows a valve recession of 0.152 mm
(0.0060 inch). This would allow you to use Schedule for Loose Connections
(C). According to Schedule (C), the next interval for
measuring that cylinder is at 5000 service hours. A walk-around inspection should only take a few
Another cylinder may have a valve recession of minutes. When the time is taken to perform these
0.254 mm (0.0100 inch). According to Schedule (A), checks, costly repairs and accidents can be avoided.
the next interval for measuring that cylinder is at
3000 service hours. For maximum engine service life, thoroughly inspect
the engine room before starting the engine. Look for
When different cylinders require different schedules, items such as leaks, loose bolts, loose connections
the schedule that requires the most frequent and trash buildup. Make repairs, as needed.
measurements should be used for all cylinders.
Subsequent measurements can result in changing • The guards must be in the proper place. Repair
the schedule that is used. For example, if the first damaged guards or replace missing guards.
measurement indicates that Schedule (A) should
be used, the next measurement should be taken at • Wipe all caps and plugs before the engine is
3000 service hours. However, if the increase in the serviced in order to reduce the chance of system
projection that is measured at 3000 hours falls on contamination.
Schedule (B), then Schedule (B) can be used for the
next measurement.

Consult your Caterpillar dealer for assistance.

SEBU6355-03 103
Maintenance Section
Water Pump - Inspect

• Inspect the exhaust system for leaks. If a leak is

NOTICE found, make repairs.
For any type of leak, clean up the fluid. If leaking is ob-
served, find the source and correct the leak. If leaking
i00524084
is suspected, check the fluid levels more often than
recommended until the leak is found or fixed, or until Water Pump - Inspect
the suspicion of a leak is proved to be unwarranted.
SMCS Code: 1361-040
NOTICE A failed water pump might cause severe engine
Accumulated grease and/or oil on an engine or deck is overheating problems that could result in cracks in
a fire hazard. Remove this debris with steam cleaning the cylinder head, a piston seizure or other potential
or high pressure water. damage to the engine.

• Ensure that cooling lines are properly clamped. Visually inspect the water pump for leaks. If leaking
Check for leaks. Check the condition of all pipes. of the water pump seals is observed, replace all of
the water pump seals. Refer to the Service Manual
• Inspect the water pumps for coolant leaks. for the disassembly and assembly procedure.

Note: The water pump seal is lubricated by coolant Inspect the water pump for wear, cracks, pin holes
in the cooling system. It is normal for a small amount and proper operation. Refer to the Service Manual or
of leakage to occur when the engine cools and the consult your Caterpillar dealer if repair is needed or
parts contract. replacement is needed.

Excessive coolant leakage may indicate the need i01665404

to replace the water pump seal. For instructions
on removal and installation of water pumps and/or Water Temperature Regulator -
seals, refer to the Service Manual, “Disassembly and
Assembly” module for the engine or consult your Replace
Caterpillar dealer.
SMCS Code: 1355-510
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil Replace the Water Temperature
pan, the oil filters and the valve covers.
Regulators in the Water
Temperature Regulator Housing
and in the Thermostatic Valve
NEVER use a flame to check for gas leaks. Use a
gas detector.

An open flame can ignite mixtures of air and fuel.

This will cause explosion and/or fire which could
result in severe personal injury or death.

• Check the fuel system for leaks. Look for loose fuel
line clamps.

• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed g00787738
Illustration 82
wires.
Replace the water temperature regulators before
• Inspect the ground straps for good connections the water temperature regulators fail. This is a
and for good condition. recommended preventive maintenance practice.
Replacing the water temperature regulators reduces
• Check the condition of the gauges. Replace any the chances for unscheduled downtime.
gauge that is damaged. Replace any gauge that
can not be calibrated.
104 SEBU6355-03
Maintenance Section
Water Temperature Regulator - Replace

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.

NOTICE
Failure to replace the water temperature regulator on
a regularly scheduled basis could cause severe en-
gine damage.

Never operate an engine without the water tempera-

ture regulator installed.

If the water temperature regulator is installed incor-

rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position.

For the procedure to replace the water temperature

regulators, see the Service Manual, “Disassembly
and Assembly” module. Consult your Caterpillar
dealer for assistance.

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.
SEBU6355-03 105
Reference Information Section
Customer Service

Reference Information Latin America, Mexico, Carribean

Caterpillar Americas Co.
Section 701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Customer Service Fax: 305-476-6801

Europe, Africa, and Middle East

i02097871
Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000; 4450 CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
USA and Canada Fax: 22-849-4544
When a problem arises concerning the operation of Far East
an engine or concerning the service of an engine, Caterpillar Asia Pte. Ltd.
the problem will normally be managed by the dealer 7 Tractor Road
in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level without additional assistance, use the phone Hong Kong
number that is listed below to talk with a Field Phone: 852-2848-0333
Service Coordinator: Fax: 852-2848-0440
1-800-447-4986 Japan
Shin Caterpillar Mitsubishi Ltd.
The normal hours are from 8:00 to 4:30 Monday SBS Tower
through Friday Central Standard Time. 10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
3. If your needs have not been met still, submit the Japan
matter in writing to the following address: Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Caterpillar Inc.
Manager, Customer Service, Engine Division Japan
Mossville Bldg AC Caterpillar Power Systems, Inc.
P.O. Box 610 SBS Tower (14th floor)
Mossville, Illinois 61552-0610 4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Please keep in mind: probably, your problem will Phone: 81-3-5797-4300
ultimately be solved at the dealership, using the Fax: 81-3-5797-4359
dealership’s facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a Australia and New Zealand
problem is experienced. Caterpillar of Australia Ltd.
1 Caterpillar Drive
Outside of the USA and of Canada Private Mail Bag 4
Tullamarine, Victoria 3043
If a problem arises outside the USA and outside Australia
Canada, and if the problem cannot be resolved at the Phone: 03-9953-9333
dealer level, consult the appropriate Caterpillar office. Fax: 03-9335-3366
106 SEBU6355-03
Reference Information Section
Customer Service

i01028392

Ordering Replacement Parts

SMCS Code: 4450; 7567

When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers’ parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.

When you order parts, please specify the following

information:

• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.

When a Caterpillar engine requires maintenance

and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform the

dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
SEBU6355-03 107
Reference Information Section
Reference Materials

Reference Materials • Maintenance log

i00912149

Maintenance Records
SMCS Code: 1000; 4450

Caterpillar Inc. recommends the retention of accurate

maintenance records. Accurate maintenance records
can be used for the following purposes:

• Determine operating costs.

• Establish maintenance schedules for other engines
that are operated in the same environment.

• Show compliance with the required maintenance

practices and maintenance intervals.

Maintenance records can be used for a variety of

other business decisions that are related to engine
maintenance.

Maintenance records are a key element of a

maintenance program that is well managed. Accurate
maintenance records can help your Caterpillar dealer
to fine tune the recommended maintenance intervals
in order to meet the specific operating situation. This
should result in a lower engine operating cost.

Records should be kept for the following items:

Fuel Consumption – A record of fuel consumption

is essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul
intervals.

Service Hours – A record of service hours is

essential to determine when the speed sensitive
components should be inspected or repaired.

Documents – These items should be easy to

obtain, and these items should be kept in the engine
history file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number, and engine serial number. The following
types of documents should be kept as proof of
maintenance or repair for warranty:

Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owner’s repair costs
• Owner’s receipts
108 SEBU6355-03
Reference Information Section
Reference Materials

i02209903

Maintenance Log
SMCS Code: 1000; 4450

Table 19
Engine Model Customer Identifier
Serial Number Arrangement Number
Service
Service Item Date Authorization
Hours
SEBU6355-03 109
Reference Information Section
Reference Materials

i00769479

Valve Data Sheet

SMCS Code: 1000

Table 20
Engine Model Serial Number Service Hours Authorization
Cylinder Valve Location Current Stem Rotator
Cylinder Wear
Pressure Measure Baseline Baseline
1 Pushrod Side
Exhaust Manifold
2 Pushrod Side
Exhaust Manifold
3 Pushrod Side
Exhaust Manifold
4 Pushrod Side
Exhaust Manifold
5 Pushrod Side
Exhaust Manifold
6 Pushrod Side
Exhaust Manifold
7 Pushrod Side
Exhaust Manifold
8 Pushrod Side
Exhaust Manifold
9 Pushrod Side
Exhaust Manifold
10 Pushrod Side
Exhaust Manifold
11 Pushrod Side
Exhaust Manifold
12 Pushrod Side
Exhaust Manifold
13 Pushrod Side
Exhaust Manifold
14 Pushrod Side
Exhaust Manifold
15 Pushrod Side
Exhaust Manifold
16 Pushrod Side
Exhaust Manifold
110 SEBU6355-03
Reference Information Section
Reference Materials

i02209917 Miscellaneous
Reference Material • Application and Installation Guide, LEKQ7250, “Air
Intake”
SMCS Code: 1000; 4450
• Engine Performance, LEBQ6117, “G3500
The following literature can be obtained through any Industrial”
Caterpillar dealer.
• Engine Performance, LEBQ6169, “G3500
Lubricants Generator Set”

• Data Sheet, PEHP0002, “Cat MPGM (Multipurpose • Electronic Troubleshooting, SENR6413, “G3500
Lithium Complex Grease with Molybdenum)” Engines”

• Data Sheet, PEHP0003, “Multipurpose Lithium • Disassembly and Assembly, SENR6419, “G3500
Complex Grease (MPG)” Engines”

• Data Sheet, PEHP0017, “Cat SPG (Special • Electronic Troubleshooting , SENR6517, “G3500
Purpose Grease)” Air/Fuel Ratio Control”

• Special Publication, PEDP7036, “S·O·S Fluid • Software Program, LEKQ6378, “Methane Number
Analysis” Program”

• Special Publication, PEHP6001, “How To Take A • Special Publication, PECP9068, “One Safe
Good Oil Sample” Source”

• Special Publication, SEBU6400, “Caterpillar • Specifications, SENR3130, “Torque Specifications”

Gas Engine Lubricant, Fuel, and Coolant
Recommendations” • Specifications, SENR6411, “G3500 Engines”

Fuels • Specifications, SENR6417, “G3500 Engine

Attachments”
• Application and Installation Guide, LEKQ7256, • Special Instruction, GMG00694, “Analyzing
“Fuels, Fuel Systems” Cylinder Condition By Measuring Air Flow”
• Application and Installation Guide, LEKQ7260, • Special Instruction, REHS0128, “Using the
“Low Energy Fuels” 147-5482 Indicator Gauge For Valve Lash and
Valve Bridge Adjustment”
• Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel, and Coolant
Recommendations”
• Special Instruction, SEHS7332, “Do Not Operate
Tag”

Coolants • Special Instruction, SEHS7633, “Battery Test

Procedure”
• Data Sheet, PEHP7057, “Coolant Analysis”
• Special Instruction, SEHS8622, “Using the FT-
• Special Publication, PEDP7036, “S·O·S Fluid 1984 Air-To-Air Aftercooler Leak Test Group”
Analysis”
• Special Instruction, SEHS8712, “Using the
• Special Publication, SEBD0518, “Know Your 8T-2700 Blowby/Airflow Indicator Group”
Cooling System”
• Special Instruction, SEHS9031, “Storage
• Special Publication, SEBD0970, “Coolant and Your Procedure for Caterpillar Products”
Engine”
• Special Instruction, SEHS9298, “Installation and
• Special Publication, SEBU6400, “Caterpillar Maintenance of Gaseous Fuel Filters”
Gas Engine Lubricant, Fuel, and Coolant
Recommendations” • Special Instruction, SEHS9769, “Installation and
Initial Start-Up Procedure for G3500 Engines”
SEBU6355-03 111
Reference Information Section
Reference Materials

• Special Publication, NEHS0526, “Service The International Organization for Standardization

Technician Application Guide” (ISO) offers information and customer service
regarding international standards and standardizing
• Special Publication, NENG2500, “Caterpillar Tools activities. ISO can also supply information on the
and Shop Products Guide” following subjects that are not controlled by ISO:
national standards, local standards, regulations,
• Special Publication, SEBF8029, “Index to certification, and related activities. Consult the
Guidelines for Reusable Parts and Salvage member of ISO in your country.
Operations”
International Organization for Standardization
• Special Publication, SEBF8062, “Procedure to (ISO)
Inspect and Clean Air Filters” 1, rue de Varembé
Case postale 56
• Systems Operation/Testing and Adjusting, CH-1211 Genève 20
SENR6412, “G3500 Engines” Switzerland
Telephone: +41 22 749 01 11
• Systems Operation/Testing and Adjusting, Facsimile: +41 22 733 34 30
SENR6418, “G3500 Engine Attachments” E-mail: [email protected]
Web site: http://www.iso.ch
• Systems Operation/Testing and Adjusting,
SENR6420, “Remote Control Panel (Status)” European classifications are established by the
Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Additional Reference Material Engines).
The “Engine Fluids Data Book” can be obtained from
CIMAC Central Secretariat
the following locations: local technological society,
Lyoner Strasse 18
local library, and local college. If necessary, consult
EMA at the following address: 60528 Frankfurt
Germany
Telephone: +49 69 6603 1567
Engine Manufacturers Association
Two North LaSalle Street, Suite 2200 Facsimile: +49 69 6603 1566
Chicago, Illinois, USA 60602
E-mail: [email protected]
(312) 827-8700
Facsimile: (312) 827-8737

The “Society of Automotive Engineers (SAE)

Specifications” can be found in your SAE handbook.
This publication can also be obtained from the
following locations: local technological society, local
library, and local college. If necessary, consult SAE
at the following address:

SAE International
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841

The “American Petroleum Institute Publication No.

1509” can be obtained from the following locations:
local technological society, local library, and local
college. If necessary, consult API at the following
address:

American Petroleum Institute

1220 L St. N.W.
Washington, DC, USA 20005
Telephone: (202) 682-8000
112 SEBU6355-03
Index Section

Index
A Cooling System Coolant (NGEC) - Change .......... 67
Clean the Cooling System ................................. 68
Actuator Control Linkage - Lubricate ..................... 62 Cleaning a Cooling System that has Heavy
After Starting Engine ............................................. 50 Deposits or Plugging ........................................ 69
Engaging the Driven Equipment ........................ 50 Drain the Cooling System .................................. 67
After Stopping Engine............................................ 54 Fill the Cooling System ...................................... 69
Aftercooler Condensation - Drain .......................... 62 Cooling System Coolant Level - Check ................. 70
Air Starting Motor Lubricator Bowl - Clean ............ 62 Add Coolant ....................................................... 70
Air Starting Motor Lubricator Oil Level - Check ..... 63 Cooling System Coolant Sample (Level 1) -
Adjust the Lubricator .......................................... 63 Obtain .................................................................. 70
Air Tank Moisture and Sediment - Drain................ 64 Cooling System Coolant Sample (Level 2) -
Alarms and Shutoffs .............................................. 33 Obtain .................................................................. 71
Setpoints for Alarms and Shutoffs ..................... 34 Cooling System Supplemental Coolant Additive
Testing Alarms and Shutoffs .............................. 33 (SCA) - Test/Add.................................................. 71
Alternator - Inspect ................................................ 64 Add the SCA, If Necessary ................................ 72
Test the Concentration of the SCA..................... 72
Crankcase Blowby - Measure/Record ................... 73
B Crankshaft Vibration Damper - Inspect ................. 73
Removal and Installation.................................... 74
Batteries - Replace ................................................ 64 Crushing Prevention and Cutting Prevention ........ 14
Battery Charger - Check........................................ 65 Customer Assistance........................................... 105
Checking After Stopping .................................... 65 Outside of the USA and of Canada.................. 105
Checking Before Start-Up .................................. 65 USA and Canada ............................................. 105
Battery Electrolyte Level - Check .......................... 66 Customer Service ................................................ 105
Before Starting Engine .................................... 15, 46 Cylinder Pressure - Measure/Record .................... 74
Air Inlet System.................................................. 46
Cooling System.................................................. 46
Driven Equipment .............................................. 46 E
Electrical System ............................................... 46
Fuel System ....................................................... 46 Electrical Connections - Check.............................. 75
Lubrication System ............................................ 47 Emergency Stopping ............................................. 52
Starting System.................................................. 47 Emergency Stop Button ..................................... 52
Walk-Around Inspection..................................... 46 Engine Air Cleaner Element - Replace.................. 75
Belts - Inspect/Adjust/Replace............................... 66 Cleaning the Primary Air Cleaner Elements ...... 76
Adjusting the Alternator Belt .............................. 66 Servicing the Air Cleaner Elements ................... 75
Adjusting the Fan Drive Belt .............................. 67 Engine Air Cleaner Service Indicator - Inspect...... 77
Inspection........................................................... 66 Test the Service Indicator................................... 78
Replacement...................................................... 67 Engine Air Precleaner - Clean ............................... 78
Burn Prevention..................................................... 13 Engine Crankcase Breather - Clean...................... 78
Batteries............................................................. 13 Engine Features and Controls............................... 27
Coolant............................................................... 13 Engine Mounts - Check ......................................... 79
Oils..................................................................... 13 Engine Oil - Change .............................................. 80
Engine Oil Filter - Change ..................................... 82
Inspect the Used Oil Filter Elements.................. 84
C Replacing the Engine Oil Filters During Engine
Operation ......................................................... 84
Carburetor Air/Fuel Ratio - Check/Adjust .............. 67 Replacing the Engine Oil Filters With the Engine
Cold Weather Starting ........................................... 47 Stopped............................................................ 83
Control Panel......................................................... 35 Engine Oil Filter (Auxiliary) - Change .................... 81
Alarm Module..................................................... 43 Engine Oil Level - Check ....................................... 85
Electronic Modular Control Panel II (EMCP II)... 39 Engine Oil Sample - Obtain ................................... 85
Generator Set Control (GSC)............................. 40 Obtain the Sample and the Analysis.................. 86
Remote Control Panel (Status) .......................... 35 Engine Operation................................................... 51
Synchronizing Lights Module ............................. 44 Operating the Engine and the Driven
Control Panel - Inspect .......................................... 67 Equipment ........................................................ 51
Record the Data and Review the Data .............. 67 Partial Load Operation ....................................... 51
Engine Protective Devices - Check ....................... 86
Visual Inspection................................................ 86
SEBU6355-03 113
Index Section

Engine Speed/Timing Sensor - Clean/Inspect....... 86 I

Engine Starting ................................................ 15, 46
Engine Stopping .............................................. 15, 52 Ignition System Spark Plugs - Check/Adjust/
Engine Valve Lash - Inspect/Adjust ....................... 87 Replace................................................................ 90
Engine Valve Lash ............................................. 87 Cleaning the Spark Plug .................................... 92
Valve Bridge....................................................... 87 Inspecting the Spark Plug .................................. 91
Exhaust Bypass - Inspect ...................................... 88 Installing the Spark Plug .................................... 92
Exhaust Manifold - Inspect (Water Cooled Exhaust Removing the Spark Plug .................................. 91
Manifolds) ............................................................ 88 Ignition System Timing - Check/Adjust .................. 93
Landfill Applications ........................................... 88 Ignition Systems .................................................... 14
Exhaust Piping - Inspect........................................ 88 Important Safety Information ................................... 2
Inlet Air System - Inspect....................................... 93

F
J
Fire Prevention and Explosion Prevention ............ 13
Fire Extinguisher ................................................ 14 Jacket Water Heater - Check ................................ 93
Foreword ................................................................. 5
California Proposition 65 Warning ....................... 4
Literature Information........................................... 4 L
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4 Lifting and Storage ................................................ 23
Operation ............................................................. 4
Overhaul .............................................................. 5
Safety................................................................... 4 M
Fuel System Fuel Filter Differential Pressure -
Check................................................................... 89 Maintenance Interval Schedule (Naturally
Aspirated) ............................................................ 60
Maintenance Interval Schedule (Turbocharged
G Aftercooled) ......................................................... 58
Maintenance Log ................................................. 108
Gas Pressure Regulator Condensation - Drain ..... 89 Maintenance Records.......................................... 107
Gauges and Indicators .......................................... 24 Maintenance Section ............................................. 55
Optional Gauges ................................................ 25 Manual Stop Procedure......................................... 53
General Hazard Information .................................. 10 Model View Illustrations......................................... 16
Asbestos Information ......................................... 12 Model Views and Specifications ............................ 16
Containing Fluid Spillage .................................... 11 Mounting and Dismounting.................................... 14
Dispose of Waste Properly ................................ 12
Fluid Penetration................................................. 11
Pressure Air and Water....................................... 11 O
Softwrap............................................................. 12
Governors and Actuators....................................... 44 Operation Section.................................................. 23
Woodward 2301A Load Sharing Governor ........ 45 Ordering Replacement Parts ............................... 106
Woodward 2301A Speed Control Governor ...... 45 Overhaul (Major).................................................... 93
Woodward 3161 Governor................................. 45 Major Overhaul Information ............................... 94
Woodward 701A Governor ................................ 45 Scheduling a Major Overhaul............................. 93
Woodward ProAct Governor .............................. 45 Overhaul (Top End) ............................................... 95
Scheduling a Top End Overhaul ........................ 95
Top End Overhaul Information ........................... 95
H Overhaul Considerations ....................................... 97
Overhaul Information ......................................... 97
Hoses and Clamps - Inspect/Replace ................... 89
Replace the Hoses and the Clamps .................. 90
P

Performance Parameters ...................................... 27

Air/Fuel Ratio ..................................................... 27
Angle of the Throttle Plate ................................. 28
Oil Consumption ................................................ 28
Optional Air/Fuel Ratio Control .......................... 28
Setting of the Exhaust Bypass (Wastegate) ...... 28
114 SEBU6355-03
Index Section

Plate Locations and Film Locations....................... 21 V

Engine Identification........................................... 21
Information Plate (2) .......................................... 21 Valve Data Sheet................................................. 109
Serial Number Plate (1) ..................................... 21 Valve Stem Projection - Measure/Record............ 101
Product Description ............................................... 17
Cooling System.................................................. 18
Engine Service Life ............................................ 19 W
Fuel System ....................................................... 17
Ignition System .................................................. 18 Walk-Around Inspection ...................................... 102
Lubrication System ............................................ 18 Inspect the Engine for Leaks and for Loose
Product Identification Information .......................... 21 Connections ................................................... 102
Product Information Section .................................. 16 Water Pump - Inspect .......................................... 103
Product Lifting........................................................ 23 Water Temperature Regulator - Replace............. 103
Product Storage..................................................... 23 Replace the Water Temperature Regulators in the
Engine Storage .................................................. 23 Water Temperature Regulator Housing and in the
Thermostatic Valve......................................... 103

Radiator - Clean .................................................... 99

Reference Information ........................................... 21
Reference Information Section ............................ 105
Reference Material ............................................... 110
Additional Reference Material........................... 111
Coolants............................................................ 110
Fuels ................................................................. 110
Lubricants ......................................................... 110
Miscellaneous ................................................... 110
Reference Materials ............................................ 107
Refill Capacities..................................................... 55
Refill Capacities and Recommendations............... 55
Cooling System.................................................. 56
Fuel .................................................................... 55
Lubrication System ............................................ 55

Safety Messages ..................................................... 6

Safety Section ......................................................... 6
Sensors and Electrical Components ..................... 29
Electronic Ignition System (EIS) ........................ 29
Junction Box ...................................................... 30
Sensors.............................................................. 31
Specifications ........................................................ 19
Starting Motor - Inspect ......................................... 99
Air Starting Motor ............................................. 100
Electric Starting Motor...................................... 100
Removal and Installation of the Starting
Motor .............................................................. 100
Starting the Engine ................................................ 48
Automatic Starting.............................................. 48
Manual Starting.................................................. 48
Purging Unburned Gas ...................................... 48
Starting with Jump Start Cables ............................ 49

Table of Contents..................................................... 3
Turbocharger - Inspect ........................................ 100
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
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