CATERPILLAR' SEBU6359-05

November 2002

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G3406 Engine
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5NW1-Up (Engine)
 V658146

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.

A WARNING
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 .

A WARNING
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 .
 3
Table of Contents

-r" 1-
I CIEDI f Content Maintenance Interval Schedule (Turbocharged
Aftercooled Engines) . .. .. . .. .. ... .. .. 56

Foreword . . .. . . .. . . . . . . ... . ... . . .... . .. . . ... . . ... . .. .. 4 Maintenance Interval Schedule (Naturally Aspirated
Engines) ... .. . . .. .. . . .. .. . .. .. . . .. .. 57
Safety Section
Maintenance Interval Schedule (Standby Generator
Safety Set Engines) 58
Messages . ... . .... .... . ... . . ... . ... . . ... . . . .. . .... . ... . . ... . . 6

General Hazard Information . . . .... . ... . . . ... ... . . .... . . ... . . 9 Reference Information Section
Burn Prevention . ... . .... . ... . . .. . . ... . . .... .... . .... .... . ... . . . ... . 12 Customer Service .... ..... .. .. . . . ... 105

Fire Prevention and Explosion Prevention 12 Reference Materials . . .... . ... . .... . ... . .... .. ... . . . . . .. . . . ... . . 107

Crushing Prevention and Cutting Prevention . . .... .. 14 Index Section

Mounting and Dismounting . . . . . .. .. .. .. .. 14 Index .... .... . . .. . . . ... . ... . .. . . . .... .... . ... . .... .... . . . . . ... . ... . . . .. 112
Ignition Systems .... . .... . ... . . .. . . .... . ... . .... .... . . .. . .. ... . .... 14

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

Electrical System . .... . ... . .... .... . . ... . .... . .... . ... . .... . .... . . . 16

Product Information Section

Model Views and Specifications .... .... . ... . . ... .. .... . ... 17
Product Identification Information . ... . . ... . ... . .... . . .... 22

Operation Section
Engine Wing and Storage . . ... . . ... .... . . .... . .. . . .... . . ... . 24

Gauges and Indicators .. . . ... ... . . . .... ... . . ... . . ... .... . . . ... . . 26

Features and Controls .. .... . ... . . . ... . ... . .... .... .... . ... .. . . 29

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

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

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

Maintenance Section
Lubricant Specifications . . . ... . .... .... . ... . . ... . . ... . .... . . . . .. 40

Fuel Specifications .... .... . ... . . .... . ... . ... . . .... .... . ... . . . .... . 44

Cooling System Specifications ... . ... . . .... . ... . ... . . . .... . 47

Refill Capacities . . . ... . . ... . . ... . .... . ... . . .. . . . ... . .... . ... . . ... . . . 55
4
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
Literature Information more 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
Some photographs or illustrations in this manual for a preventive maintenance management
show details or attachments that may be different program . If the preventive maintenance program
from your engine . Guards and covers may have is followed, a periodic tune-up is not required .
been removed for illustrative purposes . Continuing The implementation of a preventive maintenance
improvement and advancement of product design management program should minimize operating
may have caused changes to your engine which are costs through cost avoidances resulting from
not included in this manual . Whenever a question reductions in unscheduled 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
Safety of the original requirement. Each level and/or
individual items in each level should be shifted
This safety section lists basic safety precautions . ahead or back depending upon your specific
In addition, this section identifies hazardous, maintenance practices, operation and application.
warning situations . Read and understand the basic We recommend that the maintenance schedules
precautions listed in the safety section before be reproduced and displayed near the engine as
operating or performing lubrication, maintenance a convenient reminder . We also recommend that a
and repair on this product. maintenance record be maintained as part of the
engine's permanent record .
Operation
See the section in the Operation and Maintenance
Operating techniques outlined in this manual are Manual, "Maintenance Records" for information
basic. They assist with developing the skills and regarding documents that are generally accepted
techniques required to operate the engine more as proof of maintenance or repair. Your authorized
efficiently and economically. Skill and techniques Caterpillar dealer can assist you in adjusting your
develop as the operator gains knowledge of the maintenance schedule to meet the needs of your
engine and its capabilities . operating environment .

The operation section is a reference for operators .

Photographs and illustrations guide the operator
California Proposition 5 Warning
through procedures of inspecting, starting, Battery posts, terminals and related accessories
operating and stopping the engine . This section contain lead and lead compounds. Wash hands
also includes a discussion of electronic diagnostic after handling .
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.
 rrerhaul
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
Safety Section
Safety Messages

Safety t
101837168

Safety Messages
SMCS Code: 1000; 7405

A("AYS OPFRAIE iNIS ONII WI7N

1NE YANK OOOR OPEK

VANAt 1000RNtt~EO EESIRICIS

ACCESS 10 INE ENEROENCY STOP
DDIION AND COOED RESIRI IN
INNRY Oft DEAIB.
009A389

N ,. WARNING:

, . . /; AVERTISSEMENT. . : .

g00938528
Illustration 1

There may be several specific safety messages

on an engine . The exact location of the hazards
and the description of the hazards are reviewed in
this section . Please become familiar with all safety
messages .
 7
Safety Section
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 The warning label for operation is located on the
pictures are not visible . When the safety messages outside of the door of the control panel .
are cleaned, use a cloth, water, and soap. Do not
use solvent, gasoline, or other harsh chemicals to
clean the safety messages . Solvents, gasoline, or
harsh chemicals could loosen the adhesive that
secures the safety messages . The safety messages
that are loosened could drop off of the engine. DO NOT OPERATE OR WORK ON THIS ENGINE OR
GENERATOR SET UNLESS YOU HAVE READ AND

Replace any damaged safety messages or missing UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN
THE OPERATION AND MAINTENANCE MANUALS.

safety messages . If a safety message is attached FAILURE TO FOLLOW THE WARNINGS AND INSTRUCTIONS

to a part of the engine that is replaced, install a COULD RESULT IN INJURY OR DEATH. CONTACT
ANY CATERPILLAR DEALER FOR REPLACEMENT

new safety message on the replacement part . Any MANUALS. PROPER CARE IS YOUR RESPONSIBILITY .

Caterpillar dealer can provide new safety messages . 127-7071

g00306265
Do not operate or work on this engine unless you
have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the Do not operate or work on this engine or genera-
warnings could result in injury or death. Contact tor set unless you have read and understand the
any Caterpillar dealer for replacement manuals. instructions and warnings in the Operation and
Proper care is your responsibility. Maintenance Manuals .

The safety messages that may be attached on the Failure to follow the warnings and instructions
engine are illustrated and described below. could result in injury or death. Contact any
Caterpillar dealer for replacement manuals. Prop-
er care is your responsibility.
8
Safety Section
Safety Messages

(2) Emergency Stop Sutton attery

The warning label for the emergency stop button is The warning label for the battery is installed on the
located on the outside of the door of the control side of the engine or in a visible location near the
panel . battery. If batteries are located on both sides of the
package, the warning label is located on both sides
of the package.

IMPROPER JUMPER CABLE

ALWAYS OPERATE THIS UNIT WITH CONNECTIONS CAN CAUSE
THE VANDAL DOOR OPEN . EXPLOSION RESULTING IN
OPERATING THE UNIT WITH THE PERSONAL INJURY.

VANDAL DOOR CLOSED RESTRICTS BATTERIES MAY BE LOCATED IN SEPA

RATE COMPARTMENTS. WHEN USING
ACCESS TO THE EMERGENCY STOP JUMPER CABLES, ALWAYS CONNECT
BUTTON AND COULD RESULT IN POSRTVE(t} CABLE TO POSITIVE(a)
TERMINAL OF BATTERY CONNECTED
INJURY OR DEATH . TO STARTER SOLENOID AND NEGA
109-4389 TIVE(-) CABLE FROM EXTERNAL
SOURCE TO STARTER NEGATIVE(-)
TERMINAL QF MACHINE NOT EQUIPPED
WITH STARTER NEGATIVE TERMINAL
CONNECT TO ENGINE BLOCK) FOL-
LOW PROCEDURE IN THE OPERATION
MANUAL 6V-4611
g00305896

g00455028

Always operate this unit with the vandal door

open. Operating the unit with the vandal door
closed restricts access to the emergency stop Improper jumper cable connections can cause an
button and could result in injury or death. explosion resulting in personal injury.

Batteries may be located in separate compartments .

When you are using jump start cables, always
connect the positive "+" cable to the positive °+"
terminal of the battery that is connected to the
starting motor solenoid . Connect the negative "-"
cable from the external source to the negative "-"
terminal of the starting motor. If the starting motor
does not have a negative °-" terminal, connect the
negative "-" cable from the external source to the
engine block. Follow the procedure in this Operation
and Maintenance Manual, "Engine Starting" topic
(Operation Section) .
 9
Safety Section
General Hazard Information

Hazardous Atmosphere () Lifting

The warning label for the Canadian Standards The warning label for lifting is located on the base
Association (CSA) hazardous atmosphere is located near the lifting holes.
on the left side of the engine on a flat surface.

MANUFACTURER - CATERPILLAR INC.

® MODEL - 3400 SERIES
LOCATION - CLASS I DIV . 2 GROG 0

'USE FOR CATERPILLAR IGNITION SYSTEM ONLY'

WARNING
DO NOT DISCONNECT EGUIPMENT UNLESS POWER HAS BEEN
DISCONNECTED OR AREA IS KNOWN TO BE NON-NAZARDOUS t USE AMOUATE ~- AM AS KWMK 010A=
MWTEX M GiAYITY IS ABOYI RASI LIFT POINTS
1. ATTALW FO~WC PRORRET MTEB CXMN6 SNOW BASF
L7fT IKKEB T9 SRRfABFR BAR
A . AW- -N -. 1. -1T.
AVANT DE DECONNECTER L'EOUIPMENT . COLDER LE COURANT OU DYER IXN7ER ®-M ROR UYEL LI77
A. US[ %-f PMN7 O-ER LIFT AROI AWO YdiT
S*ASSURER DUE L'EMPLACEMENT EST DESIGNE NON DANGEREUX .
IWS7WOTION Ht. - -SE.
4P-6246 I

g00524148
g00938572

WARNING
Improper lift rigging can allow unit to tumble caus-
Do not disconnect equipment unless power has ing injury and damage.
been disconnected or the area is known to be non-
hazardous
1 . Use an adequate spreader bar as described
because the center of gravity is above the base
Approval by the CSA is a requirement for engines lifting points .
that operate in hazardous locations. Volatile
flammable gases are present in these locations. 2. Attach four properly rated chains from the base
The gases are normally confined within closed lifting holes to the spreader bar.
systems. The gases can only escape if the system
accidentally breaks down. The CSA warning is 3. Adjust the chain lengths in order to position the
intended to prevent a hazardous atmosphere from spreader bar over the center symbol for level lift .
igniting .
4. Use a single point center lift arch and use a
Volatile flammable gas that is contacted by a spark 5N-2171 Film when present.
will cause an explosion . This could result in personal
injury or death . Also, property could be damaged.
101359759

Do not disconnect electrical equipment unless the

power has been disconnected . Otherwise, ensure
eneral Hazard Information
that the atmosphere is not hazardous. SMCS Code : 1000 ; 4450 ; 7405

g00104545
Illustration 2
10
Safety Section
General Hazard Information

Attach a "Do Not Operate" warning tag or a similar " Do not wear loose clothing or jewelry that can
warning tag to the start switch or to the controls snag on controls or on other parts of the engine .
before the engine is serviced or before the engine
is repaired . These warning tags (Special Instruction, " Ensure that all protective guards and all covers
SEHS7332) are available from your Caterpillar are secured in place on the engine .
dealer. Attach the warning tags to the engine
and to each operator control station . When it is " Never put maintenance fluids into glass
appropriate, disconnect the starting controls . containers . Glass containers can break .
Do not allow unauthorized personnel on the engine, " Use all cleaning solutions with care.
or around the engine when the engine is being
serviced . " Report all necessary repairs .
Engine exhaust contains products of combustion Unless other instructions are provided, perform
which may be harmful to your health . Always the maintenance under the following conditions :
start the engine and operate the engine in a well
ventilated area. If the engine is in an enclosed area, " The engine is stopped. Ensure that the engine
vent the engine exhaust to the outside. cannot be started.
Cautiously remove the following parts . To help " Disconnect the batteries when maintenance
prevent spraying or splashing of pressurized fluids, is performed or when the electrical system is
hold a rag over the part that is being removed. serviced . Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks .
" Filler caps
" Do not attempt any repairs that are not
" Grease fittings understood . Use the proper tools. Replace
any equipment that is damaged or repair the
" Pressure taps equipment.
" Breathers California Proposition 65 Warning
" Drain plugs Some engine exhaust constituents are known to the
State of California to cause cancer, birth defects,
Use caution when cover plates are removed . and other reproductive harm.
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 ressure Air and Water
last two bolts or nuts, pry the cover loose in order
to relieve any spring pressure or other pressure . 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 275 kPa (40 psi) .

Illustration 3 g00702020

" Wear a hard hat, protective glasses, and other

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 .
 11
Safety Section
General Hazard Information

Fluid Penetration s estos Information

Illustration 4 g00687600 g00702022

Illustration 5

Always use a board or cardboard when you check Caterpillar equipment and replacement parts that
for a leak. Leaking fluid that is under pressure can are shipped from Caterpillar are asbestos free .
penetrate body tissue . Fluid penetration can cause Caterpillar recommends the use of only genuine
serious injury and possible death. A pin hole leak Caterpillar replacement parts. Use the following
can cause severe injury. If fluid is injected into your guidelines when you handle any replacement parts
skin, you must get treatment immediately. Seek that contain asbestos or when you handle asbestos
treatment from a doctor that is familiar with this type debris .
of injury.
Use caution . Avoid inhaling dust that might be
Containing Fluid Spillage generated when you handle components that
contain asbestos fibers . Inhaling this dust can
Care must be taken in order to ensure that fluids be hazardous to your health . The components
are contained during performance of inspection, that may contain asbestos fibers are brake pads,
maintenance, testing, adjusting and repair of the brake bands, lining material, clutch plates, and
engine . Prepare to collect the fluid with suitable some gaskets . The asbestos that is used in these
containers before opening any compartment or components is usually bound in a resin or sealed in
disassembling any component containing fluids . some way. Normal handling is not hazardous unless
airborne dust that contains asbestos is generated.
Refer to Special Publication, NENG2500, "Tools and
Shop Products Guide" for the following items: If dust that may contain asbestos is present, there
are several guidelines that should be followed :
s Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids ® Never use compressed air for cleaning .

" Tools that are suitable for containing fluids and ® Avoid brushing materials that contain asbestos .
equipment that is suitable for containing fluids
® Avoid grinding materials that contain asbestos .
Obey all local regulations for the disposal of liquids .
® 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 .

® Use exhaust ventilation on permanent machining

jobs .

® Wear an approved respirator if there is no other

way to control the dust.
12
Safety Section
Burn Prevention

® Comply with applicable rules and regulations Any contact with hot coolant or with steam
for the work place. In the United States, use can cause severe burns. Allow cooling system
Occupational Safety and Health Administration components to cool before the cooling system is
(OSHA) requirements . These OSHA requirements drained .
can be found in "29 CFR 1910 .1001" .
Check the coolant level after the engine has
® Obey environmental regulations for the disposal stopped and the engine has been allowed to cool .
of asbestos .
Ensure that the filler cap is cool before removing
® Stay away from areas that might have asbestos the filler cap. The filler cap must be cool enough
particles in the air. to touch with a bare hand. Remove the filler cap
slowly in order to relieve pressure .
Dispose of Waste Properly Cooling system conditioner contains alkali . Alkali
can cause personal injury. Do not allow alkali to
contact the skin, the eyes, or the mouth .

Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin . Also, do not allow hot components to contact
the skin.

Batteries
Electrolyte is an acid . Electrolyte can cause
g00706404 personal injury. Do not allow electrolyte to contact
Illustration 6
the skin or the eyes . Always wear protective glasses
for servicing batteries . Wash hands after touching
Improperly disposing of waste can threaten the the batteries and connectors . Use of gloves is
environment. Potentially harmful fluids should be recommended .
disposed of according to local regulations.

Always use leakproof containers when you drain 101372262

fluids . Do not pour waste onto the ground, down a
drain, or into any source of water. Fire Prevention and Explosion
Prevention
101480768
SMCS Code: 1000; 4450; 7405
rev ntl n
SMCS Code: 1000 ; 4450 ; 7405

Do not touch any part of an operating engine .

Allow the engine to cool before any maintenance
is performed on the engine . Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected .

Coolant
When the engine is at operating temperature, the Illustration 7
g00704000
engine coolant is hot. The coolant is also under
pressure . The radiator and all lines to the heaters or All fuels, most lubricants, and some coolant mixtures
to the engine contain hot coolant. are flammable.
 13
Safety Section
Fire Prevention and Explosion Prevention

Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause deterioration . The hoses must be properly routed .
a fire. Fire may cause personal injury and property The lines and hoses must have adequate support
damage. and secure clamps . Tighten all connections to the
recommended torque . Leaks can cause fires .
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after Oil filters and fuel filters must be properly installed .
an emergency shutdown . The filter housings must be tightened to the proper
torque .
Determine whether the engine will be operated in
an environment that allows combustible gases to be
drawn into the air inlet system . These gases could
cause the engine to overspeed . Personal injury,
property damage, or engine damage could result.

If the application involves the presence of

combustible gases, consult your Caterpillar dealer
for additional information about suitable protection
devices .

Remove all flammable materials such as fuel, oil,

and debris from the engine . Do not allow any
flammable materials to accumulate on the engine.

Store fuels and lubricants in properly marked

containers away from unauthorized persons . Store
oily rags and any flammable materials in protective
containers . Do not smoke in areas that are used for
storing flammable materials .

Do not expose the engine to any flame. g00704135

Illustration 8
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line, Gases from a battery can explode . Keep any open
a hose, or a seal failure . Exhaust shields must be flames or sparks away from the top of a battery. Do
installed correctly. not smoke in battery charging areas.

Do not weld on lines or tanks that contain flammable Never check the battery charge by placing a metal
fluids. Do not flame cut lines that contain flammable object across the terminal posts. Use a voltmeter or
fluid . Clean any such lines thoroughly with a a hydrometer.
nonflammable solvent prior to welding or flame
cutting . Improper jumper cable connections can cause
an explosion that can result in injury . Refer to
Wiring must be kept in good condition . All electrical the Operation Section of this manual for specific
wires must be properly routed and securely instructions .
attached . Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate Do not charge a frozen battery. This may cause
the engine. Clean all electrical connections and an explosion .
tighten all electrical connections .
The batteries must be kept clean . The covers (if
Eliminate all wiring that is unattached or equipped) must be kept on the cells. Use the
unnecessary . Do not use any wires or cables that recommended cables, connections, and battery
are smaller than the recommended gauge . Do not box covers when the engine is operated.
bypass any fuses and/or circuit breakers .
Fire Extinguisher
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly Make sure that a fire extinguisher is available . Be
maintained battery cables will help to prevent arcing familiar with the operation of the fire extinguisher.
or sparking. Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate .
14
Safety Section
Crushing Prevention and Cutting Prevention

Lines, Tubes Hoses Chips or other debris may fly off objects when
objects are struck . Before objects are struck, ensure
Do not bend high pressure lines . Do not strike high that no one will be injured by flying debris .
pressure lines. Do not install any lines that are bent
or damaged.
101372247

Repair any lines that are loose or damaged . Leaks

can cause fires. Consult your Caterpillar dealer for
non an Dismounting
repair or for replacement parts . SMCS Code : 1000; 4450; 7405
Check lines, tubes and hoses carefully. Do not Inspect the steps, the handholds, and the work
use your bare hand to check for leaks. Use a area before mounting the engine . Keep these items
board or cardboard to check for leaks. Tighten all clean and keep these items in good repair.
connections to the recommended torque .
Mount the engine and dismount the engine only at
Replace the parts if any of the following conditions locations that have steps and/or handholds. Do not
are present: climb on the engine, and do not jump off the engine .
" End fittings are damaged or leaking . Face the engine in order to mount the engine or
dismount the engine . Maintain a three-point contact
" Outer coverings are chafed or cut. with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use
® Wires are exposed . any controls as handholds.
® Outer coverings are ballooning . Do not stand on components which cannot support
your weight . Use an adequate ladder or use a work
s Flexible part of the hoses are kinked . platform . Secure the climbing equipment so that the
equipment will not move .
" Outer covers have embedded armoring .
Do not carry tools or supplies when you mount the
" End fittings are displaced . engine or when you dismount the engine . Use a
hand line to raise and lower tools or supplies .
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other i00998909
parts, and excessive heat.
Ignition Systems
101359666 SMCS Code: 1550
Crushing Preve i n an Ignition systems can cause electrical shocks . Avoid
Cutting Prevention contacting the ignition system components and
wiring .
SMCS Code : 1000 ; 4450 ; 7405
Magneto
Support the component properly when work
beneath the component is performed . The storage capacitor in a breakerless magneto can
be charged by turning the magneto by hand. The
Unless other maintenance instructions are provided, storage capacitor can be charged even when the
never attempt adjustments while the engine is wiring harness is disconnected from the magneto.
running.
If the ignition switch is in the ON position and the
Stay clear of all rotating parts and of all moving wiring harness is being connected, the storage
parts . Leave the guards in place until maintenance capacitor may discharge and a spark plug will
is performed. After the maintenance is performed, ignite . The spark plug will ignite any gas that has
reinstall the guards . accumulated in that cylinder. The crankshaft and the
driven equipment can move. Personal injury may
Keep objects away from moving fan blades . The result . The driven equipment could be damaged .
fan blades will throw objects or cut objects. Gas that has accumulated in the exhaust system
can also be ignited.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes .
 15
Safety Section
Before Starting Engine

Before connecting the wiring harness to a See the Service Manual for repairs and for
breakerless magneto, discharge the storage adjustments.
capacitor to the ground . Use the following
procedure to discharge the storage capacitor:
i00572000
1 . Attach one end of a wire to the magneto housing. Engine Starting
2. Contact the other end of the wire to the SMCS Code: 1000
connector pins for the wiring harness that is on
the magneto. If a warning tag is attached to the engine start
switch or to the controls, DO NOT start the engine
You will hear a "snap" when the storage capacitor or move the controls . Consult with the person that
discharges . attached the warning tag before the engine is
started.
3. Ground all of the connector pins .
All protective guards and all protective covers must
This will ensure that no charge is in the magneto. be installed if the engine must be started in order
Some breakerless magnetos have more than one to perform service procedures . To help prevent an
storage capacitor. accident that is caused by parts in rotation, work
around the parts carefully.
Turn the ignition switch to the OFF position before
connecting the wiring harness. If the ignition switch Start the engine from the operator's compartment or
is in the OFF position, the storage capacitor is from the engine start switch .
immediately discharged to the ground when the
wiring harness is connected to the magneto. Always start the engine according to the procedure
that is described in the Operation and Maintenance
i00659904 Manual, "Engine Starting" topic in the Operation
Section. Knowing the correct procedure will help to
Before Starting En gin prevent major damage to the engine components .
Knowing the procedure will also help to prevent
SMCS Code : 1000 personal injury.

Inspect the engine for potential hazards. To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Before starting the engine, ensure that no one is on, properly, check the water temperature gauge
underneath, or close to the engine . Ensure that the and the oil temperature gauge during the heater
area is free of personnel . operation.

Ensure that the engine is equipped with a lighting Engine exhaust contains products of combustion
system that is suitable for the conditions . Ensure which can be harmful to your health . Always start the
that all lights work properly. engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
All protective guards and all protective covers must vent the engine exhaust to the outside .
be installed if the engine must be started in order
to perform service procedures . To help prevent an
i00659907
accident that is caused by parts in rotation, work
around the parts carefully. Engine Stopping
Do not bypass the automatic shutoff circuits . Do not SMCS Code: 1000
disable the automatic shutoff circuits . The circuits
are provided in order to help prevent personal To avoid overheating of the engine and accelerated
injury. The circuits are also provided in order to help wear of the engine components, stop the engine
prevent engine damage . according to the instructions in this Operation and
Maintenance Manual, "Engine Stopping" topic
On the initial start-up of a new engine or an engine (Operation Section) .
that has been serviced, be prepared to stop the
engine if an overspeed condition occurs . This may
be accomplished by shutting off the fuel supply to
the engine, or shutting off the ignition system .
16
Safety Section
Electrical System

Use the Emergency Stop Button (if equipped) Rubber couplings may connect the steel piping of
ONLY in an emergency situation. Do not use the the cooling system and the radiator. This causes
Emergency Stop Button for normal engine stopping . the piping and the radiator to be electrically
After an emergency stop, DO NOT start the engine isolated . Ensure that the piping and the radiator is
until the problem that caused the emergency stop continuously grounded to the engine . Use ground
has been corrected. straps that bypass the rubber couplings.

On the initial start-up of a new engine or an engine Ensure that all grounds are secure and free of
that has been serviced, make provisions to stop corrosion .
the engine if an overspeed occurs . This may be
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system .

i00887114

Electrical System
SMCS Code: 1000 ; 1400

Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit
is operating . A spark can cause the combustible
gases that are produced by some batteries to ignite .

Check the electrical wires daily for wires that are

loose or frayed . Tighten all loose electrical wires
before the engine is operated . Repair all frayed
electrical wires before the engine is started .

Grounding Practices
Proper grounding is necessary for optimum engine
performance and reliability. Improper grounding will
result in uncontrolled electrical circuit paths and in
unreliable electrical circuit paths.

Uncontrolled electrical circuit paths can result

in damage to main bearings, to crankshaft
journal surfaces, and to aluminum components .
Uncontrolled electrical circuit paths can also cause
electrical activity that may degrade the engine
electronics and communications .

For the starting motor, do not attach the battery

negative terminal to the engine block.

Use a ground strap to ground the case of all control

panels to the engine block.

Ground the engine block with a ground strap that

is furnished by the customer. Connect this ground
strap to the ground plane.

Use a separate ground strap to ground the battery

negative terminal for the control system to the
ground plane .
 17
Product Information Section
Model Views and Specifications

Product n r t
Section

Model Views
Specification
101622215

Model View Illustrati s

SMCS Code: 1000; 4450

The illustrations show various typical features of the

G3406 Engine. The illustrations do not show all of
the options that are available . Because of individual
applications, your engine may appear different from
the illustrations .
18
Product Information Section
Model Views and Specifications

g00839466
Illustration 9
Turbocharged Aftercooled Industrial Engine
(1) Lifting eye (8) Carburetor
(2) Crankcase breather (9) Aftercooler
(3) Oil level gauge (10) Oil filter
(4) Oil filler (11) Air cleaner
(5) Crankcase vibration damper (12) Turbocharger
(6) Exhaust bypass valve (13) Exhaust
(7) Governor control lever (14) Oil Drain
 19
Product Information Section
(yodel Views and Specifications

g00839483
Illustration 10
Naturally Aspirated Generator Set Engine
(1) Control panel (7) Oil filter (13) Water drain
(2) Circuit breaker (8) Radiator filler neck (14) Oil Drain
(3) Battery charger (9) Lifting eye (15) Gas pressure regulator
(4) Oil filler (10) Air cleaner (16) Starting motor
(5) Crankcase breather (11) Battery (17) Generator
(6) Oil level gauge (12) Exhaust
20
Product Information Section
Model Views and Specifications

101622294 Lubrication System

Product e ri ti n The engine lubrication oil is circulated by a
gear-driven pump . The oil is cooled and the oil
SMCS Code : 1000 ; 4450 is filtered . However, bypass valves provide an
unrestricted flow of lubrication oil to the engine if
Caterpillar G3406 Engines were developed in order the following conditions occur:
to provide gas engines for industrial applications
and for generator set applications . The engines o The viscosity of the oil is high because the oil
have the ability to burn a wide variety of gaseous is cold .
fuels.
o The oil cooler becomes plugged .
Ignition System
o The oil filter becomes plugged .
The ignition system has five basic components :
magneto, an ignition transformer for each cylinder, Cooling System
wiring harness, spark plugs, and control panel.
The jacket water coolant is circulated by a
The magneto generates the electric current that gear-driven centrifugal pump . A 99 °C (210 °F)
is necessary for spark ignition . The current from temperature regulator regulates the temperature of
the magneto travels through the wiring harness to the coolant. Heat can be removed from the coolant
the ignition transformer. The transformer increases by a radiator or a heat exchanger.
the voltage. The transformer creates an electrical
impulse that arcs across the electrodes of the spark For engines with a Separate Circuit Aftercooler
plug. Engine operation is monitored by the control (SCAC), the air is cooled by a heat exchanger. The
panel . water that cools the air in the heat exchanger is
in a circuit that is separate from the jacket water.
Inlet Air and Fuel System The aftercooler coolant is pumped by an auxiliary
water pump . The SCAC is required to operate at
Inlet air is filtered by an air cleaner. G3406 Engines one of the following temperatures . The engine rating
are also available with these types of aspiration: depends on the temperature and the application .
naturally aspirated, turbocharged, turbocharged
with separate circuit aftercooling, and turbocharged 0 32 °C (90 °F)
with air-to-air aftercooling .
0 54 °C (129 °F)
For turbocharged engines, the inlet air is
compressed by the turbocharger. The turbocharger For engines with air-to-air aftercooling, the
is driven by the engine exhaust. The air is cooled aftercooler is supplied by the customer. This
in an aftercooler (if equipped) before the air enters aftercooler is similar to a radiator. The inlet air is
the carburetor. The air becomes more dense from cooled by a fan that moves the ambient air through
compression and cooling. This provides more the radiator.
oxygen for combustion .
Engine Service Life
Air is mixed with fuel in the carburetor before
combustion . The carburetor is controlled by a Engine efficiency and maximum utilization of engine
governor . The governor efficiently maintains the performance depend on adherence to proper
engine rpm that is selected by the operator. operation and maintenance recommendations . This
includes the use of recommended lubricants, fuels,
The valves and the valve mechanism control the and coolants .
flow of air and exhaust gases in the cylinder during
engine operation. Each cylinder has one inlet valve For the engine maintenance that is required,
and one exhaust valve. The camshaft actuates the refer to this Operation and Maintenance Manual,
rocker arms and valves through mechanical lifters "Maintenance Interval Schedule" (Maintenance
and pushrods. Section) .
 21
Product Information Section
Model Views and Specifications

101536234

Specifications
SMCS Code: 1000

Table 1
G3406 Engine Specifications
Cylinders and 6
Arrangement In-Line
Naturally aspirated
Aspiration Turbocharged with
separate circuit
aftercooling
Bore 137 mm (5.4 inch)
Stroke 165 mm (6.5 inch)
Total displacement 14.6 L (893 cu in)
Firing order 1-5-3-6-2-4
Rotation (flywheel end) Counterclockwise
Inlet valve lash .38 mm (.015 inch)
Exhaust valve lash 1 .02 mm (.040 inch)

g00762505
Illustration 11
G3406 Engine design
(A) Inlet valve
(B) Exhaust valve
(C) Flywheel
22
Product Information Section
Product Identification Information

Product Identificati
Information ENGINE
MODEL
SERIAL
NUMBER
i01622410

Plate Locations and Film o AT PILL "' CAT®o

Locations ARRANGEMENT
NUMBER

SMCS Code: 1000 ; 4450

(ALWAYS GIVE ALL NUMBERS)
Caterpillar engines are identified with serial MADE IN U .S .A . 3N-3790 12
numbers, with performance specification numbers,
and with arrangement numbers. In some of the
g00123229
cases, modification numbers are used . These Illustration 13
numbers are shown on the Serial Number Plate
and the Information Plate that are mounted on the The following information is stamped on the Serial
engine . Number Plate : engine serial number, model, and
arrangement number.
Caterpillar dealers need these numbers in order to
determine the components that were included with Information Plate
the engine . This permits accurate identification of
replacement part numbers.

Serial Number Plate

Illustration 12 g00839645

Location of the Serial Number Plate

Illustration 14 g00839651
The Serial Number Plate is on the left side of the Location of the Information Plate
cylinder block near the rear of the engine .
The Information Plate is on the top surface of the
flywheel housing above the timing window.
 23
Product Information Section
Product Identification Information

Table 2
nAT E) Reference Numbers
Engine Model
SEE. NO.

AR COMP. Serial Number

NO . RATIO TO 1

Arrangement Number
AFTER000LER TEMPERATURE IGNITION TIMING HTDC

Packaging Arrangement
CONSULT FUEL USAGE GUIDE
DRG.C DEG.F

POWER ke HP
Turbocharger
FULL LOAD RPM Fuel Filter Element
159-8314
Lubrication Oil Filter
Element
Illustration 15 g00361974 Auxiliary Oil Filter Element
Typical Information Plate Air Cleaner Element

The following information is stamped on the Fan Drive Belt

Information Plate : compression ratio, aftercooler Alternator Belt
temperature, power (kilowatts and horsepower), full
load rpm, and other information . Capacity of the Lubrication
System
Capacity of the Cooling
101452057
System
Reference Information Performance Specification
Number
SMCS Code: 1000 ; 4450
Low Idle rpm
Identification of the items in Table 2 may be needed High Idle rpm
in order to obtain parts and service . Some of the
numbers are on the engine Serial Number Plate Full Load rpm
and/or Information Plate . Locate the information Power Rating
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
reference .

The top level part numbers in the Parts Manual for

the engine are listed with the engine arrangement
number.

The packaging arrangement may also be called a

pricing arrangement or a customer arrangement .
This is the total package with attachments and
options that are not included in the engine
arrangement .

The performance specification can be used by

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.
24
Operation Section
Engine Lifting and Storage

perati e ti Engine Lifting with a Generator

NOTICE
Engine Lifting an rage Do not use the engine lifting eyes to remove the engine
and generator together .

101492427 A lifting plate is provided with the package

Engine Lifting generator set. Instructions for lifting the package
generator set are stamped on the lifting plate.
SMCS Code: 1000 ; 1122 Consult your Caterpillar dealer for information
regarding proper fixtures and lifting devices.

Lifting packaged generator sets will not be

level if you lift the unit with a single point lift . A
counterweight can be added between the package
frame rails whenever the application requires
frequent relocation of the unit . For complete
information about adding the counterweight, consult
your Caterpillar dealer.

The single point lifting eye is secured from the

factory before the enclosure is shipped . The correct
orientation of the single point lifting eye will allow
you to look through the eye when you stand at the
Illustration 16 g00103219 side of the enclosure. The lifting eye may stretch
when the package is lifted . This may cause the
locking nuts to loosen . This could cause the lifting
NOTICE eye to swivel . Ensure that the lifting eye is correctly
Never bend the eyebolts and the brackets. Only load oriented on the packaged generator set. Ensure
the eyebolts and the brackets under tension. Remem- that the lifting eye is tightened to the correct torque
ber that the capacity of an eyebolt is less as the angle before you lift the packaged generator set.
between the supporting members and the object be-
comes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight .

Use a hoist to remove heavy components . Use

an adjustable lifting beam to lift the engine . All
supporting members (chains and cables) should
be parallel to each other. The chains and cables
should be perpendicular to the top of the object
that is being lifted .

Some removals require lifting fixtures in order to

obtain proper balance and safety.

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 .
 i00816700

Engine Storage
SMCS Code: 1000

If the engine will not be started for several weeks,

the lubricating oil will drain from the cylinder walls
and 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, "General Coolant Information"
(Maintenance Section) .

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

engine is not planned, special precautions should
be made. If the engine will be stored for more than
one month, a complete protection procedure is
recommended .

Your Caterpillar dealer will have instructions for

preparing the engine for extended storage periods .

For more detailed information on engine storage,

see Special Instruction, SEHS9031, "Storage
Procedure for Caterpillar Products" .

Generator Storage
For information on generator storage, see the
literature that is provided by the OEM of the
generator . Consult your Caterpillar dealer for
assistance .
26
Operation Section
Gauges and Indicators

Gauges Indicators Jacket Water Coolant Temperature -- This

gauge indicates the temperature of the
101836629 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 98 °C
(190 to 205 °F). Higher temperatures may occur
Gauges provide indications of engine performance. under certain conditions .
Ensure that the gauges are in good working order.
Determine the normal operating range by observing The engine should operate within the normal
the gauges over a period of time . temperature range. The sensor for jacket water
coolant temperature must be fully submerged in
Noticeable changes in gauge readings can indicate
order to detect the temperature correctly. If the
potential gauge or engine problems . Problems may engine is operating above the normal temperature
also be indicated by gauge readings that change range, perform the following procedure:
even if the readings are within specifications .
Determine and correct the cause of any significant 1 . Reduce the load and/or the engine rpm .
change in the readings . Consult your Caterpillar
dealer for assistance . 2. Inspect the cooling system for leaks.
Your engine may not have the same gauges or all 3. Determine if the engine must be shut down
of the gauges that are described below. immediately or if the engine can be cooled by
reducing the load and/or rpm.
NOTICE
If no oil pressure is indicated, STOP the engine . The Inlet Manifold Air Temperature - This
engine will be damaged from operating without oil gauge indicates the inlet manifold air
pressure . temperature to the cylinders.

Engine Oil Pressure - This gauge NOTICE

indicates the pressure of the engine oil . High inlet manifold air temperature increases the risk
This pressure will be highest after a cold of detonation . Detonation can cause damage to the
engine is started . The pressure will decrease as engine . Ensure that the aftercooling system is operat-
the engine warms up. The pressure will increase ing properly.
when the engine rpm is increased . The pressure
will stabilize when the engine rpm and temperature
are stable . The inlet manifold air temperature depends on
the engine's aspiration and the water temperature
regulator for the separate circuit aftercooler
For G3400 Engines, the typical oil pressure at rated (if equipped). If the maximum temperature is
rpm is 275 to 600 kPa (40 to 87 psi) . exceeded, the engine will be unable to provide
rated power. Derating occurs at temperatures that
For G3400 Engines at low idle, the typical oil are greater than the maximum . See Table 3 for
pressure is 186 to 344 kPa (27 to 50 psi) . maximum temperatures of different engines.
If no engine oil pressure is indicated, then stop the
engine .

Oil Filter Differential Pressure - This

gauge indicates the difference in pressure
between the inlet side and the outlet side
of the engine oil filters . As the oil filter elements
become plugged, the pressure will increase .
Replace the engine oil filter elements when the oil
filter differential pressure reaches 103 kPa (15 psi) .
 27
Operation Section
Gauges and Indicators

Table 3 Table 4
Maximum Inlet Manifold Air Temperatures Factors for Converting Service Meter Units
for G3400 Engines to Clock Hours
Aspiration Water Maximum Inlet Operating Speed Factor
Temperature Manifold Air
Regulator Temperature Engines That Are Rated From 1000 RPM to 1400 RPM
Naturally n/a 25 °C (77 °F) (1) 1000 rpm 1 .200
aspirated 1200 rpm 1 .000
Separate Circuit 32 °C (90 °F) (2) 43 °C (110 °F) 1400 rpm 0.857
Aftercooling
Engines That Are Rated From 1500 RPM to 1800 RPM
Separate Circuit 54 °C (130 °F) (2) 65 °C (150 °F)
Aftercooling 1500 rpm 1 .200
(1 ) This temperature is for an engine at an altitude of 152 m (500 ft) 1600 rpm 1 .125
above sea level. A greater temperature or a higher altitude
requires derating. 1800 rpm 1 .000
(2) Water inlet to the aftercooler

Inlet Manifold Air Pressure (TA Engines) For example, an engine that is rated at 1800 rpm
and Inlet Manifold Vacuum (NA Engines) - has been operating at 1500 rpm . To determine
For TA engines, this gauge indicates the the number of clock hours, multiply the number
air pressure (turbocharger boost pressure) in the of service meter units by the correct factor. In this
air plenum (air inlet manifold) after the aftercooler. example, one service meter unit is equivalent to
For NA engines, this gauge is the pressure of the 1 .200 clock hours .
inlet manifold vacuum. For all engines, this pressure
is relative to the load . This pressure may be used Fuel Filter Differential Pressure - This
for estimating power output . Several factors affect gauge is provided by the customer. This
the inlet manifold air pressure . All of these factors gauge indicates the difference in fuel
must be accounted for when power is estimated pressure between the inlet side and the outlet side
from inlet manifold air pressure : air restriction, of the fuel filter. As the fuel filter element becomes
exhaust restriction, coolant temperature, ambient plugged, the difference in pressure between the
air temperature, variation of the fuel, air/fuel ratio, two sides of the fuel filter increases. Service the fuel
ignition timing, and condition of the valves . filter when the fuel filter differential pressure reaches
34 kPa (5 psi) .
For more information, see the performance curves
in the Engine Performance manual . The manual is Air Cleaner Differential Pressure - This
available from your Caterpillar dealer. gauge indicates the difference in air
pressure between the inlet side and the
Tachometer - This gauge indicates the engine side of the air filter element. The pressure is
engine rpm . measured from the turbocharger air inlet. As the
air filter element becomes plugged, the difference
in pressure between the two sides of the air
cleaner element will increase . For optimum engine
NOTICE performance, replace the air cleaner elements when
An overspeed can result in serious damage to the en- the air cleaner differential pressure reaches 2 .5 kPa
gine . To help prevent engine damage, never allow the (10 inches of H 2 0) . Maximum air cleaner differential
engine to exceed the rated rpm. pressure is 3 .75 kPa (15 inches of H 2 0) .

Note : The rated rpm is stamped on the engine Ammeter - This gauge indicates the
Information Plate. amount of charge or discharge in the
battery charging circuit. Operation of the
Service Hour Meter - This meter indicates indicator should be to the right side of "0"(zero).
the total number of service meter units that
have been operated on the engine . Table Engine Oil Temperature - This gauge
4 lists the factors for converting service meter units indicates the engine oil temperature after
to clock hours. the oil has passed through the oil cooler .
The maximum oil temperature at rated rpm and
rated load is 110 °C (230 °F) .
28
Operation Section
Gauges and Indicators

The engine oil is cooled by the jacket water. If

the cooling system cannot remove the heat from
the jacket water, the oil will not cool properly . Oil
will degrade rapidly at temperatures above 99 °C
(210 °F) . Higher than normal oil temperatures
indicate a problem in the lubrication system
and/or in the cooling system . This can damage
these components : cylinder heads, cylinder liners,
pistons, and crankshaft bearings .
 29
Operation Section
Features and Controls

eat r s and Controls 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
i01593827 information, see Application and Installation Guide,
Performance Parameters LEKQ7250, "Air Intake". Consult your Caterpillar
dealer for assistance .
SMCS Code : 1000
Temperature of the Fuel Supply
Fuel Consumption Changes in the temperature of the fuel supply
affects the air/fuel ratio . Warmer fuel is less dense
Optimum fuel consumption can be obtained by fine than cold fuel . This results in a leaner mixture
tuning the air/fuel ratio and ignition timing . In order that causes a noticeable reduction of power. The
to make fine tuning feasible, the engine must have recommended temperature differential of the air and
stable operating parameters . The parameters must the fuel is 2.8 °C (5 °F).
not exceed the followin g toleranc es .
The maximum fuel temperature depends on the
Table 5
temperature regulator of the aftercooler :
Performance Parameters of the Engine
® For engines with a 32 °C (90 °F) aftercooler, the
Parameter Tolerance
maximum temperature of the air/fuel mixture is
Jacket Water Coolant ± 6 °C (± 10 °F) 38 °C (100 °F).
Temperature
® For engines with a 54 °C (130 °F) aftercooler, the
Inlet Manifold Air ± 6 °C (± 10 °F)
Temperature maximum temperature of the air/fuel mixture is
60 °C (140 °F).
Temperature of the Gas ± 6 °C (± 10 °F)
Fuel Energy Content ± 31 .6 kJ (± 30 Btu) For more information, see Application and
Installation Guide, LEKQ7260, "Low BTU Engines" .
Load ± 5% Consult your Caterpillar dealer for assistance .

Air/Fuel Ratio Fuel Supply Pressure

Fluctuations of the fuel pressure can change the
The correct air/fuel ratio is very important for the
air/fuel ratio. For low pressure gas fuel systems,
following considerations :
the maximum fluctuation that is allowed in the fuel
pressure is ± 1 .7 kPa (± 0.25 psi) . If more than one
® Margin of detonation
engine is using the fuel supply line, ensure a stable
fuel pressure to the engine by installing a second
o Control of emissions
gas pressure regulator prior to the gas pressure
e Achieving optimum service life for the engine regulator on the engine .

Gas Pressure Regulator

If the air/fuel ratio is not appropriate for the fuel and
the operating conditions, a failure of the engine
The gas pressure regulator maintains a pressure
may occur. The service life of the turbocharger, the
differential between the air and the fuel that is
valves, and other components may be reduced.
supplied to the carburetor. Set the pressure of the
fuel supply according to the instructions in Systems
Temperature of the Air Supply Operation/Testing and Adjusting. The gas pressure
regulator will maintain the pressure differential in
Changes in the temperature of the air supply affects response to changes in the air pressure .
the air/fuel ratio. In addition to seasonal changes,
the air temperature changes overnight. Control of A water manometer is used to measure the pressure
the temperature in the engine room will help to differential . This measurement is taken when the
maintain the air/fuel ratio . engine is operating at high idle rpm with no load .
When a load is applied, the fuel pressure will
usually decrease by approximately 0.25 to 0 .5 kPa
(1 to 2 inches of H,O) . If the performance of the
gas pressure regulator is erratic, the gas pressure
regulator may require service .
30
Operation Section
Features and Controls

Throttle Angle and Exhaust Bypass

(Wastegate)
Unburned gas in the inlet manifold and/or in the
A throttle angle of approximately 70 degrees is exhaust manifold can ignite when the engine is
recommended for full load operation . started. Personal injury and/or property damage
can result. Use this procedure to clear the engine
The following factors affect the angle of the throttle: and the exhaust system of unburned gas :
® LHV of the fuel Before starting an engine that was stopped by ter-
minating the ignition system, turn the gas supply
® Air/fuel ratio OFF Crank the engine for approximately 15 sec-
onds in order to clear any unburned gas from the
® Setting of the exhaust bypass (wastegate) engine and the exhaust system .

" Altitude
If an engine protective device shuts off the engine,
After the desired exhaust emissions are achieved, always determine the cause of the shutoff. Make
the exhaust bypass is adjusted in order to achieve the necessary repairs before attempting to start
full load operation with the desired throttle angle. the engine .
Excess boost generates back pressure in the
exhaust manifold . This raises pumping losses which Become familiar with the following information :
increase fuel consumption .
® Types of the alarm and shutoff controls
Ensure that the angle of the throttle plate is properly
set. This will maintain the margin for detonation . ® Locations of the alarm and shutoff controls
This will also enable the engine to accept load
® Conditions which cause each control to function
changes without lugging .
® Resetting procedure that is required before
101336681 starting the engine
Alarms and Shutoffs Testing Alarms and Shutoffs
SMCS Code: 7400
Alarms must function properly in order to provide
Engines may be equipped with optional engine timely warning to the operator. Shutoffs help to
protective devices that are not included in this prevent damage to the engine . It is impossible
section . This section contains some general to determine if the engine protective devices are
information about the function of typical engine in good working order during normal operation.
protective devices. Malfunctions must be simulated in order to test the
engine protective devices .
Alarms and shutoffs are electronically controlled .
The operation of all alarms and shutoffs utilize NOTICE
components which are actuated by a sensing unit. During testing, abnormal operating conditions must be
The alarms and shutoffs are set at critical operating simulated.
temperatures, pressures, or speeds in order to
protect the engine from damage . The tests must be performed correctly in order to pre-
vent possible damage to the engine .
The alarms function in order to warn the operator
when an abnormal operating condition occurs . The
shutoffs function in order to shut down the engine Periodic testing of engine protective devices for
when a more critical abnormal operating condition proper operation is recommended maintenance .
occurs . The shutoffs help to prevent damage to To prevent damage to the engine, only authorized
the engine . service personnel or your Caterpillar dealer should
perform the tests.
 31
Operation Section
Features and Controls

Engines Without A Caterpillar 101408987

Remote Control Panel (Status) v rnors a Actuators
The customer must provide the relay logic for SMCS Code : 1264
engines that are not equipped with a Caterpillar
Remote Control Panel (Status) . The customer must Isochronous - The engine rpm remains constant
provide the relay logic for the following parameters :
from high idle at no load to full load operation . This
is known as zero percent droop .
® Oil pressure (high idle limit)
Droop - Droop represents a decrease in rpm from
® Oil pressure (low idle limit) high idle at no load to full load operation.
® Jacket water coolant temperature (high
The governor controls the engine rpm. For detailed
temperature)
information on governor operation, see the Service
Manual, "Systems Operation/Testing and Adjusting"
e Overspeed module .
The specific limits are listed in Table 6 . Relay logic
must be provided for shutting off the engine in Woodward P Governor
case any of the limits are reached. Consult your
Caterpillar dealer for assistance . The Woodward PSG Governor is the standard
governor for G3400 Industrial Engines. This
Table 6 hydraulic governor can be used in the droop mode
or in the isochronous mode .
G3406 Engine S hu tdow n Setpoints
Rated Minimum Oil Jacket Overspeed A positive locking manual speed control is standard
RPM Pressure Water0) RPM on the G3400 Industrial Engines . The governor
Temp . is lubricated with oil from the engine lubrication
High Low
Idle Idle system .
RPM RPM
1000 275 100 105 °C 1200 Woodward Plo-Tech Speed Control
kPa kPa (221 °F)
(40 psi) (15 psi) The Woodward Flo-Tech Speed Control is designed
to provide basic isochronous speed control for
1400 275 100 105 °C 1680 gas engines that use the Flo-Tech Throttle . The
kPa kPa (221 °F)
(40 psi) (15 psi) Woodward Flo-Tech Speed Control can be used
for industrial engines and generator set engines.
1500 275 100 105 °C 1800 The Woodward Flo-Tech Speed Control is standard
kPa kPa (221 °F) on G3406 generator sets . Current transformers,
(40 psi) (15 psi) potential transformers, and a Generator Load
1800 275 100 105 °C 2160 Sensor are required in order to control the generator
kPa kPa (221 °F) sets that will be run in parallel .
(40 psi) (15 psi)
( 1 ) To prevent overheating, the coolant pressure must be a Woodward 8290/1724 Governor
minimum of 27 .6 kPa (4 psi) .
The Woodward 8290/1724 Governor is a completely
electronic governing system . The 8290 is the
governor control and the 1724 is the actuator. The
8290 is an isochronous electronic governor. The
actuator is driven by electricity and powered by the
8290 governor. A load share module is offered as
an attachment in order to provide the capability of
sharing loads.
32
Operation Section
Engine Starting

Engine Starting " Inspect flexible piping for cracks and leaks .

Cooling System
i01626063

Before Starting Engine Inspect the cooling system for leaks or loose
connections . Inspect the condition of all the hoses
and pipes for the cooling system . Ensure that the
SMCS Code : 1000; 1400 ; 1450 connections are properly clamped .
Note : Certain procedures are required before an " Inspect the water pumps for evidence of leaks.
engine is started for the first time . Refer to the
Special Instruction, REHS0371, "Installation and " Check the coolant level. Add coolant, if necessary.
Initial Start-Up Procedure for G3300 and G3400 For information on the proper coolant to use, see
Engines" . this Operation and Maintenance Manual, "Cooling
System Specifications" (Maintenance Section) .
Perform the required daily maintenance and other
periodic maintenance before starting the engine . For engines with separate circuit aftercooling,
This can prevent major repairs at a later date. open the water supply .
Refer to the Operation and Maintenance Manual,
"Maintenance Interval Schedule" (Maintenance
Section) . Driven Equipment
Walk-Around Inspection " Check the oil levels of the driven equipment.
Perform any maintenance that is required for the
driven equipment. Refer to the literature that is
NOTICE provided by the OEM of the driven equipment.
For any type of leak (coolant, lube, orfuel) clean up the
fluid. If leaking is observed, find the source and correct " If the engine is equipped with a clutch, ensure
the leak . If leaking is suspected, check the fluid levels that the clutch is disengaged .
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be " For generator set engines, ensure that the main
unwarranted. circuit breaker is open.

To obtain maximum service life for your engine, Electrical System

make a thorough inspection before starting the
engine . Make a walk-around inspection of the Inspect the wiring for the following conditions :
installation . Look for items such as oil or coolant
leaks, loose bolts and trash buildup. Remove any " Loose connections
trash . Make repairs, if necessary.
" Wiring that is worn or frayed
" Inspect the drive belts for cracks and wear.
Inspect the gauge panel and the control panel
" The guards must be in the proper place. Repair for good condition . Reset any shutoff or alarm
damaged guards or replace missing guards . components .

" Ensure that the areas around the rotating parts

are clear.
Fuel System
Air Inlet System
" Ensure that the air inlet piping and the air filters NEVER use a flame to check for gas leaks. Use a
are in place. gas detector.

" Ensure that all clamps and connections are An open flame can ignite mixtures of air and fuel.
secure . This will cause explosion and/or fire which could
result in severe personal injury or death.
" Inspect the air cleaner service indicator (if
equipped) . Service the air cleaner filter element " Check the fuel system for leaks with a gas
when the yellow diaphragm enters the red zone, detector.
or the red piston locks in the visible position .
 33
Operation Section
Engine Starting

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

Lubrication System " 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 :

" Loose connections

Illustration 17 g00760044 " Wires that are worn or frayed

Oil level gauge (dipstick)
(1) "ADD" mark
" Corrosion
(2) "FULL" mark

101489240
NOTICE
Excessive engine oil will increase oil consumption and old eater Starting
result in excessive deposits in the combustion cham-
ber. Do not overfill the engine with oil. SMCS Code : 1000; 1250; 1450; 1453 ; 1456; 1900

Note : Oil pan immersion heaters are not

" Check the engine crankcase oil level. Maintain recommended for heating the lube oil . To ensure
the oil level between the "ADD" and "FULL" the compatibility of the components, only use
marks on the "ENGINE STOPPED" side of the oil equipment that is recommended by Caterpillar.
level gauge. For information on the proper oil to
use, see this Operation and Maintenance Manual, A jacket water heater is available as an option for
"Lubricant Specifications" (Maintenance Section) . starting in temperatures as low as 0 °C (32 °F).
The jacket water heater can maintain the water
Check for leaks at the following components: temperature at approximately 32 °C (90 °F). The
crankshaft seals, crankcase, oil filters, oil gallery heated water will help to keep the oil in the engine
plugs, sensors, and valve cover. block warm enough to flow when the engine is
started . A jacket water heater is recommended for
Inspect the tubes, and the clamps on the starting when the temperature is less than 16 °C
crankcase breathers . (60 °F).

Starting System For air starting motors, a larger volume of starting

air and/or a higher air pressure may be necessary
Note : If the engine is equipped with a system for in order to start the engine at colder temperatures .
external support, prepare the system before starting
the engine . Ensure that all of the systems for engine For electric starting, extra battery capacity may be
support are enabled. Perform all prestart checks for necessary.
the control system .
Consult your Caterpillar dealer for more information
on the starting aids that are available for cold
Air Starting Motor weather starting .
" Drain moisture and sediment from the air tank
and from any other air piping .
34
Operation Section
Engine Starting

101002456 Automatic Starting

Starting the Engine
SMCS Code: 1000 ; 1450
When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid personal
injury, always remain clear of the the engine when
the engine is in the AUTOMATIC mode .
Engine exhaust contains products of combustion
which may be harmful to your health . Always start
and operate the engine in a well ventilated area If the engine control switch is in the "AUTO"
and, if in an enclosed area, vent the exhaust to the position, the engine will automatically start when the
outside. remote start/stop initiate contact closes . The engine
will accelerate to rated rpm when the oil pressure
is sufficient .
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make Manual Starting
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the 1 . Ensure that fuel is supplied to the engine . Ensure
fuel supply and/or the ignition to the engine . that no gas is leaking .

2. Ensure that the driven equipment is unloaded .

a. For generator set engines, open the main

Unburned gas in the inlet manifold and/or in the circuit breaker.
exhaust manifold can ignite when the engine is
started. Personal injury and/or property damage b. For industrial engines, unload the compressor
can result. Use this procedure to clear the engine or pump. Disengage the clutch (if equipped).
and the exhaust system of unburned gas : Place the transmission and/or other
attachments for the power takeoff in
Before starting an engine that was stopped by ter- NEUTRAL.
minating the ignition system, turn the gas supply
OFF Crank the engine for approximately 15 sec- Note : Before starting an industrial engine, move
onds in order to clear any unburned gas from the the governor control lever to the position for 1/2 of
engine and the exhaust system. rated rpm .

Do not start the engine or move any of the controls NOTICE

if there is a "DO NOT OPERATE" warning tag or Do not engage the starting motor when flywheel is
similar warning tag attached to the start switch or turning. Do not start the engine under load.
to the controls .
If the engine fails to start within 30 seconds, release
Ensure that no one will be endangered before the the starter switch or button and wait two minutes to
engine is started and when the engine is started. allow the starting motor to cool before attempting to
start the engine again.
Perform the procedures that are described in
this Operation and Maintenance Manual, "Before 3. The method that is used for starting depends
Starting Engine" (Operation Section) . on the equipment:

Operation of the Generator Set

Control Panel
For information on operation for a specific generator
set control panel, refer to the Operation and
Maintenance Manual for the generator and the
control panel. g00523542
Illustration 18
Typical "START" button on an instrument panel
 35
Operation Section
Engine Starting

a. For electric starting, press the "START" button 101037941

or turn the start/stop switch to the "START"
position . Starting it Start
Cables
SIVICS Code: 1000; 1401 ; 1402; 1900

g WARNING
Improper jump start cable connections can cause
an explosion resulting in personal injury.

Prevent sparks near the batteries . Sparks could

cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine .

Illustration 19 g00523569 If the installation is not equipped with a backup

battery system, it may be necessary to start the
"START" valve on an air starting motor
engine from an external electrical source .
b. For starting with air, push the "START" valve. First, determine the reason that it is necessary to
Release the valve as soon as the engine start with power from an external source . Refer to
starts . Shut off the air supply to the starting Special Instruction, SEHS7768, "Use of the 6V-2150
motor. Starting/Charging Analyzer" .
Note : After starting an industrial engine, move the Many batteries which are considered unusable are
governor control lever to the position for low idle still rechargeable . After jump starting, the alternator
rpm. may not be able to fully recharge batteries that
are severely discharged . The batteries must be
4. Allow the engine to idle for three to five minutes. charged to the proper voltage with a battery
The engine speed should stabilize at low idle charger. For information on testing and charging,
rpm. Check all of the pressure gauges. Inspect refer to the Special Instruction, SEHS7633, "Battery
the engine for leaks and listen for unusual noises . Test Procedure" .
When all systems are normal, the rpm may be
increased.
NOTICE
Using a battery source with the same voltage as the
Starting Failure electric starting motor. Use ONLY equal voltage for
jump starting . The use of higher voltage will damage
If the engine fails to start after cranking for 30 the electrical system .
seconds, stop cranking . Perform the following
procedure: Do not reverse the battery cables . The alternator can
be damaged. Attach ground cable last and remove
1 . Turn the start switch to the "OFF" position . first.
2. Turn the gas supply OFF. When using an external electrical source to start the
engine, turn the engine control switch to the "OFF" po-
3. Allow the starting motor to cool for two minutes. sition . Turn all electrical accessories OFF before at-
Crank the engine for approximately 15 seconds taching the jump start cables.
in order to disperse any unburned gas from the
engine and the exhaust system . Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
4. Allow the starting motor to cool for two minutes. gine being started.
Turn the gas supply ON . Repeat the starting
procedure.
1 . Turn the start switch on the stalled engine to the
OFF position . Turn off all accessories.
36
Operation Section
Engine Starting

2. Connect one positive end of the jump start cable The engine will reach normal operating temperature
to the positive cable terminal of the discharged faster when the engine is operated at rated rpm
battery. Connect the other positive end of the and low power demand . This procedure is more
jump start cable to the positive cable terminal effective than idling the engine with no load. The
of the electrical source . engine should reach normal operating temperature
in a few minutes.
3. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical Engaging the Driven Equipment
source . Connect the other negative end of the
jump start cable to the engine block or to the
chassis ground . This procedure helps to prevent Industrial Engines
potential sparks from igniting combustible gases
that are produced by some batteries . 1 . Ensure that the gauges are in the normal ranges
for the engine rpm .
4. Charge the batteries. The engine will not
continue to run after starting if the batteries have 2. Apply the load . Begin operating the engine at
not been charged . low load.

5. Start the engine . The engine will reach normal operating

temperature faster when the engine is operated
6. Immediately after the stalled engine is started, at rated rpm and low power demand. This
disconnect the jump start cables in reverse order. procedure is more effective than idling the
engine with no load. The engine should reach
Refer to the Electrical Schematic for your engine . normal operating temperature in a few minutes.
Consult your Caterpillar dealer for more information .
3. After the temperature gauges begin to rise, the
engine may be operated at full load.
101232055
4. Continue to monitor the gauges and the driven
After Starting i equipment.
SMCS Code: 1000
Generator Set Engines
Note : After the engine has been installed or rebuilt,
carefully monitor the engine in order to detect any 1 . Ensure that the gauges are in the normal ranges
unusual engine performance. for the engine rpm .

2. Increase the engine rpm to rated rpm. Always

Warm-up increase the engine speed to rated rpm before
applying the load .
1 . Operate the engine at low idle for two to three
minutes . Allow the jacket water temperature to 3. Adjust the voltage and the frequency, if
begin to rise before increasing the engine rpm necessary.
to rated rpm.
4. Close the main circuit breaker in order to apply
Note : More warm-up time may be necessary when the load .
the ambient temperature is below -18 °C (0 °F) .
5. Continue to check the gauges and the driven
2. Check all of the gauges during the warm-up equipment.
period .

3. Make another walk-around inspection . Inspect

the engine for fluid leaks and air leaks.

The time that is needed for the engine to reach the

normal mode of operation is usually less than the
time that is needed for a walk-around inspection .
 37
Operation Section
Engine Operation

ngin 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
101367463 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 7 .
Proper operation and maintenance are key factors Table 7
in attaining the maximum service life and economy
for the engine . Follow the instructions in this Time Limits For Lo w Load Operatio n
Operation and Maintenance Manual in order to Engine Torque NA Engines TA Engines
minimize operating costs and maximize the service
0 to 30% 1/2 hour 1/2 hour
life of the engine .
31 to 50% 2 hours 2 hours
Observe the gauges frequently while the engine is
operating. Record the data from the gauges in a log 51 to 60% 24 hours Continuous(')
regularly. Compare the data to the specifications 61 to 100% Continuous Continuous(')
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 :

e Power loss

e Poor performance

a Accelerated wear of components

Caterpillar Engines can be operated at very light

loads (torques) for limited times with no harmful
effects . Table 7 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,
38
Operation Section
Engine Stopping

Engine t X01020551

u l t roce re
101618316
SMCS Code: 1000 ; 7418
Emergency Stopping
NOTICE
SMCS Code: 1000 ; 7418 Stopping the engine immediately after the engine has
been operating under a load can result in overheating
NOTICE and accelerated wear of the engine components .
Emergency shutoff controls are for EMERGENCY use
ONLY DO NOT use emergency shutoff devices or Allow the engine to gradually cool before stopping the
controls for normal stopping procedure. engine .

Ensure that any system that provides external Note : Remove the load at a rate that will avoid
support to the engine is secured after the engine detonation .
is stopped.
Disengage the driven equipment .
NOTICE a. For generator set engines, open the main
Do not start the engine until the problem necessitating circuit breaker.
the emergency stop has been located and corrected .
b. For industrial engines, unload the compressor
or pump . Disengage the clutch (if equipped).
Emergency Stop utton Place the transmission and/or other
attachments for the power take-off in
NEUTRAL.

Note: Extended idling can cause excessive oil

consumption and related problems. See this
Operation and Maintenance Manual, "Engine
Operation" topic (Operation Section) .

2. Reduce the engine rpm to low idle .

3. Operate the engine at low idle rpm for a cool

0 0
00
0
00
0
00 0 down period .
If the engine has been operated at a low load,
g00520710 operate the engine at low idle for approximately
Illustration 20 30 seconds before stopping the engine .
Emergency stop button on the junction box
If the engine has been operated at a high load,
For the junction box, the emergency stop button is operate the engine at low idle for three to five
in the OUT position for normal engine operation . minutes before stopping the engine .
For an emergency stop, push the emergency stop
button . The button must be reset before the engine 4. To stop the engine, shut off the fuel supply.
can be started .
The engine will coast to a stop . Ensure that any
To reset the button, turn the button clockwise . The system that provides external support to the engine
spring-loaded button will return to the OUT position . is secured after the engine is stopped .
 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.
40
Maintenance Section
Lubricant Specifications

Maintenance ti Due to significant variations in the quality and in

the performance of commercially available oils,
Caterpillar makes the following recommendation :

Lubricant eci icati " Caterpillar Natural Gas Engine Oil (NGEO)
Caterpillar NGEO has been tested throughout
100708567 the world in demanding environments . Caterpillar
NGEO has been tested in engines that use all types
Lubricant Information of gaseous fuel . The formulation of the oil has been
proven to be superior to many brands of oil that
SMCS Code: 1000 ; 1300 ; 7581 are locally available .
Engine oil performs several functions: For maximum service life of the engine and the
engine oil, use Caterpillar NGEO with low sulfur
" Keeping the engine clean gaseous fuels that contain less than 0.43 mg H,S/MJ
(0.45 pg H,S/Btu) .
" Preventing rust and corrosion
Caterpillar NGEO may also be used with high sulfur
" Acting as a coolant natural gas . The use of these fuels may require a
reduced oil change interval .
" Reducing friction and wear
Caterpillar NGEO is formulated and blended with
Engines that use gaseous fuel require oils that are special additives in order to provide protection
formulated with additives that are specific to these against oxidation and nitration. Caterpillar NGEO
engines . also has thermal stability.
No performance specifications are available to Caterpillar NGEO also provides the following
define the performance levels that are required benefits :
by engines that use gaseous fuels. Field tests
must be used in order to define oils that are " Reduction of the formation of carbon and sludge
acceptable . To aid in oil selection, guidelines are
provided in Supplement, SEBU6400, "Caterpillar " Resistance to foaming
Gaseous Fueled Spark Ignited Engines Lubrication
Specifications" . Resistance to corrosion
Grease is classified by the National Lubricating " Improved cleanliness of cylinder liners, pistons,
Grease Institute (NLGI) . The classification is valves, and valve seats
based on the "ASTM D217-68 Worked Penetration"
characteristics . The characteristics have a number " Lubrication that helps to protect against scoring,
for consistency that is defined . For information scuffing, and wear
on grease, see this Operation and Maintenance
Manual, "Lubricating Grease" topic (Maintenance Table 8 lists the oil properties of Caterpillar
Section). NGEO. The properties are based on ASTIVI test
specifications .
101330669

Engine Oil
SMCS Code : 1300 ; 1348 ; 7581

Caterpillar Oils have been developed and tested in

order to provide the full performance and service
life that has been designed and built into Caterpillar
Engines . These oils are offered by Caterpillar
dealers for continued use when the engine oil is
changed . Consult your Caterpillar dealer for more
information on these oils.
 41
Maintenance Section
Lubricant Specifications

Table 8 Field Testing of Oil

Caterpillar NGEO Properties
Note : For more information, see , SEBU6400-02,
Characteristic ASTM SAE Viscosity "Operation and Maintenance Manual", "Field
Test Grade Evaluation of Commercial Oil" .
30W 40W
API Gravity "D 0286" 28 .4 27 .5 Sour Gas and Bio®Gas Applications
Flash Point "D 0092" 265 265 Note : For more information, see the specific
Pour Point "D 0097" -15 -15 engine's Operation and Maintenance Manual, "Fuel
Recommendations" .
Viscosity (cSt) at "D 0455" 95 130
40 °C (104 ° F) Many gaseous fuels contain sulfur compounds.
Viscosity (cSt) at "D 0455" 11 13 .5 These compounds are primarily composed of
100 °C (212 °F) hydrogen sulfide (H 2S) . If the concentration is less
than the following amount, the gaseous fuels are
Viscosity Index "D 0567" 99 99 considered to be "sweet" . If the concentration is
Weight (Percent) of "D 0874" 0.48 0.48 greater than the following amount, the gaseous
Sulfated Ash fuels are considered to be "sour" .
Total Base Number "D 2896" 6.2 6.2 " 0.43 mg H,S/MJ (0 .45 pg H,S/Btu)
Weight (Percent) of "D 4951" 0.030 0.030
Phosphorus Sour gas can reduce the service life of an engine
and the engine oil . When the sulfur compounds
are combined with water, acids are produced in
Commercial Oils the engine oil. These acids attack the metals in
the engine crankcase. This causes corrosive wear.
Commercial oil specifications do not exist for To reduce the effects of these sulfur compounds,
Caterpillar Engines that operate on gaseous fuels . Caterpillar recommends the use of devices that
The performance of lubrication oil for gas engines treat the fuel .
is determined by a field test . Successful field
operation has been achieved with oils that meet the If the sour gas cannot be treated in order to reduce
following guidelines : the level of sulfur, additional measures must be
taken in order to protect the engine . To reduce the
" Caterpillar recommends the use of oils that harmful effects of sour gas, Caterpillar recommends
are formulated specifically for heavy-duty gas the following guidelines :
engines. Do not use oils that are specially
formulated for gasoline engines or for diesel " Obtain frequent oil analyses .
engines .
e Reduce the oil change interval according to the
" Caterpillar recommends the use of oils that have results of oil analysis .
a sulfated ash content between 0 .40 and 0.60
percent. Caterpillar does not recommend the use of engine
oils with a high concentration of sulfated ash in
" The oil must demonstrate adequate protection order to reduce the harmful effects of sour gas .
for a minimum of 7000 hours in a field test under High levels of sulfated ash may produce excessive
controlled conditions . deposits on the valves and on the turbine wheel of
the turbocharger. These deposits will reduce the
NOTICE service life of the engine . These deposits will also
Failure to follow these oil recommendations can cause increase the cost of maintenance.
shortened engine service life due to deposits and/or
excessive wear. For additional information on gaseous fuels and on
treatment of the fuel, see the following publications :

NOTICE *Application and Installation, LEKQ7256,

Caterpillar recommends the use of oils that are formu- "Fuels/Fuel Systems"
lated specifically for heavy duty spark ignited gaseous
fueled engines . Oils that are formulated for gasoline " Application and Installation, LEKQ7260, "Low
engines only or for diesel engines only should not be BTU Engines"
used .
42
Maintenance Section
Lubricant Specifications

e Maintenance Management Schedules, Some synthetic base oils have performance

SEBU6127, "Schedules for Industrial and EPG characteristics that enhance the service life of the
Spark Ignited Gas Engines" oil . However, Caterpillar does not recommend the
automatic extension of oil change intervals for
For information regarding condemning limits of any type of oil . Oil change intervals for Caterpillar
the lubrication oil, refer to this Operation and engines can only be adjusted after an oil analysis
Maintenance Manual, "S-O-S Oil Analysis" topic program that contains the following tests: oil
(Maintenance Section) . condition and wear metal analysis (Caterpillar's
S-O-S oil analysis), trend analysis, fuel consumption,
and oil consumption .
Lubricant Viscosity
Recommendations 101275698

The proper SAE viscosity grade of oil is determined fterrnarket iI Additive

by the minimum ambient temperature during
cold engine start-up, and the maximum ambient SMCS Code : 1348; 7581
temperature during engine operation . To determine
the oil viscosity that is required for starting a cold Caterpillar does not recommend the use of
soaked engine, refer to the minimum temperature in aftermarket additives in oil. It is not necessary
Table 9 . To select the oil viscosity for operation at to use aftermarket additives in order to achieve
the highest anticipated ambient temperature, refer the engine's maximum service life or rated
to the maximum temperature in Table 9 . Use the performance . Fully formulated, finished oils consist
highest oil viscosity that is available in order to meet of base oils and of commercial additive packages .
the required temperature during start-up . These additive packages are blended into the base
oils at precise percentages in order to help provide
Table 9
finished oils with performance characteristics that
Engine Oil Viscosity meet industry standards .
Caterpillar Ambient Temperature
NGEO - e There are no industry standard tests that
Grade of Minimum Maximum
evaluate the performance or the compatibility of
Viscosity aftermarket additives in finished oil .
SAE 3011 ) 0 °C (32 °F) 40 °C (104 °F) ® Aftermarket additives may not be compatible with
SAE 400) 5 °C (41 °F) 50 °C (122 °F) the finished oil's additive package, which could
lower the performance of the finished oil.
( 1 ) Caterpillar NGEO is available in these grades only. Multigrade
oils are NOT recommended for use in Caterpillar Gas Engines .
If other grades of viscosity are selected, ensure that the oil ® The aftermarket additive could fail to mix with the
meets the requirements for Caterpillar Gas Engines . Consult finished oil. This could produce sludge in the
the supplier of the oil . crankcase.

101111406
® Caterpillar discourages the use of aftermarket
additives in finished oils .
Synthetic t Its
To achieve the best performance from a Caterpillar
SMCS Code: 1348; 7581 engine, conform to the following guidelines :

Synthetic base oils are acceptable for use ® Select the proper Caterpillar oil or commercial oil.
in Caterpillar engines if these oils meet the
performance requirements that are specified for the ® See the appropriate "Lubricant Viscosities" table
engine compartment . in order to find the correct oil viscosity grade for
your engine .
Synthetic base oils generally perform better than
conventional oils in the following two areas: a At the specified interval ; service the engine
compartment. Use new oil and install a new oil
e Synthetic base oils have improved flow at low filter.
temperatures especially in arctic conditions .
® Perform maintenance at the intervals that are
® Synthetic base oils have improved oxidation specified in the Operation and Maintenance
stability especially at high operating temperatures . Manual, "Maintenance Interval Schedule" .
 43
Maintenance Section
Lubricant Specifications

i01489947 Condemning Limits f the Oil

®O®S Oil Analysts Oil analysis is the only method of determining if
an oil is protecting the engine . The oil analysis
SMCS Code : 1348 ; 7542-008
is compared to limits that have been established
through experience .
Caterpillar recommends the S-O-S oil analysis
program in order to monitor the condition of the The condemning limits for lubrication oil were
oil and the maintenance requirements of the
developed from experience with engine operation
engine . The S-O-S program is part of the preventive
and from the analysis of used oil . The limits provide
maintenance program .
guidelines for determining the useful service life of
the engine oil. Table 10 lists the limits for the service
The S-O-S oil analysis includes these tests:
life of the oil.
" The Wear Rate Analysis monitors wear by Table 10
detecting, identifying and assessing the amount
and the type of wear metal that is in the oil. The S-O-S Oil Analysis
Condemning Limits
increase in the rate of engine wear metal in the
oil is as important as the quantity of engine wear Parameter Limit
metal in the oil. For this reason, regular sampling
at specified intervals is necessary in order to Oxidation 100% defined by the
establish wear rates. Intermittent sampling does S-O-S Oil Analysis
not allow wear rate trend lines to be established. Nitration 100% defined by the
Engine wear metals in the oil sample are S-O-S Oil Analysis
compared to established Caterpillar norms in
Water 0.5% maximum
order to determine acceptability. Potential failures
can be identified when the wear rate and/or the Glycol 0%
contaminants exceed the established trend .
Silicon (Bio-gas) 25 ppm
" Tests are conducted in order to detect Wear Metals Based on Caterpillar
contamination of the oil by water and/or glycol . norms and on the trend of
the Wear Rate Analysisl>>
" The Oil Condition Analysis determines the loss Additional Oil Analysis
of the oil's lubricating properties . An infrared
analysis is used to compare the properties of Viscosity at 100 °C (212 °F) Increase of 3 cSt from
new oil to the properties of the used oil sample . by "ASTM D445" new oil
This analysis allows technicians to determine the Total acid number (TAN) by 3.0 maximum TAN or
amount of deterioration of the oil during use. "ASTM D664" 2.0 greater TAN than
the new oil
The test results of the oil samples will then be used
as a basis for determining the oil change interval Total base number by 50% of new oil TBN
"ASTM D2896"
for the engine . The results of the S-O-S oil analysis
may enable the engine to operate longer between (1) A trend can be established from the results of three oil analyses .
oil changes without the risk of damage .

Obtain each oil sample when the oil is warm and

well mixed in order to ensure that the sample is
representative of the oil in the engine crankcase.

Oil analysis is essential in order to determine

satisfactory performance of the oil.

Refer to Special Publication, PEDP7036, "S-O-S

Fluid Analysis" for more information.

Consult your Caterpillar dealer for complete

information and assistance about the program .
44
Maintenance Section
Fuel Specifications

Fuel The methane number and the appropriate Engine

Performance, "Fuel Usage Guide" are used for
determining the following parameters:
101351565
" Compression ratio
Fuel Rec
" Ignition timing
SMCS Code: 1280
" Rated load
General Fuel Information For a detailed explanation of methane numbers,
Gaseous fuels consist primarily of hydrocarbons see Application and Installation Guide, LEKQ7256,
(combinations of hydrogen and carbon) and some "Fuels/Fuel Systems" .
inert gases. Pipeline natural gas and propane gas
have been used for many years. Other types of Follow the recommendations for fuel usage that is in
fuel such as wellhead gas needs to be reviewed the appropriate Engine Performance, "Fuel Usage
for acceptability. Guide" . Engine Performance publications can be
obtained from your Caterpillar dealer.
Each commercial fuel gas is a mixture of gases .
Some of the gases are combustible and some of ry Natural Gas
the gases are inert. The compositions of these gas
mixtures have extreme variations . Dry natural gas is a mixture of methane, ethane,
propane, and butane . Dry natural gas may also
Caterpillar Gas Engines will operate successfully have traces of heavier hydrocarbons .
on a broad range of gaseous fuels . Adjustments
must be made to the fuel system when the fuel is The Low Heat Value (LHV) of a gas is the high
changed . Consult your Caterpillar dealer about the heat value (HHV) minus the heat that is required to
proper adjustments . vaporize the water that is formed by combustion .
For more information on heat values, see Application
Permissible fuels must be analyzed in order to and Installation Guide, LEKQ7256, "Fuels/Fuel
determine the following characteristics: Systems" .

" Composition The heat value of dry natural gases may vary.
This depends on the composition of the gas. Dry
" Specific gravity natural gas usually has an LHV that is between
33.53 to 34 .65 kJ/L (900 to 930 Btu/ft3). Caterpillar
" Heat value Gas Engines are adjusted at the factory with a dry
natural gas that is within this range.
" Methane number
For dry natural gas, the acceptable limit of hydrogen
The fuel analysis enables the requirements for the sulfide is 0.43 mg HzS/MJ (0.450 ug HzS/Btu) .
following parameters to be established :

" Ignition timing Propane

" Rated load Propane is transported to a site as a liquid . The
liquid is converted into a gas at the site. Some
regulations do not permit the use of liquid propane
" Compression ratio
inside of a facility. Review the local building codes
before final plans are made for a propane system .
A fuel's potential for detonation is indicated by a
methane number. The methane number of any gas
(fuel) can be determined with the following method: For the guidelines in this Operation and
Maintenance Manual, propane must meet these
HD-5 specifications :
1 . Obtain a fuel analysis of the gas .
" 95 percent propane
2. Enter the data from the fuel analysis into the
Caterpillar Software Program, LEKQ6378,
" Remaining 5 percent is not heavier than butane .
"Methane Number Program" .

This software program calculates the fuel's methane

number.
 45
Maintenance Section
Fuel Specifications

HD-5 propane can be used in all naturally aspirated " Exhaust manifolds
engines . Turbocharged engines can run on propane
fuels. In either case, the engine must be properly " Aftercoolers
equipped for the use of propane. The use of pistons
with a low compression ratio and a derating is Analyze the gas before use. If the gas has more
required. than 0.43 mg H,S/MJ (0.450 pg H,S/Btu), treat the
gas in order to reduce the content of hydrogen
Consult your Caterpillar dealer before operating sulfide.
your gas engine with this fuel.
Various devices can reduce the content of hydrogen
HD-5 propane has an LHV between sulfide. Examples are chemically active filters,
2427 to 2532 kJ/0 .305 m3 (2300 to 2400 Btu/ft') . reactive beds, and solutions . The performance of
This is between two and three times the LHV of the devices deteriorates as the reactive chemicals
processed dry natural gas. are depleted . The devices must be serviced or
replaced in order to maintain effectiveness .
Mixtures of Propane and Air
Establish an oil analysis program in order to ensure
Mixtures of propane and air have an LHV that that the oil change intervals are not extended
is approximately the same LHV of natural gas. beyond the condemning limits of the oil. The oil
Mixtures of propane and air are generally used analysis will also be able to detect other problems
as a standby fuel for occasions when the flow of that may occur.
natural gas is interrupted. Mixtures of propane and
air require the ignition timing, the rated load, and Wellhead Gas (Field Gas)
the compression ratio that is required by propane .
Derating may be required in order to use this fuel . Wellhead gas is natural gas that has not been
Consult your Caterpillar dealer before operating the processed . The composition of gas from the
engine with this fuel . wellheads in different gas fields varies . The
composition of the gas from different wellheads
Sour Gas within the same gas field can vary. As a result,
the gas from one source may be acceptable for
Sour gas refers to fuels that contain more than use but the gas from a different source may not
0.43 mg H,S/MJ (0 .450 pg H,S/Btu) . The following be acceptable . For this reason, a fuel analysis is
gases are within this category : required to determine if the fuel is acceptable for a
particular Caterpillar Engine .
" Some wellhead gases
Note : The composition of the gas from a field can
" Landfill gas change over time . Allow some adaptability for this
change during the life of the project.
" Digester gas
Wellhead gas has minimal processing before
"Sweet" gas pertains to fuels that have less than entering the fuel manifold . This fuel is commonly
0.43 mg H,S/MJ (0 .450 pg HZS/Btu) . used in engines that power gas compressors . The
engines burn the same gas that is compressed in
The use of gases that have hydrogen sulfide can order to be transferred through pipelines.
damage the engine . Products of combustion (water
vapor and sulfur oxides) form sulfurous acid and Some gas fields contain significant amounts
sulfuric acid . Sulfur reacts easily with "bright" metals of hydrogen sulfide . In these cases, follow the
such as copper. Therefore, oil coolers are usually precautions that are recommended for using sour
the first components that are affected by the acids. gas. Obtain a fuel analysis and determine the
Other engine parts that are attacked by the acids methane number.
include the following components :
Follow the recommendations for fuel usage that is in
" Valves the appropriate Engine Performance, "Fuel Usage
Guide" . The Engine Performance publications can
" Valve guides be obtained from your Caterpillar dealer.

" Piston pin bushings Many wellhead gases have some heavier
hydrocarbons such as pentane, isobutane and
" Piston rings other gasolines. These heavier hydrocarbons cause
detonation and other problems.
" Cylinder liners
46
Maintenance Section
Fuel Specifications

Consult your Caterpillar dealer before operating the

engine with fuel that has more than one percent of
hydrocarbons that are heavier than butane .

Gaseous Fuel Filters

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

Fuel filters are no less important than air filters to

protect gas engines from dirt and debris . A proper
fuel filter removes impurities that can damage the
internal components of the engine .

The gas must be supplied to the engine at a

pressure that is acceptable. For optimum operation,
use a fuel filter that is properly sized for the gas
pressure.

For many gas engines, fuel filters are a provision

of the design for the application . These devices
are part of the normal maintenance for the plant .
Therefore, Caterpillar does not include a standard
fuel filter as a part of each gas engine . However,
fuel filters are available from your Caterpillar dealer.

Consult your Caterpillar dealer about the

requirements for filtering your engine's fuel .
 47
Maintenance Section
Cooling System Specifications

Cooling Syste Many engine failures are related to the cooling

system . The following problems are related to
pe ific ti ns cooling system failures : overheating, leakage of the
water pump, plugged radiators or heat exchangers,
and pitting of the cylinder liners .
i01640527
These failures can be avoided with proper cooling
General Coolant Inf rrnation system maintenance . Cooling system maintenance
is as important as maintenance of the fuel system
SNICS Code: 1350 ; 1395 and the lubrication system . Quality of the coolant
is as important as the quality of the fuel and the
NOTICE lubricating oil.
Never add coolant to an overheated engine . Engine
damage could result . Allow the engine to cool first. Coolant is normally composed of three elements:
water, additives, and glycol .
NOTICE
If the engine is to be stored in, or shipped to an area Water
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temper- NOTICE
ature or drained completely to prevent damage. Never use water alone without Supplemental Coolant
Additives (SCA) or without inhibited coolant. Water
alone is corrosive at engine operating temperatures .
NOTICE Water alone does not provide adequate protection
Frequently check the specific gravity of the coolant for against boiling or freezing .
proper freeze protection or for anti-boil protection.
Water is used in the cooling system in order to
Clean the cooling system for the following reasons: transfer heat.

" Contamination of the cooling system Distilled water or deionized water is

recommended for use in engine cooling systems.
" Overheating of the engine
DO NOT use the following types of water in cooling
® Foaming of the coolant systems: hard water, softened water that has been
conditioned with salt, and sea water.
Note : Air pockets can form in the cooling system if
the cooling system is filled at a rate that is greater If distilled water or deionized water is not available,
than 20 L (5 US gal) per minute . use water with the properties that are listed in Table
11 .
After you drain the cooling system and after you
refill the cooling system, operate the engine .
Operate the engine without the filler cap until the
coolant reaches normal operating temperature and
the coolant level stabilizes . Ensure that the coolant
is maintained to the proper level.

NOTICE
Never operate an engine without water temperature
regulators in the cooling system . Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.

Refer to Special Instruction, SEBDO518, "Know

Your Cooling System" and Special Instruction,
SEBD0970, "Coolant and Your Engine" for more
detailed information .
48
Maintenance Section
Cooling System Specifications

Table 11 " Reduction of heat transfer -

Caterpillar Minimum Acceptable Water Requirements
e Leakage of the water pump seal
Property Maximum Limit ASTM Test
® Plugging of radiators, coolers, and small
40 mg/L "D512",
Chloride (CI) passages
(2 .4 grains/US gal) °D4327"

Sulfate (SO,)
100 mg/L
(5 .9 grains/US gal) "D516" Glycol
170 mg/L Glycol in the coolant helps to provide protection
Total Hardness "D1126"
(10 grains/US gal) against the following conditions:
340 mg/L
Total Solids °D1888" " Boiling
(20 grain/US gal)
Acidity pH of 5 .5 to 9.0 "D1293" " Freezing

For a water analysis, consult one of the following " Cavitation of the water pump and the cylinder liner
sources :
For optimum performance, Caterpillar recommends
" Caterpillar dealer a 1 :1 mixture of a water/glycol solution .

" Local water utility company Note: Use a mixture that will provide protection
against the lowest ambient temperature .
" Agricultural agent
Note: 100 percent pure glycol will freeze at a
" Independent laboratory temperature of -23 °C (-9 °F) .

Most conventional heavy-duty coolant/antifreezes

Additives use ethylene glycol . Propylene glycol may also be
used. In a 1 :1 mixture with water, ethylene and
Additives help to protect the metal surfaces of propylene glycol provide similar protection against
the cooling system . A lack of coolant additives freezing and boiling . See Tables 12 and 13.
or insufficient amounts of additives enable the
following conditions to occur: Table 12

" Corrosion Ethylene Glycol

Freeze Boil
" Formation of mineral deposits Concentration
Protection Protection

" Rust 50 Percent -36 °C (-33 °F) 106 °C (223 °F)

60 Percent -51 °C (-60 °F) 111 °C (232 °F)

" Scale

" Pitting and erosion from cavitation of the cylinder NOTICE

liner Do not use propylene glycol in concentrations that ex-
ceed 50 percent glycol because of propylene glycol's
" Foaming of the coolant reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against
Many additives are depleted during engine boiling or freezing .
operation . These additives must be replaced
periodically. This can be done by adding
Supplemental Coolant Additives (SCA) to Diesel
Engine Antifreeze/Coolant (DEAC) .

Additives must be added at the proper

concentration . Overconcentration of additives can
cause the inhibitors to drop out-of-solution . The
deposits can enable the following problems to
occur:

" Formation of gel compounds

 49
Maintenance Section
Cooling System Specifications

Table 13 In those engine applications that do not require

Propylene Glycol protection from boiling or freezing, a mixture
of SCA and water is acceptable . Caterpillar
Freeze Anti-Boil recommends a minimum of six percent to a
Concentration
Protection Protection maximum of eight percent SCA concentration in
50 Percent -29 °C (-20 °F) 106 °C (223 °F) those cooling systems . Distilled water or deionized
water is preferred . Water which has the acceptable
characteristics may be used . For the acceptable
To check the concentration of glycol, use the characteristics, see this publication, "General
1U-7298 Coolant/Battery Tester (Degree Celsius) Coolant Information" topic (Maintenance Section) .
or use the 1U-7297 Coolant/Battery Tester (Degree
Fahrenheit). The testers give readings that are Note : Table 14 is a list of the coolants that are
immediate and accurate . The testers can be used recommended and the service life (calendar) of
with ethylene or propylene glycol . the coolants . The service life of coolant is also
limited by use (service hours) . Refer to the specific
engine's Operation and Maintenance Manual,
101452829
"Maintenance Interval Schedule" (Maintenance
Coolant Recommendations Section) . To achieve this service life, the coolants
must be properly maintained . The maintenance
SMCS Code : 1350 ; 1352 ; 1395 program includes S-O-S coolant analysis .

Table 14
NOTICE
Do not use a commercial coolant/antifreeze that only Coolant Service Life -
meets the ASTM D3306 or D4656 specification. This Coolant Type Service Life
type of coolant/antifreeze is made for light duty auto-
motive applications . Caterpillar DEAC Three Years
Commercial Heavy-Duty
Coolant/Antifreeze that Two Years
The following coolants are the primary types of
meets "ASTM D5345"
coolants that are used in Caterpillar Gas Engines:
Commercial Heavy-Duty
Preferred - Caterpillar Diesel Engine Coolant/Antifreeze that One Year
Antifreeze/Coolant (DEAC) or a commercial meets "ASTM D4985"
heavy-duty coolant/antifreeze that meets "ASTM Caterpillar SCA and
D4985" or "ASTM D5345" specifications Two Years
Water

Acceptable - A mixture of Caterpillar Supplemental Commercial SCA and

One Year
Coolant Additive and water that has the acceptable Water
characteristics 1) The service life of coolant is also limited by use (service hours) .
Refer to the specific engine's Operation and Maintenance
Caterpillar recommends a 1 :1 mixture of water and Manual, "Maintenance Interval Schedule" (Maintenance
Section) .
glycol . This mixture will provide optimum heavy-duty
performance as a coolant/antifreeze .
101111753
Note : Caterpillar DEAC DOES NOT require a
treatment with an SCA at the initial fill . Commercial Diesel Engine Antifreeze/
heavy-duty coolant/antifreeze that meets °ASTM
D4985" or "ASTM D5345" specifications MAY
Coolant (DEA
require a treatment with an SCA at the initial fill .
SMCS Code : 1350 ; 1352 ; 1395
Read the label or the instructions that are provided
by the OEM of the product.
Caterpillar recommends using Caterpillar
Diesel Engine Antifreeze/Coolant (DEAC) for
cooling systems that require a heavy-duty
coolant/antifreeze . Caterpillar DEAC is an alkaline
single-phase ethylene glycol type antifreeze that
contains corrosion inhibitors and antifoam agents .

Caterpillar DEAC is formulated with the correct

amount of Caterpillar Supplemental Coolant Additive
(SCA) . Do no use SCA at the initial fill when DEAC
is used .
50
Maintenance Section
Cooling System Specifications

Containers of several sizes are available. Consult 101069295

your Caterpillar dealer for the part numbers.
le nt l la Additive
If concentrated DEAC is used, Caterpillar (CA)
recommends mixing the concentrate with distilled
water or with deionized water. If distilled water is SMCS Code : 1350; 1352; 1395
not available or deionized water is not available,
use water which has the required properties . For The use of SCA helps to prevent the following
the water properties, see this publication, "General conditions from occurring :
Coolant Information" topic (Maintenance Section) .
® Corrosion
101164588
* Formation of mineral deposits
Commercial Heavy-Duty
® Cavitation erosion of the cylinder liners
Coolant/Antifreeze and C
® Foaming of the coolant
SMCS Code: 1350 ; 1352 ; 1395
Caterpillar Diesel Engine Antifreeze/Coolant (DEAC)
If Caterpillar DEAC is not used, select a is formulated with the correct level of Caterpillar
coolant/antifreeze with low silicate content for SCA. When the cooling system is initially filled with
heavy-duty applications that meets "ASTM D5345" DEAC, adding more SCA is not necessary until the
or "ASTM D4985" specifications . concentration of SCA has been depleted . To ensure
that the correct amount of SCA is in the cooling
Note : When you are not using Caterpillar DEAC the system, the concentration of SCA must be tested
cooling system must be drained one time during on a scheduled basis. Refer to the specific engine's
every year. The cooling system must be flushed at Operation and Maintenance Manual, "Maintenance
this time as well. Interval Schedule".
When a heavy-duty coolant/antifreeze is used, Containers of SCA are available in several sizes .
treat the cooling system with three to six Consult your Caterpillar dealer for the part numbers.
percent Caterpillar SCA by volume . For more
information, see this publication, "Conventional
Coolant/Antifreeze Cooling System Maintenance" 101166959
topic (Maintenance Section) .
n entional Coolant/
If Caterpillar SCA is not used, select a commercial
SCA . The commercial SCA must provide a minimum
ntifreeze Cooling System
of 1200 mg/L or 1200 ppm (70 grains/US gal) of aintenance
nitrites in the final coolant mixture.
SMCS Code : 1350; 1352; 1395
Coolant/antifreeze that meets "ASTM D5345" or
"ASTM D4985" specifications MAY require treatment NOTICE
with SCA at the initial fill . These coolants WILL Never operate an engine without water temperature
require treatment with SCA on a maintenance basis. regulators in the cooling system . Water temperature
regulators help to maintain the engine coolant at the
When concentrated coolant/antifreeze is mixed, proper operating temperature . Cooling system prob-
Caterpillar recommends mixing the concentrate with lems can develop without water temperature regula-
distilled water or with deionized water . If distilled tors.
water or deionized water is not available, water
which has the required properties may be used . For
the water properties, see this publication, "General Check the coolant/antifreeze (glycol concentration)
Coolant Information" topic (Maintenance Section) . in order to ensure adequate protection against
boiling or freezing . Caterpillar recommends the
use of a refractometer for checking the glycol
concentration . Use the 1 U-7298 Coolant/Battery
Tester (Celsius) or use the 1U-7297 Coolant/Battery
Tester (Fahrenheit) . The testers give readings that
are immediate and accurate . The testers can be
used with ethylene or with propylene glycol .
 51
Maintenance Section
Cooling System Specifications

Adding the SCA to Conventional Test the coolant/antifreeze periodically for the
Coolant/Antifreeze at the Initial Fill concentration of SCA . For the interval, see the
specific engine's Operation and Maintenance
Manual, "Maintenance Interval Schedule"
Note : Caterpillar DEAC DOES NOT require an
(Maintenance Section) . SCA test kits are available
addition of SCA when the cooling system is initially
from your Caterpillar dealer . Test the concentration of
filled .
SCA or submit a coolant sample to your Caterpillar
dealer. For more information on coolant analysis,
Commercial heavy-duty coolant/antifreeze
see the Operation and Maintenance Manual, "S . 0-S
that meets "ASTM 134985" or "ASTM 135345"
Coolant Analysis" topic (Maintenance Section) .
specifications MAY require an addition of SCA when
the cooling system is initially filled . Read the label
Additions of SCA are based on the results of the
or the instructions that are provided by the OEM
test or based on the results of the coolant analysis .
of the product.
The size of the cooling system determines the
amount of SCA that is needed .
The size of the cooling system determines the
amount of SCA that is required . Use the equation
Use the equation that is in Table 17 to determine
that is in Table 15 to determine the amount of
the amount of Caterpillar SCA that is required .
Caterpillar SCA that may be required when the
cooling system is initially filled with heavy-duty Table 17
coolant/antifreeze that meets "ASTM D4985" or
°ASTM D5345" specifications . Equation For Adding The SCA To Conventional
Coolant/Antifreeze For Maintenance
Table 15 V x 0 .014 = X
Equation For Adding The SCA At The Initial Fill V is the total volume of the cooling system .
Coolant/Antifreeze That Meets "ASTM D4985"
or "ASTM 135345" Specifications (1) X is the amount of SCA that is required .
Vx0.045=X
Table 18 is an example for using the equation that
V is the total volume of the cooling system .
is in Table 17 .
X is the amount of SCA that is required .
Table 18
(1) Read the label or the instructions that are provided by the OEM
of the product . Example Of The Equation For Adding The SCA To
Conventional Coolant/Antifreeze For Maintenance
Table 16 is an example for using the equation that
Total Volume Factor for Amount of SCA
is in Table 15 . of the Cooling Multiplication that is Required
System (V) (X)
Table 16
Example of the Equation For Adding The 946L x0 .014 13L
SCA At The Initial Fill (250 US gal) ( - (3 .5 US gal)
Coolant/Antifreeze That Meets "ASTM 134985"
or "ASTM 135345" Specifications Note : Specific engine applications may require
Total Volume Factor for Amount of SCA maintenance practices to be periodically evaluated
of the Cooling Multiplication that is Required in order to properly maintain the engine's cooling
System (V) (X) system .

946 L x 0.045 43 L
Table 19 lists part numbers and quantities of SCA
(250 US gal) (11 US gal)
that is available from your Caterpillar dealer.

Adding the SC to Conventional Table 19

Caterpillar Liquid SCA

Coolant/Antifreeze For
Maintenance Part Number Quantity
8C-3680 19 L (5 US gal)
Heavy-duty coolant/antifreeze of all types REQUIRE
5P-2907 208 L (55 US gal)
oeriodic additions of an SCA.
52
Maintenance Section
Cooling System Specifications

Cleaning the Cooling System ®f The quality of the water is a very important factor
in this type of cooling system . Distilled water
Heavy-Duty Coolant/Antifreeze or deionized water is recommended for use in
cooling systems . If distilled water or deionized
Caterpillar Cooling System Cleaner dissolves
water is not available, use water that meets the
mineral scale, corrosion products, light oil
minimum requirements that are listed in the table for
contamination and sludge.
recommended water properties in this publication,
o Clean the cooling system after used coolant is "General Coolant Information" topic (Maintenance
Section).
drained or before the cooling system is filled with
new coolant . A cooling system that uses a mixture of SCA
and water only needs more SCA than a cooling
® Clean the cooling system whenever the coolant is
system that uses a mixture of glycol and water. The
contaminated or whenever the coolant is foaming .
SCA concentration in a cooling system that uses
SCA and water should be six to eight percent by
101318169 volume . Refer to Table 20 for the amount of SCA
that is required for various capacities of the cooling
Water/Supplemental lant system .
Additive ( ) Table 20
SMCS Code: 1350; 1352; 1395 Caterpillar SCA Requirements for SCA and
Water Coo ling Systems
NOTICE Cooling System Caterpillar SCA Caterpillar SCA
All Caterpillar diesel engines equipped with air-to-air Capacity at Initial Fill at 250 Hours
aftercooling (ATAAC) require a minimum of 30 percent 22 to 30 L
glycol to prevent water pump cavitation . 1 .75 L (64 fl oz) 0.44 L (15 fl oz)
(6 to 8 US gal)
31 to 38 L 2 .30 L (80 fl oz)
(9 to 10 US gal) 0.57 L (20 fl oz)
NOTICE
Never use water alone without Supplemental Coolant 39 to 49 L
Additives (SCA) or without inhibited coolant . Water 3 .00 L (100 fl oz) 0.75 L (25 fl oz)
(11 to 13 US gal)
alone is corrosive at engine operating temperatures .
Water alone does not provide adequate protection 50 to 64 L 3.90 L (128 fl oz) 0.95 L (32 fl oz)
against boiling or freezing . (14 to 17 US gal)
65 to 83 L 5 .00 L (168 fl oz) 1 .25 L (42 fl oz)
(18 to 22 US gal)
Note: Premix the coolant solution in order to provide
protection to the lowest ambient temperature that 84 to 110 L 6.60 L (224 fl oz) 1 .65 L (56 fl oz)
is expected . (23 to 29 US gal)
111 to 145 L 8 .75 L (296 fl oz)
Note: Pure undiluted antifreeze freezes at -23 °C 2.19 L (74 fl oz)
(30 to 38 US gal)
(-9 °F).
146 to 190 L 11 .50 L 2.88 L (98 fl oz)
In engine cooling systems that use water alone, (39 to 50 US gal) (392 fl oz)
Caterpillar recommends the use of SCA . SCA helps 191 to 250 L 15.00 L
to prevent the following conditions from occurring : (51 to 66 US gal) (512 fl oz) 3.75 L (128 fl oz)

e Corrosion
Refer to Table 21 for part numbers and for quantities
o Formation of mineral deposits of SCA .

® Cavitation erosion of the cylinder liner

e Foaming of the coolant

If Caterpillar SCA is not used, select a commercial

SCA . The commercial SCA must provide a minimum
of 2400 mg/L or 2400 ppm (140 grains/US gal) of
nitrites in the final coolant mixture .
 53
Maintenance Section
Cooling System Specifications

Table 21 Use the 8T-5296 Coolant Conditioner Test Kit to

Caterpillar Liquid SCA test the concentration of SCA . Make the following
modifications to Steps 3 and 5 of the 8T-5296
Part Number Quantity Coolant Conditioner Test Kit instructions :
6V-3542 0.24 L (8 oz)
STEP 3 - Add tap water to the vial up to the °20
111-2372 0.36 L (12 oz) ml" mark .
8T-1589 0.47 L (16 oz)
STEP 5 - When the defined procedure is used,
3P-2044 0.94 L (32 oz) a concentration of six to eight percent will yield
between 20 drops and 27 drops . If the number of
8C-3680 19 L (5 US gal)
drops is below 20 drops, the concentration of SCA
5P-2907 208 L (55 US gal) is low. If the number of drops is above 27 drops, the
concentration of SCA is high . Make the appropriate
Maintain the SCA in the same way as you would adjustments to the concentration of SCA .
maintain a cooling system that uses heavy-duty
coolant/antifreeze . Adjust the maintenance for the Test the concentration of SCA or submit a
amount of SCA additions . See Table 20 for the coolant sample to your Caterpillar dealer. See
amount of SCA that is required . this publication, "S .0-S Coolant Analysis" topic
(Maintenance Section) .

Cooling Systems with Larger Additions of SCA are based on the results of the
Capacities test or based on the results of the coolant analysis .
The size of the cooling system determines the
amount of SCA that is required .
Adding the SCA to Water at the Initial Fill
Use the equation that is in Table 22 to determine
Use the equation that is in Table 22 to determine
the amount of Caterpillar SCA that is required for
the amount of Caterpillar SCA that is required at maintenance, if necessary:
the initial fill . This equation is for a mixture of only
SCA and water. Table 24
Table 22 SCA To Water Addition Equation For Maintenance

Equation For Adding The SCA To Water Vx0.023= X

At The Initial Fill
V is the total volume of the cooling system .
Vx0 .07=X
X is the amount of SCA that is required .
V is the total volume of the cooling system .
X is the amount of SCA that is required . Table 25 is an example for using the equation that
is in Table 22 .
Table 23 is an example for using the equation that Table 25
is in Table 22 .
SCA To Water Addition Equation Example
Table 23 For Maintenance
Example Of The Equation For Adding The SCA Total Volume Multiplication Amount of SCA
To Water At The Initial Fill of the Cooling Factor that is Required
System (V) (X)
Total Volume Multiplication Amount of SCA
of the Cooling Factor that is Required 946 L x 0.023 22 L
System (V) (X) (250 US gal) (6 US gal) -J
946 L x 0.07 66 L
(250 US gal) (18 US gal) Note : Specific engine applications may require
maintenance practices to be periodically evaluated
in order to properly maintain the engine's cooling
Adding the SCA to Water for Maintenance system .

For the recommended service interval, refer to the Table 21 lists part numbers and quantities of SCA
Operation and Maintenance Manual, "Maintenance that is available from your Caterpillar dealer.
Interval Schedule" for your engine .
54
Maintenance Section
Cooling System Specifications

101069690 Caterpillar's S-0-S coolant analysis is a program

with two levels . The program is based on periodic
S-0-S Coolant Analysis samples. The samples are analyzed . The results
are reported, and appropriate recommendations are
SMCS Code : 1350 ; 1352 ; 1395 made according to the results .
Testing the engine coolant is important to ensure
that the engine is protected from internal cavitation S-0-S Coolant Analysis (Level I)
and from corrosion. The analysis also tests the
ability of the coolant to protect the engine from A coolant analysis (Level I) is a test of the properties
boiling and from freezing . of the coolant that includes the following items :

Coolant analysis can be performed at your Glycol concentration for protection from boiling
Caterpillar dealership . Caterpillar's S-0-S coolant and freezing
analysis is an excellent way to monitor the condition
of your coolant and your cooling system . " Ability to protect from erosion and corrosion

The most critical aspect of coolant analysis is pH

the interpretation of the results. The analyst must
be properly trained in order to provide a correct " Conductivity
diagnosis . The analyst must understand several
variables. Water hardness

Different coolants have different formulations and " Visual analysis

different condemning limits . Different commercial
labs may use different methods to test for the " Analysis of the odor
same variable . These other considerations are also
important for interpreting the results of a coolant The results are reported, and appropriate
analysis : recommendations are made .

" The number of hours on the sample S "S Coolant Analysis (Level Il)
" The equipment that uses the coolant A coolant analysis (Level II) is a comprehensive
chemical evaluation of the coolant. This analysis is
" The application of the equipment also a check of the overall condition of the inside
of the cooling system . The following services are
Analysts at Caterpillar's S-0-S fluid labs are trained provided :
to determine the acceptability of coolants . These
analysts have knowledge of the equipment and " Full Level I analysis
applications . These qualifications enable the
analysts to detect problems before damage occurs . " Identification of the source of metal corrosion and
of contaminants
NOTICE
Do not use the same vacuum sampling pump for ex- " Identification of buildup of the impurities that
tracting oil samples that is used for extracting coolant cause corrosion
samples.
" Identification of buildup of the impurities that
A small residue of either type sample may remain in cause scaling
the pump and may cause a false positive analysis for
the sample being taken. " Determination of possible electrolysis within the
engines' cooling system
Always use a designated pump for oil sampling and a
designated pump for coolant sampling . The results are reported, and appropriate
recommendations are made .
Failure to do so may cause a false analysis which
could lead to customer and dealer concerns . For more information on S-0-S coolant analysis,
consult your Caterpillar dealer.
 55
Maintenance Section
Refill Capacities

Refill a itie Table 28

Approximate Refill Capacities for the G3406
Engine Cooling System
101622547
Compartment or System Liters US Gallons
Refill Capacities Jacket Water System Only 32 8
SMCS Code; 1000; 1348; 1395 ; 7560 SCAC System Only 6.5 2

Lubrication System
The capacity of the Engine Crankcase includes the
capacity of the oil filters that are installed at the
factory. Auxiliary oil filter systems (if equipped) will
require additional oil .

For the recommended oil, refer to this Operation

and Maintenance Manual, "Engine Oil" topic
(Maintenance Section).

Table 26
Approximate Refill Capacity for the G3406
Engine Lubrication System
Compartment or System Liters US Gallons
Engine Crankcase (1) ( 76 ( 20
h> This is the approximate capacity of the engine crankcase sump.
Engines with auxiliary oil filters will require additional oil .

Capacities of Auxiliary Oil Filter Systems

Table 27
Approximate Capacities for Auxiliary
Oil Filter Systems
Capacity
Auxiliary Oil Capacity With Without
Filter System Elements Elements
4P-2781 Oil 87 L (23 US gal) 110 L (29 US gal)
Filter Assembly

Cooling System
To properly maintain the cooling system, the Total
Cooling System capacity must be determined. The
Total Cooling System capacity will vary between
individual installations . The External System
capacity can include the following components :
engine, expansion tank, heat exchanger, radiator,
and piping . Refer to the specifications that are
provided by Caterpillar or by the OEM of the
equipment . Record the Total Cooling System
capacity in the appropriate Table.

For the recommended coolant, refer to this

Operation and Maintenance Manual, "Coolant
Recommendations" (Maintenance Section).
56
Maintenance Section
Maintenance Interval Schedule

101846036 Gas Pressure Regulator Condensation - Drain . . . . 83

Hoses and Clamps - Inspect/Replace . ... . . . .... .. .. . . . 84
Maintenance Interval Schedule Ignition System Spark Plugs - Check/Adjust/
(Turbocharged Aftercooled Replace . ... . .... . . .. .. . ... . .... . . .... . .... . ..... .... . ... . . . .... .... . ..
Ignition System Timing - Check/Adjust ... . . . .... ..... . .
85
89
Engines) Inlet Air System - Inspect . .... . ... . . .... . .... . ... . . . .... . ... . . . 90
Radiator - Clean ... . . ... . .... . . .... . .... . . ... . .... . ... . . . .... .... . . . 97
SMCS Code: 1000 ; 4450 ; 7500
Initial 750 Service Hours
Before performing any operation or maintenance
procedures, ensure that the Safety Information, Valve Stem Projection - Measure/Record . . .... . ... . 101
warnings, and instructions are read and
understood. Every 1500 Service Hours

Before each consecutive interval is performed, all Actuator Control Linkage - Lubricate .. . ... . . . .... . . .... . 59
of the maintenance requirements from the previous Carburetor Air/Fuel Ratio - Check/Adjust . ...... .... . . . 63
interval must be performed . Crankcase Blowby - Measure/Record . ... . ...... .... . . . 68
Cylinder Pressure - Measure/Record . . ... . ...... . .... . . 69
Note: For information on generator maintenance, Engine Crankcase Breather - Clean ... . ... . .. .... . .... . . 74
see the Operation and Maintenance Manual for the Engine CM Filter (Auxiliary) - Change . . ... . ...... . .... . . 75
generator. Engine Protective Devices - Check . ... . . .. . . ...... .... . . . 80
Engine Speed/Timing Sensor - Clean/Inspect . .... . 81
When Required Speed Sensor - Clean/Inspect . . . ... . . ... . . ... . .. .... . ..... . 98

Engine Ad (leaner Element - Replace . .... . . .... .. ... . 71 Every 3000 Service Hours
Overhaul Considerations . ... . ... .. . .. ..... . 95
Valve Stem Projection - Measure/Record . . . .... . ... 101 Cooling System Coolant Analysis (Level 11) -
Obtain . . . ... . .... . . ... . .... . . ... . .... . . ... . . ... . . .... . ... . .. ..... . .... . 66
Daily Driven Equipment - Check . . . . ... . .... . . .... .... . ....... . .... . 70
Engine Mounts - Check . . .... . . ... . . .... . .... . ... . .. ..... . .... . 75
Air Tank Moisture and Sediment - Drain ... . . .... . ... . . 59 Ignition System Transformer Resistance - Test .. 89
Control Panel Inspect . .... .... . ... . .... . . ... . . ..... . .... ..... . 63 Inlet Air System -Inspect ..... . ... . .... . . .... . ... . .. ...... .... . 90
Cooling System Coolant Level - Check ..... . .... . .... . 66 Starting Motor - Inspect . . . .... . ... . . .... . .... . ... . . . .. .... .... . 99
Water Pump - Inspect . .... . .... . .. ... .... . .... . ... . . . .. .... ... 104
Driven Equipment - Inspect/Replace/Lubricate . . 70
Engine Air Cleaner Service Indicator - Inspect . .... 73
Engine Air Precleaner - Clean .. . . ... . . .... . . . ... . .... . . .... 74 Every 4000 Service Hours
Engine Oil Level - Check .. .... . ... . .... . . .... . .... . . . ... . . ... . 76
Fuel System Fuel Filter Differential Pressure - Alternator - Inspect ..... . ... . .... . . . ... . .... .... . ... . . . . . . ... . . ... 60
Check .. .... . ... . .. .... .... . ... . .... .... . ... . . ... . . .... . . . ... . . .... . . _ 83
Instrument Panel - Inspect .... . ... . .... . . .... . . .... . . .... . .... 90 Every 8000 Service Hours
Power Take-Off Clutch - Check/Adjust/Lubricate .. 96
Walk-Around Inspection . ... . ... . ... . . . .. . . .... . . . ... . . . ... . .. 102 Turbocharger - Inspect . .... .... . . . ... . .... .... . ..... . . . . .... . . 100

Every 250 Service Hours Between 9000 and 12 000 Service Hours

Engine OH Sample - Obtain 77 Overhaul (Top End) . . ... . .... ...... . ... . .... . ... . . . ... . . . . . .... ... 92

Every 750 Service Hours Between 18 000 and 24 000 Service Hours

Aftercooler Core - Clean/Test . . ... . .... . ..... . .... . . .... .... 59 Overhaul (Major) . .... . ... . .... . .... . . ... . .... . ... . . ... . . . . . . .... . .. 90
Alternator and Fan Belts - Inspect/Adjust/
Replace ... . . ... . . .... . . .... . ... .... ... . . .... . .... . . ... . . ..... . .... .... 60 Every 24 000 Service Hours or 3 Years
Battery Electrolyte Level - Check . .... .. . ..... 62 64
Cooling System Coolant (DEAL) - Change
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add . .. .. .. .. . . ... ... .. ... .. 67
Crankshaft Vibration Damper - Inspect .. . . . ... . . ... . . .. 68
Engine - Clean . .. .. .. . .. .. .. .. . .. . . . 70
Engine Oil and Filter - Change . ... ... . . . .. .. 78
Engine Valve Lash - Inspect/Adjust ... . ..... . ... .. . .... .. 81
Engine Valve Rotators - Inspect ... . ..... . ... .. . ... . . . ... . .. 81
Exhaust Piping - Inspect . .... .... . ... . . . .... . ..... . ..... . .... .. 82
Gas Pressure Regulator - Check . . . .... . . .... . ..... . .... .. 83
 57
Maintenance Section
Maintenance Interval Schedule

01846045 Inlet Air System - Inspect . . . ... . . .. . .... . .... . .. . . .... . ... . ... . 90
Radiator - Clean . . . ... . ... . .... . . ... . . .. . . ... . ... . ... . . .... .... . ... . 97
Maintenance Interval Schedule
(Naturally Aspirated Engines) Initial 750 Service Hours

SMCS Code: 1000; 4450 ; 7500 Engine Valve Rotators - Inspect . ... . . ... .... . . .... .... . ... . 81
Valve Stem Projection - Measure/Record ... . .... . .. 101
Before performing any operation or maintenance
procedures, ensure that the Safety Information, Every 1500 Service Hours
warnings, and instructions are read and Actuator Control Linkage - Lubricate . . ... . . .. . . .. .. . ... . 59
understood . Carburetor Air/Fuel Ratio - Check/Adjust ... . . .... . ... . 63
Crankcase Blowby - Measure/Record ... . ... . . .... . ... . 68
Before each consecutive interval is performed, all Cylinder Pressure - Measure/Record .... . ... . . ... . . ... . 69
of the maintenance requirements from the previous Engine Crankcase Breather - Clean . . .... . ... . . .... . ... . 74
interval must be performed . Engine Oil Filter (Auxiliary) - Change ... . .... . ... . . . ... . 75
Engine Protective Devices - Check ... .. . . . . 80
Note: For information on generator maintenance, Engine Speed/Timing Sensor - Clean/Inspect . . ... . 81
see the Operation and Maintenance Manual for the Engine Valve Lash - Inspect/Adjust . .. ... .. .. . 81
generator. Engine Valve Rotators - Inspect ... . .... . ... . .... .... . .... . . 81
Speed Sensor - Clean/Inspect . .... . .... . ... . .... .... . . .... . 98
When Required
Engine Air Cleaner Element - Replace . . . ... . .... ..... . 71 Every 3000 Service Hours
Overhaul Considerations ... . .... . ... . .... . ... . . .... . 95 Cooling System Coolant Analysis (Level 11) -
Valve Stem Projection - Measure/Record . . . .... .... 101 Obtain .. . ... . .... . . .... . ... . .... .... . . ... . .... . .... . ... . .... .... . .... . . 66
Driven Equipment - Check . . . . .. . ... . ..... . .. . . ... . .... . .... . . 70
Daily Engine Mounts - Check . .. .. ... .. .. .. .. .. . . 75
Ignition System Transformer Resistance - Test .. 89
Air Tank Moisture and Sediment - Drain . ... .... . .... . . 59
Inlet Air System - Inspect ... . . ... . ... . . .... . ... . ... . .... . .... . . 90
Control Panel - Inspect . . ... . ... . . .... . .... .... . . . ... . ... . .... . . 63
Starting Motor - Inspect . .... . . . .. . ... . . ... . . .. . . .... .... . . .. . . . 99
Cooling
Driven System Coolant Level - Check 66
Water Pump -Inspect .... .... . . ... . .... . .... . .. . . .... .... . . ... 104
Equipment - Inspect/Replace/Lubricate . . . 70
Engine Air Cleaner Service Indicator - Inspect ... . . 73
Engine Air Predeaner - Clean . ... . ... . .... . . . .. . .... . .... . . 74 Every 4000 Service Hours
Level
EngMe CM - Check .. . ... . . .. . . . ... . .... . ... . . ... . . .... . . 76 Alternator - Inspect ... . .... .... . . . ... ... . . ... . . ... . .... ..... . .... . 60
Fuel System Fuel Filter Differential Pressure -
Check . . . . . . . . . . . . . . . . . . . . . ... . .... . . ... . ... . . .... . . 83 Between 10 000 and 14 000 Service Hours
Instrument Panel - Inspect .... . .... . ... . . .... . ... . .... . . .... . . 90
Power Take-Off Clutch - Check/Adjust/Lubricate . . 96 Overhaul (Top End) ... . .... ..... . . ... .... . .... . ... . .... .. ... . . ... . 92
Walk-Around Inspection .... .... . ... . . . ... . .... . .... . ... . . .... 102
Between 20 000 and 28 000 Service Hours
Every 250 Service Hours
Overhaul (Major) . . . . ... . .... .... . . ... . ... . . .... . ... . .... . ... . . ... . . 90
Engine OH Sample - Obtain .. . . ... . .... . .... . ... . .... . . .... . . 77
Every 24 000 Service Hours or 3 Years
Every 750 Service Hours
Cooling System Coolant (DEAC) - Change ... . . ... . . 64
Alternator and Fan Belts - Inspect/Adjust/
Replace . . . .... . .... .... . .... . . ... . .... . ... . . . ... . .... . ... . .... . . ... . . . 60
Battery Electrolyte Level - Check . .. . . .... . ... . . ... . . .... . . 62
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add . . ....... .. .. ... . ... .. . . 67
Crankshaft Vibration Damper - Inspect . ... . .... . ..... . . 68
Engine - Clean ... .... . .... . . .... .... . ... . . . .. . . .... . . .. . .... . . ... . . . 70
Engine Oil and Filter - Change . . .. ... . . .. ... . 78
Exhaust Piping - Inspect ... .... . ... . . . .. . . .... . ... . . ... . . .... . . 82
Gas Pressure Regulator - Check . .. . . .... . ... . .... . . .... . . 83
Gas Pressure Regulator Condensation - Drain .. . . 83
Hoses and Clamps - Inspect/Replace 84
Ignition System Spark Plugs - Check/Adjust/
Replace . . .. . ... .. .. ..... . . .. .. .. .. . 85
Ignition System Timing - Check/Adjust 89
58 Section
Maintenance
Maintenance Interval Schedule

01846042 Engine Crankcase Breather - Clean . . ... . ... . . . .... . ... . 74

Engine Mounts - Check . . ... . . . .... . . .... . ... . . . .. . . . . .... . .... 75
Maintenance Interval Schedule Engine OH Sample - Obtain 77
(Standby Generator Set Engine Performance - Test
Engine Protective Devices - Check . . ... . .... .... .... . ... . 80
80
Engines) Engine Speed/Timing Sensor - Clean/Inspect . . . ... 81
Engine 'hive Lash - Inspect/Adjust . ... . . ... .... .... . 81
SMCS Code: 1000 ; 4450; 7500 Engine Valve Rotators -Inspect . . ... . . ... . .... ........ . .... 81
Gas Pressure Regulator - Check ... . . ... . .... ........ ... . 83
Before performing any operation or maintenance Gas Pressure Regulator Condensation - Drain . ... 83
procedures, ensure that the Safety Information, Hoses and Clamps - Inspect/Replace 84
warnings, and instructions are read and Ignition System Spark Plugs - Check/Adjust/
understood . Replace 85
Ignition System Timing - Check/Adjust --------- 89
Before each consecutive interval is performed, all Inlet Air System - Inspect . . . . ..... . .... . .... . .... . .. ...... . .... 90
of the maintenance requirements from the previous Radiator - Clean . .... . ... . . . ... . ...... . . .... . ... . . ... . ... . . .... . ... . 97
interval must be performed . Speed Sensor - Clean/Inspect . . .... . ... . .... . ... . . .... . . ... 98
Starting Motor - Inspect ... . ...... . ..... . ... . .... . ... . . .... . .... 99
Note: For information on generator maintenance, Turbocharger - Inspect . . ... . ...... . . .... . ... . .... . ... . . .... . . . 100
see the Operation and Maintenance Manual for the Water Pump - Inspect . . . ... . ...... . . .... . ... . .... .... . . .... . . . 104
generator.
Every 3 Years
Every Week
Batteries - Replace . . ... . . ... . ...... . . ... . . ... . .... .... . . ..... . . .. 61
Air Tank Moisture and Sediment - Drain . .... . ... . . . ... 59 Belts - Replace . . .... . ... . . . ... . ...... ...... . ... . .... .... . . .... . . . .. 63
Automatic Start/Stop -Inspect 61 Cooling System Coolant (DEAL) - Change 64
Battery Charger - Check 62 Exhaust Bypass - Inspect . ...... .... . . .... . ... . ... . . . .... . . . .. 82
Battery Electrolyte Level - Check . . ... .. .. .. .. 62 Exhaust Piping - Inspect .. . ..... . .... . . . ... . ... . .... . . . . .. . . . .. 82
Control Panel - Inspect . . . ... . . .... . ... . ... . .... . . .... . ... . . . ... 63 Governor - Inspect . . ... . . .... . .... . . .... . ... . . . ... . ... .. . .... . . . .. 84
Cooling System Coolant Level - Check 66 Hoses and Clamps - Replace . .. .. .... ... . 85
Engine Air Cleaner Service Indicator - Inspect . . ... 73 Ignition System Spark Plug Wires - Replace ..... . .. 85
Engine Air Precleaner - Clean 74 Ignition System Transformer Resistance - Test . . . ., 89
Engine Oil Level - Check .... . .... .... . ... . .... . . .... . ... . .... . 76 Water Temperature
Regulator - Replace .. .. . ...... . 104
Fuel System Fuel Filter Differential Pressure -
Check . ... . .... . ... . . . .. . .... ... . . .... . .... .... . ... . .... . . .... . ... . . . ... 83
Instrument Panel - Inspect . .. .. .. .. . .. .. . . . 90
Jacket Water Heater - Check .... .. . .. .. .. . .. 90
Standby Generator Set Maintenance
Recommendations .... ... . .... . .... .... . ... . . . .... .... . .... . . ... 98
Walk-Around Inspection . . ... . . .... .... . ... . ..... . .... . ... . . . . 103

Every 250 Service Hours or 1 Year

Engine Oil and Filter - Change .... . ... . ...... .... . ... . . . ... 78

Every Year
Actuator Control Linkage - Lubricate . . . .. ... .. 59
AUtercooler Core - Clean/Test . .. .. . .. .. .. . .. 59
Alternator- Impel . ... .. ... .. .... .. .. 60
Alternator and Fan Belts - Inspect/Adjust/
Replace . . . ..... ... . . ... . .... ... . . ... . .... .... . .... . . .... .... . .... . . ... 60
Carburetor Air/Fuel Ratio - Check/Adjust ... . . .... . . ... 63
Cooling System Coolant Analysis (Level 11) -
Obtain . ... . . .... ... . . ... . .... ... . . ... . .... . . . . . . ... . . .... .... . .... . . ... 66
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .. .. . ... .. .. .. . .. . . .. . .. 67
Crankcase Blowby - Measure/Record .... . ... . . .... . ... 68
Crankshaft Vibration Damper - Inspect ... . . .. . . . ... . ... 68
Cylinder Pressure - Measure/Record . .... . . ... . . ... . ... 69
Engine - Clean ... . ... . .... .... . ... . . . .. . . .... . ... . .... . . ... . . ... . . .. 70
Engine Air Cleaner Element - Replace ... . . ... . . ... . .. . 71
 59
Maintenance Section
Actuator Control Linkage - Lubricate

101622942

Actuator Control Linkage - Personal injury can result from air pressure .
Lubricate
Personal injury can result without following prop-
SMCS Code : 1265-086 er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes .

Pressurized air is the preferred method for removing

loose debris . Direct the air in the opposite direction
of the fan's air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move
the air nozzle in a direction that is parallel with the
tubes. This will remove debris that is between the
tubes.

Pressurized water may also be used for cleaning .

g00839869
Illustration 21 The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi) . Use pressurized
Apply grease to the grease fittings . Use a hand water in order to soften mud. Clean the core from
grease gun and lubricate the grease fittings with both sides.
MPGM .
Use a degreaser and steam for removal of oil and
Check the Linkage grease . Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
Check the linkage for proper operation. Adjust core with clean water.
the linkage, if necessary. For the adjustment
procedure, refer to the Service Manual, "Systems After cleaning, start the engine and accelerate the
Operation/Testing and Adjusting" module. engine to high idle rpm . This will help in the removal
of debris and drying of the core . Stop the engine .
Use a light bulb behind the core in order to inspect
101371758 the core for cleanliness. Repeat the cleaning, if
necessary.
Aftercooler Core - Clean/Test
(Air-To-Air Aftercooler) Inspect the fins for damage . Bent fins may be
opened with a "comb" .
SMCS Code: 1064-070 ; 1064-081 ; 1064
Note : If parts of the aftercooler system are repaired
Note : Adjust the frequency of cleaning according to or replaced, a leak test is highly recommended .
the effects of the operating environment.
Inspect these items for good condition : welds,
Inspect the aftercooler for these items: damaged mounting brackets, air lines, connections, clamps,
fins, corrosion, dirt, grease, insects, leaves, oil, and and seals. Make repairs, if necessary.
other debris . Clean the aftercooler, if necessary.
For more detailed information on cleaning and
For air-to-air aftercoolers, use the same methods inspection, see Special Publication, SEBD0518,
that are used for cleaning radiators. "Know Your Cooling System" .

i00351324

Tank Moisture and

it
Sediment - Drain
SMCS Code : 1466-543-M&S
Moisture and sediment in the air starting system
can cause the following conditions :
60
Maintenance Section
Alternator - Inspect

® Freezing Slippage of loose belts can reduce the efficiency

of the driven components . Vibration of loose belts
o Corrosion of internal parts can cause unnecessary wear on the following
components :
® Malfunction of the air starting system
o Belts

a Pulleys
When opening the drain valve, wear protective Bearings
gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could If the belts are too tight, unnecessary stress is
cause debris to be blown and result in personal placed on the components . This reduces the
injury. service life of the components .

1 . Open the drain valve that is on the bottom of Replacement

the air tank. Allow the moisture and sediment
to drain. For applications that require multiple drive belts,
replace the drive belts in matched sets . Replacing
2. Close the drain valve. one drive belt of a matched set will cause the new
drive belt to carry more load because the older
i00839754 drive belts are stretched . The additional load on the
new drive belt could cause the new drive belt to fail .
Alternat r ® Inspect
Alternator Belt Adjustment
SMCS Code : 1405-040

Inspect the alternator for the following conditions :

® Loose connections

® Proper charging of the battery

Observe the ammeter during engine operation in

order to ensure proper battery performance and/or
proper performance of the electrical system .

Make repairs, if necessary. See the Service Manual

for service procedures . Consult your Caterpillar
dealer for assistance .

i01368836

Alternator and Fan Belts -

Inspect/Adjust/Replace
g00741969
SMCS Code: 1357-025 ; 1357-040; 1357-510 ; 1405 Illustration 22
(1) Adjusting nuts
Inspection (2) Mounting bolt

Inspect the alternator belt and the fan drive belts for 1 . Remove the drive belt guard .
wear and for cracking . Replace the belts if the belts
are not in good condition. 2. Loosen mounting bolt (2) and adjusting nuts (1).

Check the belt tension according to the information 3. Turn adjusting nuts (1) in order to increase or
in the Service Manual, "Specifications" . decrease the drive belt tension .
4. Tighten adjusting nuts (1) . Tighten mounting bolt
(2).
 61
Maintenance Section
Automatic Start/Stop - Inspect

5. Reinstall the drive belt guard. 101041029

If new drive belts are installed, check the drive belt aeries - elate
tension again after 30 minutes of engine operation
at the rated rpm. SMCS Code : 1401-510

Fan Drive Belt Adjustment WARNING

1 . Loosen the mounting bolt for the pulley . Batteries give off combustible gases which can
explode. A spark can cause the combustible gas-
2. Loosen the adjusting nut for the pulley. es to ignite . This can result in severe personal in-
jury or death.
3. Move the pulley in order to adjust the belt
tension. Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
4. Tighten the adjusting nut. der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
5. Tighten the mounting bolt . serviced.

101039675
1 . Turn the key start switch to the OFF position .
Remove the key and all electrical loads.
Automatic Start/ top - Inspect
2. Turn OFF the battery charger. Disconnect the
(Generator Set) charger.
SMCS Code: 4462 3. The NEGATIVE "-" cable connects the NEGATIVE
-" battery terminal to the ground plane .
The generator set must be ready to operate under a Disconnect the cable from the NEGATIVE "-"
load at any time . After performing maintenance on battery terminal .
the generator set, inspect the position of the control
switches . Ensure the following conditions : 4. The POSITIVE °+" cable connects the POSITIVE
"+" battery terminal to the starting motor.
" The starting system is enabled . Disconnect the cable from the POSITIVE
battery terminal .
" The control switches are in the correct position
for automatic starting . Note : Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
" The switchgear and the automatic transfer recycling facility.
switches that are associated with the generator
are enabled . 5. Remove the used battery.
For more information, see the Operation and 6. Install the new battery.
Maintenance Manual for the generator and the
control panel . Note : Before connecting the cables, ensure that the
key start switch is OFF

7. Connect the cable from the starting motor to the

POSITIVE "+" battery terminal .

8. Connect the cable from the ground plane to the

NEGATIVE "-" battery terminal .
62
Maintenance Section
Battery Charger - Check

101039758 ® The battery emits smoke or a dense vapor (gas) .

attery Charger - heck Perform one of the following procedures if the
battery shows symptoms of overcharging :
SMCS Code: 1401-535
® Reduce the rate of charging by a significant
Checking Before Start-Up amount. Complete the charging at the reduced
rate .
Check the battery charger for proper operation . If
the batteries are properly charged, the needle of e Turn OFF the charger .
the ammeter will register near "0" (zero) .
Table 29 describes the effects of overcharging on
The battery charger must not produce excessive different types of batteries.
current during start-up. Alternatively, the charger
must be automatically disconnected for start-up . Table 29
If the engine has an alternator, the charger must Effects of Overcharging Batteries
be automatically disconnected during start-up and
during engine operation . Type of Battery Effect

Charging the Battery Caterpillar General Service All of the battery cells have
Batteries a low level of electrolyte .
Caterpillar Premium High
g WARNING Output Batteries

Never disconnect any charging unit circuit or bat-

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

3. Connect the POSITIVE "+" lead of the charger

to the POSITIVE "+" battery terminal . Connect
hecking After Stopping
the NEGATIVE "-" lead of the charger to the Ensure that the battery charger is connected
NEGATIVE °-" battery terminal . properly. Observe the meter of the charger. Record
the amperage.
4. Turn ON the battery charger.

Overcharging of Batteries 101639002

Overcharging reduces the service life of batteries . attery Electrolyte Level -

Use a battery charger that will not overcharge the
battery. DO NOT charge the battery if the meter of
Check
the battery charger is in the RED zone . SMCS Code: 1401-535-FLV
Overcharging is indicated by the following When the engine is not run for long periods of
symptoms : time or when the engine is run for short periods,
the batteries may not fully recharge. Ensure a full
a The battery is very warm to the touch . charge in order to help prevent the battery from
freezing. If batteries are properly charged, ammeter
® A strong odor of acid is present . reading should be very near zero.
 63
Maintenance Section
Belts - Replace

Check the belt tension according to the information

in the Service Manual, "Specifications" module.
All lead-acid batteries contain sulfuric acid which To adjust the belt tension, see this Operation and
can burn the skin and clothing . Always wear a face Maintenance Manual, "Alternator and Fan Belts
shield and protective clothing when working on or - Inspect/Adjust/Replace" topic (Maintenance
near batteries. Section) .
After new belts are installed, check the belt tension
Remove the filler caps. Maintain the electrolyte again after 30 minutes of engine operation at rated
level to the "FULL" mark on the battery. rpm.

If the addition of water is necessary, use distilled

water. If distilled water is not available use 101005891

clean water that is low in minerals. Do not use

artificially softened water.
Carburetor Air/Fuel Rati
Check/Adjust
2. Check the condition of the electrolyte with the
1U-7298 Coolant/Battery Tester (°C) or the SMCS Code : 1266-535; 1266
1U-7297 Coolant/Battery Tester (°F) .
An engine failure may occur if the air/fuel ratio is
3. Keep the batteries clean. not appropriate for the fuel and for the operating
conditions . The service life of the turbocharger, of
Clean the battery case with one of the following the valves, and of the other components may be
cleaning solutions : reduced.

" A mixture of 0 .1 kg (0.2 lb) of baking soda and Ensure that the carburetor is adjusted properly so
1 L (1 qt) of clean water that the air/fuel ratio is correct .

" A mixture of 0.1 L (0.11 qt) of ammonia and For information on adjusting the carburetor, refer
1 L (1 qt) of clean water to the Service Manual, "Systems Operation/Testing
and Adjusting", or refer to the Special Instruction,
Thoroughly rinse the battery case with clean "Installation and Initial Start-Up Procedure" .
water.
Use a fine grade of sandpaper to clean the 101762721

terminals and the cable clamps. Clean the items

until the surfaces are bright or shiny. DO NOT
Control Panel - Inspect
remove material excessively. Excessive removal SMCS Code : 4490-040 ; 7451-040
of material can cause the clamps to not fit
properly . Coat the clamps and the terminals with Inspect the condition of the panel. If a component is
5N-5561 Silicone Lubricant, petroleum jelly or damaged, ensure that the component is repaired or
MPGM grease . that the component is replaced . If equipped, ensure
that the electronic displays are operating properly.
101041135
Inspect the wiring for good condition. Ensure that
Belts - Replace the wiring connections are secure .

SMCS Code : 1357-510 ecord the Data and Review the

Remove the used fan drive belt and the accessory Data
drive belt . Install new belts.
If equipped, check the gauges and check the
For applications that require multiple drive belts, indicators frequently during normal operation .
replace the belts in matched sets . Used belts are Record the data in a log . Compare the new data to
stretched . Replacing only one belt of a matched set the data that was previously recorded . Comparing
will cause the new belt to carry an excessive load . the new data to the recorded data will establish the
The additional load on the new belt could cause the normal gauge readings for the engine . A gauge
new belt to break. reading that is abnormal may indicate a problem
with operation or with the gauge.
64
Maintenance Section
Cooling System Coolant (DEAL) - Change

101622967 3. Open the cooling system drain valve. Remove

the engine block drain plug.
Cooling System Coolant
(DEAC) ® Change NOTICE
Dispose of used engine coolant properly or recycle .
SMCS Code : 1350-044 Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems . The full
Clean the cooling system before the recommended distillation procedure is the only method acceptable by
maintenance interval if the following conditions exist: Caterpillar to reclaim the used coolant.
® The engine overheats frequently.
For information regarding the disposal and the
e Foaming is observed . recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology
" Oil has entered the cooling system and the Group :
coolant is contaminated .
Outside Illinois : 1-800-542-TOOL
Inside Illinois : 1-800-541-TOOL
Drain the Cooling system Canada: 1-800-523-TOOL
1 . Stop the engine and allow the engine to cool .
Ensure that the engine will not start when the Clean the Cooling System
cooling system is drained .
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 valve. Clean the

engine block drain plug and install the plug.

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

NOTICE
Illustration 23 g00781022
Fill the cooling system no faster than 19 L (5 US gal)
(1) Filler cap per minute to avoid air locks.
(2) Drain valve

2. Loosen the cooling system filler cap slowly 3. Fill the cooling system with a mixture of clean
in order to relieve any pressure . Remove the water and Caterpillar Fast Acting Cooling System
cooling system filler cap . Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity . Install
the cooling system filler cap .

4. Start the engine . Operate the engine for

a minimum of 30 minutes with a coolant
temperature of at least 82 °C (180 °F) .

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

Loosen the cooling system filler cap slowly in
order to relieve any pressure . Remove the cooling
system filler cap . Open the cooling system drain
valve. Remove the engine block drain plug.

Illustration 24 g00719034

Engine block drain plug

 65
Maintenance Section
Cooling System Coolant (DEAC) - Change

NOTICE NOTICE
Improper or incomplete rinsing of the cooling system Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com- can result in damage to copper and other metal com-
ponents. ponents.
To avoid damage to the cooling system, make sure To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa- to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the ter. Continue to flush the system until all signs of the
cleaning agent are gone. cleaning agent are gone.

6. Allow the water to drain . Flush the cooling system 6. Flush the cooling system with clean water until
with clean water until the water that drains is the water that drains is clean. Close the cooling
clean . Close the cooling system drain valve. system drain valve . Clean the engine block drain
Clean the engine block drain plug and install the plug and install the plug .
plug.
Fill the Cooling System
Cleaning a Cooling System that
has Heavy Deposits or Plugging NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
Note: For the following procedure to be effective, per minute to avoid air locks.
there must be an active flow through the cooling
system components .
Note : For information about the proper coolant
1 . After the cooling system has been drained, flush to use, refer to the Operation and Maintenance
the cooling system with clean water in order to Manual, "Coolant Recommendations" (Maintenance
remove any debris . Section) . For the capacity of the cooling system,
refer to the Operation and Maintenance Manual,
2. Close the cooling system drain valve. Clean the "Refill Capacities" (Maintenance Section) .
engine block drain plug and install the plug.
Fill the cooling system with coolant/antifreeze . Do
not install the cooling system filler cap .
NOTICE
Use of commercially available cooling system clean- 2. Start the engine . Operate the engine in order
ers may cause damage to cooling system compo- to purge the air from the cavities of the engine
nents. Use only cooling system cleaners that are ap- block. Allow the coolant to warm and allow the
proved for Caterpillar engines. coolant level to stabilize. Stop the engine .

3. Check the coolant level. Maintain the coolant to

NOTICE the proper level on the sight gauge (if equipped).
Fill the cooling system no faster than 19 L (5 US gal) If a sight gauge is not equipped, maintain the
per minute to avoid air locks. coolant within 13 mm (0.5 inch) below the bottom
of the filler pipe.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System 4. Clean the cooling system filler cap . Inspect the
Cleaner. Add 0 .5 L (1 pint) of cleaner per gaskets of the cooling system filler cap. If the
3.8 to 7.6 L (1 to 2 US gal) of the cooling system gaskets of the cooling system filler cap are
capacity. Install the cooling system filler cap . damaged, discard the old cooling system filler
Install vent plug (4) . cap and install a new cooling system filler cap. If
the gaskets of the cooling system filler cap are
4. Start the engine . Operate the engine for not damaged, use a 9S-8140 Pressurizing Pump
a minimum of 90 minutes with a coolant in order to pressure test the cooling system filler
temperature of at least 82 °C (180 °F). cap . The correct pressure is stamped on the face
of the cooling system filler cap . If the cooling
5. Stop the engine and allow the engine to cool . system filler cap does not maintain the correct
Loosen the cooling system filler cap slowly pressure, install a new cooling system filler cap.
in order to relieve any pressure . Remove the
cooling system filler cap. Open the cooling 5. Start the engine . Inspect the cooling system for
system drain valve. Remove the engine block leaks and for proper operating temperature .
drain plug . Allow the water to drain.
66
Maintenance Section
Cooling System Coolant Analysis (Level II) - Obtain

101065859 101197583

Cooling System C plant ooling System Coolant Level

Analysis (Level 11) - btain - Check
SMCS Code: 1350 SMCS Code: 1350-535-FLV

For conventional heavy-duty coolant/antifreeze, Check the coolant level when the engine is stopped
check the concentration of supplemental coolant and cool.
additive (SCA) regularly. The concentration of SCA
can be checked with an S-O-S coolant analysis
(Level I). A more detailed coolant analysis is
recommended periodically.

For example, considerable deposits are found in the

water jacket areas on the external cooling system,
but the concentrations of coolant additives were
carefully maintained . The coolant water probably
contained minerals which were deposited on the
engine over time.

A coolant analysis can be conducted in order to

verify the condition of the water that is being used 01
in the cooling system . A full water analysis may be g00285520
Illustration 25
obtained from the following sources:
Cooling system filler cap
e Caterpillar dealer

® Local water utility company A WARNING

Pressurized System : Hot coolant can cause seri-
" Agricultural agent
ous burns . To open the cooling system filler cap,
stop the engine and wait until the cooling system
® Independent laboratory components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
Caterpillar recommends an S-O-S coolant analysis
sure.
(Level II) . This is a comprehensive chemical
evaluation of the coolant . This analysis is also a
check of the overall condition of the inside of the 1 . Remove the cooling system filler cap slowly in
cooling system . The following services are provided : order to relieve pressure .

" Full Level I analysis 2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe . If the engine is
" Identification of the source of metal corrosion and equipped with a sight glass, maintain the coolant
of contaminants level to the proper level in the sight glass .

" Identification of buildup of the impurities that

cause corrosion

" Identification of buildup of the impurities that

cause scaling

" Determination of possible electrolysis within the

engines' cooling system

A report of the results of the analysis is provided.

Maintenance recommendations are based on the
results .

For more information about S-O-S coolant analysis,

g00103639
consult your Caterpillar dealer. Illustration 26
Typical filler cap gaskets
 67
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

3. Clean the cooling system filler cap and check the Sao-S Coolant nalysis (Level I)
condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets Level I is a basic analysis of the coolant. The
are damaged . Reinstall the cooling system filler following items are tested : SCA concentration,
cap. glycol concentration, pH, and conductivity.
4. Inspect the cooling system for leaks. The results are reported, and recommendations
are made according to the results. Consult your
Caterpillar dealer for information on the benefits of
101613281
managing your equipment with an S-O-S analysis .
Cooling System Supplemental
Coolant Additive (SCA) Add the SCA, If Necessary
Test/Add
A WARNING
SMCS Code: 1352-045 ; 1395-081
Pressurized System: Hot coolant can cause seri-
This maintenance procedure is required for ous burns. To open the cooling system filler cap,
conventional coolants such as DEAC and for stop the engine and wait until the cooling system
mixtures of water and SCA. components are cool . Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
WARNING
Cooling system coolant additive contains alkali . 1 . Remove the cooling system filler cap slowly.
To help prevent personal injury, avoid contact with
the skin and eyes . Do not drink cooling system Note : Always dispose of fluids according to local
coolant additive . regulations.

2. If necessary, drain some coolant in order to allow

Note : Test the concentration of the SCA or obtain an space for the addition of the SCA.
S-O-S coolant analysis (Level I).
NOTICE
Test the Concentration of the SCA Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
Coolant/Antifreeze and SCA faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer
NOTICE could cause cracking of the cylinder head and other
Do not exceed the recommended six percent supple- high temperature components .
mental coolant additive concentration.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat exchang-
Test the concentration of the SCA with the 8T-5296 er, overheating, and/or accelerated wear of the water
Coolant Conditioner Test Kit or the 4C-9301 Coolant pump seal .
Conditioner Test Kit. Follow the instructions that are
on the label of the test kit. Do not exceed the recommended amount of supple-
mental coolant additive concentration.
Water and SCA
3. Add the proper amount of SCA. The
NOTICE concentration of the SCA depends on the type
Do not exceed the recommended eight percent sup- of coolant that is used.
plemental coolant additive concentration.
a. For cooling systems that use conventional
Test the concentration of the SCA with the 8T-5296 coolant/antifreeze, refer to this Operation
Coolant Conditioner Test Kit. Follow the instructions and Maintenance Manual, "Conventional
that are in this Operation and Maintenance Manual, Coolant/Antifreeze Cooling System
"Water/Supplemental Coolant Additive (SCA)" topic Maintenance" topic (Maintenance Section) .
(Maintenance Section) .
68
Maintenance Section
Crankcase Blowby - Measure/Record

b. For cooling systems that use only a mixture " The piston rings are not seated properly.
of water and SCA, refer to this Operation and
Maintenance Manual, "Water/Supplemental " Worn parts such as valve guides were not
Coolant Additive (SCA)" topic (Maintenance replaced .
Section) .
Excessive blowby may indicate the need for an
4. Clean the cooling system filler cap. Install the overhaul . By keeping a record of the results, a
cooling system filler cap . gradual increase in the amount of the blowby will
be noted until the amount has become excessive .
101333307
To measure the blowby, use the 8T-2700
Crankcase I®wb Blowby/Air Flow Indicator. Refer to Special
Instruction, SEHS8712, "Using the 8T-2700
Measure/Record Blowby/Airflow Indicator Group" . The instruction is
provided with the tool.
SMCS Code : 1317
Keep a record of the results.
Note: For a new G3400 Engine, the typical
range for crankcase blowby is approximately For more information, see the Service Manual,
22 to 37 L/Bkw-hr (0.6 to 1 .0 cu ft/Bhp-hr) . "Systems Operation/Testing and Adjusting" . For
assistance, consult your Caterpillar dealer.
Measure the crankcase blowby of new engines.
Record the data . Continue to periodically measure
the blowby. Comparing the recorded data to the 101333457

new data provides information about the condition Crankshaft Vibration Damper
of the engine .
® Insect
Note: Crankcase blowby is one of the three factors
that help to determine the major overhaul interval . SMCS Code : 1205-040
For more information, see this Operation and
Maintenance manual, "Overhaul (Major)" topic Damage to the crankshaft vibration damper or
(Maintenance Section) . failure of the crankshaft vibration damper can
increase torsional vibrations. This can result in
After a new engine is used for a short time, the damage to the crankshaft and to other engine
blowby can decrease as the piston rings are components. A deteriorating damper can cause
seated . The blowby will gradually increase as the excessive gear train noise at variable points in the
following components show wear: speed range.

" piston rings The damper is mounted to the crankshaft which is

located behind the belt guard on the front of the
" cylinder liners engine .

Note : A problem with the piston rings causes the

oil to deteriorate rapidly. Information regarding the
amper
condition of the piston rings can be obtained from The visconic damper has a weight that is located
the measurement of the blowby and the results of inside a fluid filled case. The weight moves in the
oil analysis . case in order to limit torsional vibration.
The blowby of a worn engine may exceed the Inspect the damper for evidence of fluid leaks. If
blowby of a new engine by two times or more . a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone . Silicone has
A sudden increase in blowby could indicate a the following characteristics: transparent, viscous,
broken piston ring . The following conditions are smooth, and adhesive .
other potential sources of blowby :
If the fluid leak is oil, inspect the crankshaft seals for
" Worn valve guides leaks. If a leak is observed, replace the crankshaft
seals.
" A turbocharger seal that leaks
Inspect the damper and repair or replace the
A rebuilt engine can have a high blowby due to the damper for any of the following reasons:
following factors:
 69
Maintenance Section
Cylinder Pressure - Measure/Record

® The damper is dented, cracked, or leaking . ® A broken piston ring

e The paint on the damper is discolored from heat. e Worn piston rings

o The engine has had a failure because of a broken e Worn cylinder liners
crankshaft .
If the cylinder pressure has risen by one or more
" Analysis of the oil has revealed that the front main compression ratios, the engine needs a top end
bearing is badly worn. overhaul in order to remove deposits . Failure to
remove the deposits will increase the chance for
® There is a large amount of gear train wear that is detonation . Severe guttering of the valves will occur.
not caused by a lack of oil .
To measure the cylinder pressure, use the
Refer to the Service Manual or consult your 193-5859 Cylinder Pressure Gauge Gp . Follow the
Caterpillar dealer for information about damper procedure in the Special Instruction, NEHS0798
replacement. that is included with the gauge group . Record
the pressure for each cylinder. Use the Operation
and Maintenance Manual, "Valve Data Sheet"
101519864
(Reference Materials Section).
Cylinder Pressure - Illustration 27 is a graph of typical cylinder pressures
Measure/Record for engines with different compression ratios.

SMCS Code: 1223-082-CC ; 1223 ; 7450-082

2136 (310)
Measure the cylinder pressure of new engines. 2067 (300)
Record the data. Continue to periodically measure 1998 (290)
the cylinder pressure . Comparing the recorded data
to the new data provides information about the 1929 (280)
condition of the engine. 1860 (270)
1791 (260)
Note: Cylinder pressure is one of the three
1723 (250)
factors that help to determine the major overhaul
interval. For more information, see this Operation 1654 (240)
and Maintenance manual, "Overhaul (Major)" 1585 (230)

a
(Maintenance Section) .
1516 (220)
Cylinder pressure can be measured during 1447 (210)
inspection of the spark plugs. Use the following 1378 (200)
guidelines for checking the cylinder pressure :
1309 (190)
® Remove all of the spark plugs . 1240 (180) LVA

1171 (170)
® Fully open the throttle plate .
1102 (160)
" Minimize the cranking time. This will enable a 1034 (150)
maximum consistent cranking speed for the 965 (140)
check. Also, the battery power will be conserved .
7 :1 8:1 9:1 10 :1 11 :1 12 :1
Y X
A loss of cylinder pressure or a change of pressure
in one or more cylinders may indicate the following Illustration 27 g00760309
conditions . These conditions may indicate a (Y) Cylinder pressure in kPa (psi)
problem with lubrication : (X) Compression ratio
(1) Normal range for cylinder pressure
® Excessive deposits

® Guttering of valves

e A broken valve

® A piston ring that sticks

70
Maintenance Section
Driven Equipment - Check

100449093 101664717

Driven Equipment - Check Engine - Clean

SMCS Code: 3279-535 SMCS Code: 1000-070

To minimize bearing problems and vibration of

the engine crankshaft and the driven equipment, g WARNING
the alignment between the engine and driven Personal injury or death can result from high volt-
equipment must be maintained properly. age.
Check the alignment according to the instructions Moisture could create paths of electrical conduc-
that are provided by the following manufacturers: tivity.
" Caterpillar Make sure the unit is off line (disconnected from
utility and/or other generators), locked out and
" OEM of the coupling tagged "Do Not Operate" .
" OEM of the driven equipment
NOTICE
i00935098
Water or condensation can cause damage to gen-
erator components . Protect all electrical components
Driven Equipment - from exposure to water.
Inspect/Replace/Lubricate
NOTICE
SMCS Code: 3279-040 Accumulated grease and oil on an engine is a fire haz-
ard . Keep the engine clean. Remove debris and fluid
Observe the driven equipment during operation. spills whenever a significant quantity accumulates on
Look for the following items: the engine .
" Unusual noise and vibration
Steam cleaning the engine will remove accumulated
" Loose connections oil and grease . A clean engine provides the
following benefits :
" Damaged parts
" Easy detection of fluid leaks
Perform any maintenance that is recommended
by the OEM of the driven equipment. Refer to the " Maximum heat transfer characteristics
literature of the OEM of the driven equipment for the
following service instructions . " Ease of maintenance

" Inspection Note : For more information on cleaning and drying

electric generators, refer to Special Instruction,
" Lubricating grease and lubricating oil SEHS9124, "Cleaning and Drying of Electric Set
requirements Generators".

" Specifications for adjustment

" Replacement of components

" Requirements for ventilation
 71
Maintenance Section
Engine Air Cleaner Element - Replace

101749609

Engine Air leaner Element

Replace
SMCS Code: 1051-510; 1054-510

NOTICE
Never run the engine without an air cleaner element
installed . Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air
borne debris from entering the air inlet. Illustration 28 g00317608

Fasteners for the air cleaner cover

NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine .

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
pressure can split the filter material of the element.
Unfiltered air will drastically accelerate internal
engine wear. Your Caterpillar dealer has the proper
air cleaner elements for your application.

The air cleaner may be mounted high above the

engine . If necessary, use a ladder or a platform to Illustration 29
g00781084

reach the air cleaner. (1) Cover

(2) Element
" Check the precleaner (if equipped) daily for (3) Air inlet
accumulation of dirt and debris . Remove any dirt
and debris, as needed . 1 . Release the fasteners for cover (1).

" Operating conditions (dust, dirt and debris) may 2. Remove the cover and element (2) .
require more frequent service of the air cleaner
element. 3. Cover air inlet (3) with tape in order to keep dirt
out.
" The air cleaner element may be cleaned up to
six times if the element is properly cleaned and 4. Clean the inside of the cover and the body with
inspected. a clean, dry cloth.

" The air cleaner element should be replaced 5. Remove the tape for the air inlet. Install a new
at least one time per year. This replacement element or a clean element.
should be performed regardless of the number
of cleanings. 6. Install the cover.

Replace the dirty paper elements with clean 7. If necessary, reset the air cleaner service
elements . Before installation, thoroughly inspect the indicator.
element for tears and/or holes in the filter material .
Inspect the gasket or the seal of the element for
damage . Maintain a supply of suitable elements for
replacement purposes.
72
Maintenance Section
Engine Air Cleaner Element - Replace

Cleaning the rimary it leaner Aim the hose so that the air flows inside the element
Elements along the length of the filter in order to help prevent
damage to the paper pleats . Do not aim the stream
The primary air cleaner element can be used up of air directly at the primary air cleaner element.
to six times if the element is properly cleaned and Dirt could be forced into the pleats .
inspected . When the element is cleaned, check the
filter material for rips or tears . Replace the element Note : Refer to "Inspecting the Primary Air Cleaner
at least one time per year regardless of the number Elements" .
of cleanings.
Vacuum Meaning
Use clean elements while dirty elements are being
cleaned . Vacuum cleaning is a good method for cleaning
elements which require daily cleaning because of a
NOTICE dry, dusty environment . Cleaning with pressurized
Do not clean the air cleaner elements by bumping or air is recommended prior to vacuum cleaning .
tapping. This could damage the seals. Do not use el- Vacuum cleaning will not remove deposits of carbon
ements with damaged pleats, gaskets or seals. Dam- and oil .
aged elements will allow dirt to pass through . Engine
damage could result . Note: Refer to "Inspecting the Primary Air Cleaner
Elements" .

Visually inspect the elements before cleaning . Inspecting the Primary Air Cleaner
Inspect the elements for damage to the seal, the
gaskets, and the outer cover. Discard any damaged Elements
elements.
Air cleaner elements can be cleaned with
pressurized air and with a vacuum .

Pressurized Air
Pressurized air can be used to clean elements
that have not been cleaned more than two times.
Pressurized air will not remove deposits of carbon
and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi) .

Illustration 31 g00281693

Inspect the clean, dry element. Use a 60 watt blue

light in a dark room or in a similar facility. Place
the blue light in the element. Rotate the element.
Inspect the element for tears and/or holes . Inspect
the element for light that may show through the filter
material . If it is necessary in order to confirm the
result, compare the element to a new element that
has the same part number.

Do not use an element that has any tears and/or

holes in the filter material . Do not use an element
g00281692
Illustration 30 with damaged pleats, gaskets or seals. Discard
damaged elements .
Note : When the elements are cleaned, always begin
with the clean side (inside) in order to force dirt Storing Primary Air Cleaner Elements
particles toward the dirty side (outside).
If an element that passes inspection will not be
used immediately, store the element for future use.
 73
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

g00281694 g00517797
Illustration 32 Illustration 33
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, service indicator.
wrap the elements in Volatile Corrosion Inhibited
(VCI) paper. Observe the service indicator . Clean the air cleaner
element or replace the element when the following
Place the element into a cardboard box for storage. 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 3.7 kPa
® Number of cleanings (15 inches of H,O) .
Store the container in a dry location . Inspect the service indicator daily for cracks, holes,
or loose fittings . If any of these conditions are
For more detailed information on cleaning the present, repair the service indicator or replace the
primary air cleaner element, refer to Special service indicator.
Publication, SEBF8062, "Procedure to Inspect and
Clean Air Filters" .
Test the Service Indicator
i01505252 Service indicators are important instruments .
Engine Air leaner Service ® Check for ease of resetting . The service indicator
Indicator ® Inspect should reset in less than three pushes .

SMCS Code : 7452-040 Check the movement of the yellow core when the
engine is accelerated to the engine rated rpm.
A service indicator may be mounted on the air The yellow core should latch approximately at the
cleaner element or in a remote location . greatest vacuum that is attained .

If the service indicator does not reset easily, or if the

yellow core does not latch at the greatest vacuum,
replace the service indicator. If the new service
indicator will not reset, the fitting for the service
indicator may be plugged .
74
Maintenance Section
Engine Air Precleaner - Clean

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).

Note : When the engine is operated in dusty

applications, more frequent cleaning is required.

101505354

Engine Crankcase Breather -

g00351792
Clean
Illustration 34
Porous filter SMCS Code : 1317-070
A porous filter is part of a fitting that is used for
1011111158
mounting of the service indicator. Inspect the filter
for cleanliness . Clean the filter, if necessary. Use
compressed air or a clean, nonflammable solvent.
The service indicator may need to be replaced
frequently in environments that are severely dusty.
Replace the service indicator annually regardless
of the operating conditions . Replace the service
indicator when the engine is overhauled, and
whenever major engine components are replaced .

Note : When a new service indicator is installed,

excessive force may crack the top of the service g00781173
indicator. Tighten the service indicator to a torque Illustration 36
of 2 N-m (18 Ib in) . (1) Hose clamp
(2) Breather assembly
(3) Retaining clamp
101397717
1 . Loosen hose clamp (1) . Slide the hose from
Engine Air recl an r - lean breather assembly (2) .
SMCS Code: 1055-070 2. Loosen retaining clamp (3) . Remove breather
assembly (2). Remove the crankcase breather's
seal.

3. Wash the breather assembly in clean,

nonflammable solvent. Allow the breather
assembly to dry.

4. Inspect the seal for cracks or damage. If

necessary, replace the seal . Install the seal .

Note: Coat the rubber parts with clean engine oil or

petroleum jelly in order to make installation easier.

5. Install the breather assembly and the hose.

g00736588
Illustration 35
6. Tighten retaining clamp (3) to the torque that
Typical precleaner is recommended in the engine's Specifications
(1) Wing nut module . Tighten hose clamp (1) according
(2) Cover
(3) Body
to this Operation and Maintenance Manual,
"Spec if icatons" topic.
 75
Maintenance Section
Engine Mounts - Check

101397742

Engine Mounts - Check

SMCS Code: 1152-535
r_

g00736591
Illustration 37
(1) Mounting bolts for the engine g00787079
(2) Mounting bolts for the generator Illustration 38
(3) Levelling bolts for the isolators Auxiliary oil filter housing
(1) vent plug
Misalignment of the engine and the driven (2) Drain plug
equipment will cause extensive damage . Excessive
vibration can lead to misalignment . Excessive 1 . If the engine is equipped with an auxiliary oil
vibration of the engine and the driven equipment filter system, remove vent plug (1) . Remove drain
can be caused by the following conditions : plug (2). Allow the oil to drain . After the oil has
drained, clean the drain plug .
" Improper mounting

" Loose bolts

" Deterioration of the isolators

Ensure that the mounting bolts are tightened to

the proper torque . For standard torques, see
the Operation and Maintenance Manual, "Torque
Specifications" in the Maintenance Section.

Ensure that the isolators are free of oil and

contamination. Inspect the isolators for deterioration .
Ensure that the bolts for the isolators are tightened
to the proper torque .

Replace any isolator that shows deterioration . For

more information, see the literature that is provided
by the OEM of the isolators. Also see the Application
and Installation Guide for the engine . Consult your
Caterpillar dealer for assistance .

101665179

Engine Oil Filter (Auxiliary) -

Change
SMCS Code : 1318

Note : An auxiliary oil filter system enables the oil

capacity of the engine to be increased . Use of the
auxiliary oil filter elements is not recommended .

Perform this procedure after the oil has been

drained from the auxiliary oil filter housing .
76
Maintenance Section
Engine Oil Level - Check

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 Ib ft) .

Note : Use of the auxiliary oil filter elements is not

required .

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

install new elements .

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

bolt (12).

g00787105 10. Install spring (11) on spider (14). Install spring

Illustration 39 retainer (10) and nut (9) on bolt (12) .
(1) Vent plug
(2) Drain plug
(3) Nut
11 . Tighten nut (9) in order to compress spring (11)
(4) Washer until the spring retainer bottoms out on bolt (12).
(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
(9) Nut amount of oil, refer to the Operation and
(10) Spring retainer Maintenance Manual, "Refill Capacities" topic
(11) Spring (Maintenance Section) .
(12) Bolt
(13) Washer
(14) Spider
13 . Inspect cover gasket (8) for tears, breaks, or
(15) Plate other damage. If the cover gasket is damaged,
replace the old cover gasket with a new cover
1 . Remove 12 nuts (3), washers (4), and bolts (6). gasket . Install cover gasket (8). Install cover (7) .

2. Remove cover (7) and gasket (8). Do not 14. Install twelve bolts (6), washers (4), and nuts
damage the gasket . (3). Tighten nuts sequentially around the cover
until the nuts are snug . Tighten the nuts to
100 ± 15 N-m (75 ± 11 Ib ft) .

15 . Install vent plug (1).

Possible injury can occur during the removal of
the nut, the spring retainer, and the spring . Spring
force will be released when the nut and the spring 101623016
retainer are removed. Be prepared to hold the
spring retainer as the nut is loosened . IILevel
SMCS Code: 1348-535-FLV
3. Remove nut (9), spring retainer (10), and spring
(11) . Hold spring retainer (10) as nut (9) is The most accurate check of the oil level is
loosened. performed when the engine is stopped . Perform
this maintenance on a surface that is as level as
possible.
 77
Maintenance Section
Engine Oil Sample - Obtain

The oil level should be between "ADD" 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.

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.
Illustration 40 g00839936

(1) Oil level gauge (dipstick) If the oil level is above the "FULL" mark on the oil level
(2) Oil filler cap gauge, drain some of the oil immediately.

2. If necessary, remove oil filler cap (2) and add

oil . For the correct oil to use, see this Operation
and Maintenance Manual, "Engine Oil" topic
c MM -o -- 0- (Maintenance Section) . Do not fill the crankcase
above "FULL" mark (6). Clean the oil filler cap.
Install the oil filler cap.

1- n we role rnu raa. on 3. Record the amount of oil that is added. For the
next oil sample and analysis, include the total
amount of oil that has been added since the
previous oil change. This will help to provide the
most accurate oil analysis .
g00789825
Illustration 41
i01363663
(3) "ENGINE STOPPED" side
(4)
(5)
"LOW IDLE" side
"ADD" mark
Engine Oil Sample - Obtain
(6) "FULL" mark
SMCS Code : 1348-554-SM
Note : For engines with positive crankcase
ventilation, remove the oil filler cap . Allow the In addition to a good preventive maintenance
crankcase pressure to stabilize before checking the program, Caterpillar recommends using S-O-S oil
engine oil level. analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
1 . Ensure that oil level gauge (1) is seated . maintenance requirements of the engine .

a. If the engine is stopped, remove oil level btain the Sample and the Analysis
gauge (1) . Observe the oil level on "ENGINE
STOPPED" side (3) .

b. If the engine is operating, reduce the engine

speed to low idle. Remove oil level gauge Hot oil and hot components can cause personal
(1) and observe the oil level on "LOW IDLE" injury. Do not allow hot oil or hot components to
side (4) . contact the skin .
78
Maintenance Section
Engine Oil and Filter - Change

Before taking the sample, complete the Label, 101623048

PEEP5031 for identification of the sample . To help
obtain the most accurate analysis, provide the Engine Oil and Filter - Change
following information:
SMCS Code: 1318-510
o Engine model

o Service hours on the engine

Hot oil and hot components can cause personal
o The oil's hours of use injury. Do not allow hot oil or hot components to
contact the skin .
o The amount of oil that has been added since the
last oil change
NOTICE
To ensure that the sample is representative of the Ensure that the engine is stopped before performing
oil in the crankcase, obtain a warm, well mixed oil this procedure. Attach a DO NOT OPERATE tag to the
sample . starting controls .

To avoid contamination of the oil samples, the tools

and the supplies that are used for obtaining oil Do not drain the oil when the engine is cold . As
samples must be clean . the oil cools, suspended waste particles settle on
the bottom of the oil pan . The waste particles are
Caterpillar recommends using the sampling valve not removed when the cold oil is drained. Drain the
in order to obtain oil samples. The quality and crankcase with the oil warm, immediately after the
the consistency of the samples is better when the engine is stopped . This method of draining allows
sampling valve is used . The location of the sampling the waste particles that are suspended in the oil
valve allows oil that is flowing under pressure to be to be drained .
obtained during normal engine operation.
Failure to follow this recommended procedure will
The 8T-9190 Fluid Sampling Bottle Group is cause the waste particles to be recirculated through
recommended for use with the sampling valve . The the engine lubrication system with the new oil .
bottle group includes the parts that are needed
for obtaining oil samples. Instructions are also
provided .

NOTICE
Do not use the same vacuum sampling pump for ex-
tracting oil samples that is used for extracting coolant
samples.

A small residue of either type sample may remain in

the pump and may cause a false positive analysis for
the sample being taken.

Always use a designated pump for oil sampling and a

designated pump for coolant sampling . Illustration 42 g00839949

(1) Oil filler

Failure to do so may cause a false analysis which (2) Oil level gauge (dipstick)
could lead to customer and dealer concerns. (3) Oil filter
(4) Oil drain plugs

If the engine is not equipped with a sampling valve,

use the 1U-5718 Vacuum Pump . The pump is Drain the Engine Oil
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion 1 . After the engine has been operated at normal
into the sump . operating temperature, STOP the engine .

For instructions, see Special Publication, PEHP6001, Note : Drain the oil into a suitable container. Dispose
"How To Take A Good Oil Sample" . Consult your of fluids according to local regulations .
Caterpillar dealer for complete information and
assistance in establishing an S-O.S program for 2. Drain the oil .
your engine .
 79
Maintenance Section
Engine Oil and Filter - Change

a. If the engine has an oil drain valve, open the 3. Clean the sealing surface of the filter mounting
valve in order to drain the oil . After the oil has base. Ensure that all of the old oil filter gasket
drained, close the valve. is removed .

b. If the engine does not have a drain valve, NOTICE

remove an oil drain plug . Allow the oil to drain . Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Replace the Oil Filter Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
1 . Remove the oil filter with a 1U-8760 Chain the larger waste particles from unfiltered oil entering
Wrench . the engine lubricating system . Only use oil filters
recommended by Caterpillar.
2. Cut the oil filter open with a 4C-5084 Oil Filter
Cutter. Break apart the pleats and inspect the oil 4. Apply clean engine oil to the new oil filter gasket .
filter for metal debris .

An excessive amount of metal debris in the oil NOTICE

filter may indicate early wear or a pending failure. Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
Use a magnet to differentiate between the ed . Contaminated oil can cause accelerated wear to
ferrous metals and the nonferrous metals that engine components.
are found in the oil filter element. Ferrous metals
may indicate wear on the steel and cast iron 5. Install the oil filter. Tighten the oil filter until the
parts of the engine . oil filter gasket contacts the base . Tighten the oil
filter by hand according to the instructions that
Nonferrous metals may indicate wear on the are shown on the oil filter. Do not overtighten the
aluminum parts, brass parts or bronze parts of oil filter.
the engine . Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads . Fill the Engine Crankcase
Aluminum debris may indicate problems with NOTICE
the bearings of the front gears. If aluminum Only use oils that are recommended by Caterpillar.
debris are found, inspect the crankshaft vibration For the proper oil to use, refer to this Operation and
damper and the bearings of the front idler gear. Maintenance Manual, "Engine Oil" topic (Maintenance
Section) .
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 NOTICE
debris is found in the oil filter element, consult Engine damage can occur if the crankcase is filled
your Caterpillar dealer in order to arrange for above the "FULL" mark on the oil level gauge (dip-
further oil analysis . stick) .
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems : re-
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption.

Excessive oil consumption will cause deposits to form

on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems : guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
g00103713
Illustration 43 If the oil level is above the "FULL" mark on the oil level
Typical filter mounting base and filter gasket gauge, drain some of the oil immediately.
80
Maintenance Section
Engine Performance - Test

1 . Remove the oil filler cap. Fill the crankcase with i00626013
the proper amount of oil. Refer to the Operation
and Maintenance Manual, "Refill Capacities" n in Protective Devices
topic (Maintenance Section) . Check
NOTICE SMCS Code : 7400-535
To prevent crankshaft damage or bearing damage,
crank the engine with the fuel supply line closed . This Alarms and shutoffs must function properly. Alarms
will ensure that all of the oil filters are filled with oil be- provide timely warning to the operator. Shutoffs help
fore the engine is started. Do not crank the engine for to prevent damage to the engine . It is impossible
more than 30 seconds. Allow the starting motor to cool to determine if the engine protective devices are
for two minutes before cranking again . in good working order during normal operation .
Malfunctions must be simulated in order to test the
engine protective devices.
2. Close the fuel supply line . Crank the engine until
normal oil pressure shows on the oil pressure A calibration check of the engine protective devices
gauge . Open the fuel supply line. will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective
3. Start the engine according to this Operating devices are functioning properly.
and Maintenance Manual, "Starting the Engine"
procedure (Operation Section) . Operate the
engine at low idle rpm for two minutes. NOTICE
During testing, abnormal operating conditions must be
This will ensure that the lubrication system has simulated.
oil and that the oil filters are filled . Inspect the
engine for oil leaks . The tests must be performed correctly in order to pre-
vent possible damage to the engine .
4. Stop the engine and allow the oil to drain back
to the sump for a minimum of ten minutes. To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
5. Remove the oil level gauge and check the oil perform the tests.
level . Maintain the oil level between the "ADD"
and "FULL" marks on the "ENGINE STOPPED"
side of the oil level gauge . Visual Inspection
Visually check the condition of all gauges, sensors
and wiring . Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
Engine erfor anc or components should be repaired or replaced
immediately.
SMCS Code: 1000-081

Operate the engine for a minimum of two hours at a

minimum load of 60 percent.
® Monitor the operation of the generator set.

® Observe the gauges . Ensure that the gauges are

in the normal ranges .
® Record the data . Maintain a record of the data for
the engine performance,
 81
Maintenance Section
Engine Speed/Timing Sensor - Clean/Inspect

101623767 Valve Bridge

Engine Speed/Timing Sensor Check the valve bridge and adjust the valve bridge,
Clean/Inspect if necessary. Perform the procedure for both valve
bridges for each cylinder.
SMCS Code : 1905-040; 1905-070; 1907-040 ;
1907-070 After the valve bridge is checked for each cylinder,
proceed with the valve lash adjustment, if necessary.

Engine Valve Lash

NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.

Operation of Caterpillar engines with improper valve

adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life .
g00798126
Illustration 44
Engine speed/timing sensor in the front cover of the governor drive
(G3406 Engine)
If the valve lash is within the tolerance, an
adjustment of the valve lash is NOT necessary.
1 . Remove the sensor from the cover. Check the
condition of the end of the magnet. Check for Perform valve lash adjustment if the dimension is not
signs of wear and contaminants . within the tolerance. The valve bridge adjustment
must be performed before making a valve lash
2. Clean the metal shavings and other debris from adjustment.
the face of the magnet .
Perform the valve lash setting when the engine is
3. Install the sensor and adjust the sensor cold . After the engine has been shut down and the
according to the engine's Specifications . valve covers are removed, the engine is considered
cold .

101009779 Before performing maintenance, prevent the entry

of foreign matter into the top of the cylinder head
Engine Valve Lash and the valve mechanism . Thoroughly clean the
Inspect/Adjust area around the valve mechanism covers .

SMCS Code : 1102-025 For the valve lash setting, see this Operation and
Maintenance Manual, "Engine Description" topic
(Product Information Section) .

Ignition systems can cause electrical shocks. 101765711

Avoid contacting the ignition system components
and wiring during operation . nine Valve ®tat rs ® Inspect
SMCS Code : 1109-040
For procedures on adjusting the valve bridge and
the engine valve lash, see the engine's Service NOTICE
Manual, "Systems Operation/Testing and Adjusting" A valve rotator which does not operate properly will
module. accelerate valve face wear and valve seat wear and
shorten valve life . If a damaged rotator is not replaced,
Consult your Caterpillar dealer for assistance . valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
82
Maintenance Section
Exhaust Bypass - Inspect

Note: Use of a platform may be necessary to reach 3. Inspect diaphragm (1) . If the diaphragm is worn
the engine valve rotators . or cracked, replace the diaphragm .

Perform this procedure after the valve lash has 4. Inspect valve stem (2) and the valve guide . If the
been set . parts are excessively worn, replace the parts .

1 . Mark the tops of the valve rotators with a 5. Clean breather (3).
permanent marker. Note the position of the
marks . 6. Assemble the valve .

2. Install the valve covers. See the Service Manual 7. Install the valve .
for the procedure .

3. Start the engine. Operate the engine for 5 X00721010

minutes. Stop the engine. Exhaust Piping ® Inspect

4. Remove the valve covers . Observe the position SMCS Code: 1061-040
of the marks that are on the valve rotators .

If a valve fails to rotate, consult your Caterpillar

dealer.
Hot engine components can cause injury from
burns . Before performing maintenance on the
.01505507 engine, allow the engine and the components to
cool.
Exhaust Bypass ® Inspect
SMCS Code: 1057-040 Inspect the components of the exhaust system .
Repair the components or replace the components
For instructions on removal and installation, see the if any of the following conditions occur:
Service Manual, "Disassembly and Assembly" .
" Damage
1 . Remove the exhaust bypass valve .
" Cracks

A WARNING " Leaks

The exhaust bypass valve cover is under spring " Loose connections
compression . To prevent personal injury, use cau-
tion when removing the cover. Consult your Caterpillar dealer for assistance .

2. Disassemble the valve . Water Cooler! Exhaust Manifolds

The water cooled exhaust manifolds do not require
maintenance unless excessive deposits build up in
the exhaust passages . Buildup of deposits cause
an increase in back pressure that will cause the
following conditions:

" Increased fuel consumption

" Reduced boost pressure

If excessive deposits build up in the exhaust

passages, clean the passages in order to remove
the deposits .
Illustration 45 g00781274

Exhaust bypass valve

(1) Diaphragm
(2) Valve stem
(3) Breather
 83
Maintenance Section
Fuel System Fuel Filter Differential Pressure - Check

101505536 Pressure of the Fuel Supply To the

Fuel System Fuel Filter Carburetor
Differential Pressure - heck The gas pressure regulator maintains a pressure
differential between the air and the fuel that is
SMCS Code : 1261-535 supplied to the carburetor. After setting, the gas
pressure regulator will maintain the pressure
A fuel filter differential pressure gauge must be differential in response to changes in the air
installed in order to determine when the fuel filter pressure .
requires service . This gauge and the fuel filter are
supplied by the customer. Use a water manometer for measuring the pressure
differential . Obtain the measurement when the
A fuel filter differential pressure gauge indicates the engine is operating at high idle rpm. After a load
difference in fuel pressure between the inlet side is applied, the fuel pressure will usually decrease
and the outlet side of the fuel filter. The differential by approximately 0.1 to 0 .25 kPa (0 .50 to 1 inches
pressure increases as the fuel filter becomes of H2 0) . If the performance of the gas pressure
plugged . regulator is erratic, the gas pressure regulator may
require service.
Operate the engine at the rated speed and at
the normal operating temperature. Check the fuel
Natural Gas
filter differential pressure . Service of the fuel filter
depends on the pressure of the fuel system :
Set the pressure of the fuel supply to a maximum of
1 to 1 .2 kPa (4 to 4 .5 inches of H2 O) HIGHER than
" For low pressure gas fuel systems, service the
the ambient air pressure .
fuel filter when the fuel filter differential pressure
reaches 1 .7 kPa (0 .25 psi) .
Propane
" For high pressure gas fuel systems, service the
fuel filter when the fuel filter differential pressure Set the pressure of the fuel supply to
reaches 34 kPa (5 psi) . -0 .37 ± -0 .06 kPa (-1 .5 ±0 .250 inches of H2 O)
LOWER than the ambient air pressure .
For instructions, see Special Instruction, SEHS9298,
"Installation and Maintenance of Gaseous Fuel
101642256
Filters" . Consult your Caterpillar dealer for
assistance . as Pressure Regulator
Condensation - rain
101359547

Gas Pressure Regulator - SMCS Code : 1270-543

Check To collect condensation, drip legs should be

installed in the following locations:
SMCS Code : 1270-535
" Supply line for the gas pressure regulator
Check the fuel pressure before the gas pressure
regulator and after the gas pressure regulator. Table " Balance line for the gas pressure regulator
30 lists the fuel pressure that is required for the gas
pressure regulator. " Supply line to the gas shutoff valve

Table 30
Requirements for Fuel Pressure To the Gas
Pressure Regulator
Fuel System Pressure
Low pressure gas 10 .3 to 34 ± 2 kPa
(1 .50 to 5 ± 0.25 psi)
High pressure gas 172 to 207 ± 7 kPa
(25 to 30 ± 1 psi)
84
Maintenance Section
Governor - Inspect

Replace hoses that are cracked or soft . Tighten any

loose clamps .

NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses . Repair
any loose or damaged fuel and oil lines, tubes and
hoses . Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
ommended torque .

Check for the following conditions :

g00829869
" End fittings that are damaged or leaking
Illustration 46
(1) Cap on the drip leg for the balance line " Outer covering that is chafed or cut
(2) Cap on the drip leg for the gas supply line to the gas pressure
regulator
" Exposed wire that is used for reinforcement
1 . Close the main gas supply valve .
" Outer covering that is ballooning locally
2. Remove caps (1) and (2) from the drip legs .
" Flexible part of the hose that is kinked or crushed
3. Allow the moisture to drain into a suitable
container. Inspect the drip legs for debris . Clean " Armoring that is embedded in the outer covering
the drip legs, if necessary.
A constant torque hose clamp can be used in
4. Clean the caps. Install the caps. place of any standard hose clamp. Ensure that the
constant torque hose clamp is the same size as
5. Perform Step 2 through Step 4 for the drip leg the standard clamp .
on the supply line to the gas shutoff valve .
Due to extreme temperature changes, the hose
6. Open the main gas supply valve . will heat set. Heat setting causes hose clamps to
loosen . This can result in leaks. A constant torque
hose clamp will help to prevent loose hose clamps .
i01041704
Each installation application can be different. The
Governor - Inspect differences depend on the following factors:
SMCS Code: 1264-040 " Type of hose
Inspect the governor for oil leaks . " Type of fitting material
For service information, see the literature that is " Anticipated expansion and contraction of the
provided by the OEM of the governor. hose

" Anticipated expansion and contraction of the

i00907072
fittings
Hoses n
Inspect/Replace eplace the Hoses and the damps
SMCS Code: 7554-040 ; 7554-510

Inspect all hoses for leaks that are caused by the Pressurized System : Hot coolant can cause seri-
following conditions : ous burns . To open the cooling system filler cap,
stop the engine and wait until the cooling system
" Cracking components are cool . Loosen the cooling system
pressure cap slowly in order to relieve the pres-
" Softness sure.
" Loose clamps
 85
Maintenance Section
Hoses and Clamps - Replace

1 . Stop the engine . Allow the engine to cool . 4. Fill the cooling system .

2. Loosen the cooling system filler cap slowly 5. Start the engine . Inspect the hose connections
in order to relieve any pressure . Remove the for leaks.
cooling system filler cap.

Note : Drain the coolant into a suitable, clean 101042052

container. The coolant can be reused . Ignition System Spark Plug

3. Drain the coolant from the cooling system to Wires - Replace
a level that is below the hose that is being
replaced .
(Standard Ignition Systems)
SMCS Code: 1558-510
4. Remove the hose clamps .

5. Disconnect the old hose . WARNING -

6. Replace the old hose with a new hose . Ignition systems can cause electrical shocks.
Avoid contacting the ignition system components
Note : For torques on hose clamps, see this and wiring during operation.
Operation and Maintenance Manual, "Torque
Specifications" (Maintenance Section) .
NOTICE
7. Install the hose clamps with a torque wrench. Pulling on the wiring harness may break the wires. Do
not pull on the wiring harness.
Note : For the proper coolant to use, see this
Operation and Maintenance Manual, "Coolant 1 . Disconnect the spark plug wire assembly from
Recommendations" (Maintenance Section) . the transformer.
8. Refill the cooling system . 2 . Disconnect the wire assembly from the spark
plug. Discard the wire assembly .
9. Clean the cooling system filler cap. Inspect the
cooling system filler cap's gaskets. Replace 3. Connect the new wire assembly to the spark
the cooling system filler cap if the gaskets are plug.
damaged . Install the cooling system filler cap .
4. Connect the wire assembly to the transformer.
10. Start the engine . Inspect the cooling system for
leaks.
101842350

101819514 Ignition System Spark Plugs -

Hoses a Clamps - Replace Check/Adjust/Replace
SMCS Code: 1380-510 SMCS Code : 1555-535

Note : For instructions on draining the cooling system

and filling the cooling system, see this Operation
and Maintenance Manual, "Cooling System Coolant Ignition systems can cause electrical shocks .
(DEAC) - Change" topic or see the Operation and Avoid contacting the ignition system components
Maintenance Manual, "Cooling System Coolant and wiring during operation.
(ELC) - Change" topic (Maintenance Section) .
1 . Drain the cooling system . Maintenance of the spark plugs is required in order
to achieve the following benefits :
2. Remove the used hoses and clamps . Discard
the items. ® Normal fuel consumption

3. Install new hoses and clamps . For the ® Normal level of emissions
correct torque to use on the hose clamps,
see the Specifications, RENR3130, "Torque ® Maximum service life of the spark plugs
Specifications", "Hose Clamps" topic.
86
Maintenance Section
Ignition System Spark Plugs - Check/Adjust/Replace

® Stable operation 4. Ensure that the area around the spark plug is
clean and free of dirt and debris . Thoroughly
The service life of the spark plugs is affected by remove any debris . Use compressed air. The
fouling due to deposits from the oil and by peak maximum air pressure for cleaning purposes
voltage. Maintenance of the ignition system is also must be below 207 kPa (30 psi) . The spark plug
affected by voltage . Higher voltage is required can also be cleaned with a nonmetallic brush.
by higher inlet manifold air pressure, a higher
compression ratio, and a leaner air/fuel ratio. Higher 5. Use a spark plug socket with an extension in
voltage reduces the service life of components such order to remove spark plug (5).
as spark plugs, wires, and transformers .
NOTICE
Removing the Spark Plug The use of a thread tap will remove metal unnecessar-
ily. This will also reduce the heat transfer for the spark
1 . Turn the ignition switch to the "OFF" position . plug . This can result in a reduction of the spark plug
This will ground the magneto. This will also service life and a reduction of the detonation margin .
discharge any capacitors that may be charged.
If the spark plug resists removal by hand, apply
penetrating oil to the threads. Use the wrench and
apply steady pressure to the spark plug until the
spark plug is loose.

If the spark plug cannot be removed by hand, clean

the internal threads with the 154-9521 Spark Plug
Seat Cleaner. This tool scrapes debris from the seat
and from the threads in the spark plug adapter. Be
sure to remove any debris from the cylinder.

CSA Ignition System

Note: The CSA ignition system is equipped with an
integral transformer. The transformer screws onto
the spark plug . The transformer and the spark plug
are removed separately. The transformer and the
spark plug are installed separately.

Illustration 47 g00939844

(1) Seal
(2) Wire
(3) Transformer assembly
(4) Boot
(5) Spark plug

NOTICE
Pulling on the wiring harness may break the wires. Do
not pull on the wiring harness.

2. Disconnect wire (2) from transformer assembly

(3). The wire may break if you pull on the wire .

3. Remove boot (4) and remove extension.

Pressurized air can cause personal injury. When

pressurized air is used for cleaning, wear a protec-
tive face shield, protective clothing, and protective
shoes.
 87
Maintenance Section
Ignition System Spark Plugs - Check/Adjust/Replace

Inspecting the Spark Plug

g00939393
Illustration 48
g00939767
CSA Ignition System Illustration 49
(1) Wiring harness (1) Terminal post
(2) Boot (2) Insulator
(3) Transformer (3) Shell
(4) Copper washer (4) Gasket
(5) Spark plug (5) Electrodes
(6) Spark plug gasket
Inspect the spark plug closely for damage . The
1 . Turn the ignition switch to the OFF position . condition of the spark plug can indicate the
operating condition of the engine .
2. Disconnect wiring harness (1).
Terminal post (1) must not move. If the terminal post
3. Remove boot (2). can be moved by hand, discard the spark plug.
4. Remove transformer (3). Inspect insulator (2) for cracks . If a crack is found,
discard the spark plug.
5. Ensure that the area around the spark plug is
clean . Ensure that the area around the spark Faint marks may extend from shell (3) onto the
plug is free from dirt and debris . Remove spark insulator. The marks may be a result of a corona
plug (5) and remove gasket (6) from the cylinder that forms at the top of the shell . The conductor
head. Remove the gasket and remove copper will develop a corona when a very high voltage
washer (4) . Discard the gasket and discard the potential ionizes the air. This is a normal condition.
copper washer. This is not an indication of leakage between the
shell and the insulator.

Inspect the shell for damage. Cracks can be caused

by overtightening the spark plug. Overtightening
can also loosen the shell. Discard any spark plug
that has a shell that is cracked or loose.
88
Maintenance Section
Ignition System Spark Plugs - Check/Adjust/Replace

Inspect electrodes (5) for excessive wear. Flat Installing the Spark Plug
surfaces with sharp edges provide the best
conditions for creating a spark. Caterpillar spark Note : Use the 9U-7516 Spark Plug Gauge to
plugs have precious metal tips on the ends of the measure the electrode gap. Do not use a flat feeler
electrodes and the ground strap . This material will gauge for measuring the electrode gap of used
gradually erode. Use extreme care when you set spark plugs . A feeler gauge will incorrectly measure
the electrode gap. Maintain even spacing and the actual electrode gap because the used precious
proper alignment between the two precious metal metal tips are curved .
surfaces . Replace the spark plug if the precious
metal is worn off. 1 . Before installing the spark plug, set the electrode
gap to 0.38 mm ( .015 inch) .
A light brown deposit or a beige deposit is
produced by normal operation . White deposits or Adjust the electrode gap by bending the ground
gray deposits may be caused by the following electrode at the existing bend . Then bend the
substances : strap near the weld in order to achieve proper
alignment and even spacing between the two
" Excessive oil precious metal surfaces . Measure the electrode
gap after the alignment. Correct the electrode
" Use of the wrong oil gap, if necessary.
" A substance that is introduced through the fuel Note : Do not use anti-seize compound on spark
system or the air system plugs. Most of the heat is transferred through the
threads and the seat area of the spark plug. The
A spark plug can operate despite a buildup of ash . surfaces must be in contact in order to provide the
However, a buildup of ash can cover the electrode heat transfer that is required.
gap . This will cause misfire. Large deposits may
retain heat which can cause premature fuel ignition . 2. Ensure that the spark plug is clean and free of
This can lead to uncontrollable detonation . dirt and oil.
A standard ohmmeter (nine volt) can be used 3. Always use a new gasket when a spark plug is
for measuring the resistance of the spark plug . installed . If a used spark plug is installed orient
The ohmmeter can be used only for spark plugs the tab of the gasket toward the electrode . If a
with wire-wound resistors . It is not possible to use gasket for a spark plug is installed incorrectly,
a standard ohmmeter (nine volt) for measuring do not increase the torque on the spark plug
the resistance of other types of spark plugs . in order to improve the seal . Do not reuse the
Measure the resistance between terminal post (1) gasket . Install a new gasket .
and electrode (5) . Discard any spark plug with a
wire-wound resistor if the resistance is outside the
range of 1000 to 1500 ohms. NOTICE
Do not overtighten the spark plug . The shell can be
cracked and the gasket can be deformed. The metal
Cleaning the Spark Plug can deform and the gasket can be damaged . The shell
can be stretched . This will loosen the seal that is be-
Thoroughly clean the spark plug. Do not use a wire tween the shell and the insulator, allowing combustion
brush . Glass beads are the preferred method for pressure to blow past the seal . Serious damage to the
cleaning . engine can occur.

Follow these guidelines for the use of glass beads: Use the proper torque.
" Always use clean glass beads.
4. Install the spark plug by hand until the spark
" Use care in order to clean only the electrode and plug bottoms out. Tighten the spark plug to
the insulator near the electrode. 38 ± 3 N-m (28 ± 2 lb ft) .

" Do not use glass beads on the outside of the

shell or on the upper part of the insulator.
 89
Maintenance Section
Ignition System Timing - Check/Adjust

1 . Install a new copper spacer (4) on top of spark

plug (5). Install a new gasket (6) onto the bottom
of the spark plug. Install the spark plug by hand
until the spark plug bottoms out. Tighten the
spark plug to 38 ± 3 N-m (28 ± 2 Ib ft).

2. Screw transformer (3) onto the spark plug until

the transformer is finger tight. Then tighten the
transformer for an additional one-eighth turn (45
degrees) .

3. Inspect boot (2) and wiring harness (1) . If the

components are in good condition, install the
components. If a component is not in good
condition, replace the old component with a new
component.

i01005974

Ignition System Timing -

Illustration 50 g00939844 Check/Adjust
(1) Seal
(2) Wire SMCS Code: 1550-025; 1550-535
(3) Transformer assembly
(4) Boot After maintenance has been performed on the
(5) Spark plug ignition system, check the timing of the ignition
system . Adjust the timing, if necessary.
5. Inspect boot (4) and wire (2). If the components
are in good condition, install the components. If The optimum ignition timing for a gas engine varies
the components are not in good condition, install according to several factors:
new components.
" Compression ratio of the engine
6. Turn the ignition switch to the "ON" position .
" Inlet air temperature
CSA Ignition System
" Methane number of the gas

For the proper timing, see the Engine Performance

publication for the engine .

Adjust the timing according to the Service Manual,

"Systems Operation/Testing and Adjusting" module .
Consult your Caterpillar dealer for assistance .

i00682407

Ignition System Transformer

Resistance - Test
SMCS Code: 1550-081

The transformers produce a voltage increase. For

good operation, the connections must be clean and
secure . Inspect the transformers for the following
conditions . If any of the conditions are found,
g00939393 correct the condition :
Illustration 51
(1) Wiring harness. (2) Boot. (3) Transformer . (4) Copper washer . ® Corrosion
(5) Spark plug . (6) Spark plug gasket .
Dirty insulator
90
Maintenance Section
Inlet Air System - Inspect

" Loose connections 101021379

" Moisture Instrument Panel - Inspect

" Open circuits SMCS Code: 7451-040

" Short circuits Inspect the instrument panel for good condition .
Check the condition of all of the gauges . If a gauge
Test the resistance of the transformers . Test each is broken, repair the gauge or replace the gauge
transformer at both the side with high voltage and immediately.
the side with low voltage . See the Service Manual,
"Specifications" module for the procedure . Consult Frequently monitor the following parameters during
your Caterpillar dealer for assistance . normal operation :

" Fuel filter differential pressure

101113853

Inlet Air System - Inspect " Inlet air restriction

" Inlet manifold air temperature

SMCS Code: 1058-040 ; 1071-040 ; 1087-040
" Jacket water temperature
Inspect the components of the air inlet system for
the following conditions : " Oil filter differential pressure
" Cracks " Oil pressure
" Leaks Record the data in a log . Compare the new data to
the data that was previously recorded. Comparing
" Loose connections the new data to the recorded data will establish the
normal gauge readings for the engine . A gauge
Inspect the following components: reading that is abnormal may indicate a problem
" Piping between the air cleaner and the with operation or a problem with the gauge .
turbocharger
101042517
" Turbocharger
Jacket Water Heater - Check
" Piping between the turbocharger and the
aftercooler SMCS Code: 1383-535

" Aftercooler Jacket water heaters help to improve startability in

ambient temperatures that are below 21 °C (70 °F) .
" Connection of the aftercooler to the air plenum All installations that require automatic starting
should have jacket water heaters .
" Connection of the air plenum to the cylinder head
Check the operation of the jacket water heater. For
Ensure that all of the connections are secure. an ambient temperature of 0 °C (32 °F), the heater
Ensure that the components are in good condition . should maintain the jacket water temperature at
approximately 32 °C (90 °F).
Make repairs, if necessary. For information regarding
removal and installation of the components, see 101614355
the Service Manual, "Disassembly and Assembly"
module. Consult your Caterpillar dealer for
assistance .
ver ul (Major)
SMCS Code: 7595-020-MJ

Scheduling a Major verhaul

Note: For information on estimating operating
hours before an overhaul, refer to Maintenance
Management Schedules, SEBU6127 .
 91
Maintenance Section
Overhaul (Major)

The need for a major overhaul is determined by Major Overhaul Information

several factors.
A major overhaul includes all of the work that is
" An increase of oil consumption done for top end overhauls . A major overhaul
includes additional parts and labor. Additional parts
® An increase of crankcase blowby and labor are required in order to completely rebuild
the engine . In some cases, the engine is relocated
" A decrease and variation of cylinder compression for disassembly.

The following changes in the three conditions For the major overhaul, all of the bearings,
normally require a scheduled overhaul : seals, gaskets, and components that wear
are disassembled . The parts are cleaned and
® A 300 percent increase in oil consumption inspected. If necessary, the parts are replaced . The
crankshaft is measured for wear. The crankshaft
® A 200 percent increase in crankcase blowby may require regrinding . Alternatively, the crankshaft
may be replaced with a Caterpillar replacement
" A 20 percent loss of cylinder compression part.

Note : These indications do not require an engine Your Caterpillar dealer can provide these services
to be shut down for service. These indications and components . Your Caterpillar dealer can ensure
only mean that an engine should be scheduled for that the components are operating within the
service in the near future . If the engine operation appropriate specifications .
is satisfactory, an immediate overhaul is not a
requirement . If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the
The engine does not require an overhaul if the following recommendations .
engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder The following definitions explain the terminology for
compression . the services that are performed during an overhaul :

Other factors must also be considered for Inspect - Inspect the components according to
determining a major overhaul : the instructions that are in Caterpillar reusability
publications . Refer to Guidelines for Reusable
" The service hours of the engine Parts and Salvage Operations, SEBF8029, "Index
of Publications on Reusability or Salvage of Used
® The wear metal analysis of the lube oil Parts" . The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
" An increase in the levels of noise and vibration unnecessary expenditures . New parts are not
required if the existing parts can still be used,
An increase of wear metals in the lube oil indicates reconditioned, or repaired . If the components are
that the bearings and the surfaces that wear may not in the reusability guidelines, refer to the Service
need to be serviced . An increase in the levels of Manual, "Specifications" module .
noise and vibration indicates that rotating parts
require service . Rebuild - The component can be reconditioned in
order to comply with reusability guidelines .
Note : It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil . The cylinder Replace - The service life of the part is exhausted .
liners may be worn so that polishing of the bore The part may fail before the next maintenance
occurs . Also, the increased use of lube oil will dilute interval . The part must be replaced with a part that
the wear metals . meets functional specifications . The replacement
part may be a new part, a CAT remanufactured
Monitor the engine as the engine accumulates part, a rebuilt part, or a used part . Some worn
service hours. Consult your Caterpillar dealer about components may be exchanged with your
scheduling a major overhaul . Caterpillar dealer. Consult your Caterpillar dealer
about repair options for your engine .
Note : The driven equipment may also require
service when the engine is overhauled . Refer to the Replacing of Components
literature that is provided by the OEM of the driven
equipment. Note : The cylinder head may be rebuilt, when
possible .
 92
Maintenance Section
Overhaul (Top End)

Replace the following components during the major " Gas regulator
overhaul .
" Inlet air piping
" Alternator
" Oil pump
" Alternator and fan drive belts
" Starting motor
" Camshaft bearings
" Turbocharger
" Connecting rod bearings
" Water pumps
" Crankshaft bearings
Inspecting Components
" Crankshaft seals
Inspect the following components according to
" Crankshaft vibration damper the instructions that are in Caterpillar reusability
publications . Refer to Guidelines for Reusable
" Cylinder liners Parts and Salvage Operations, SEBF8029, "Index
of Publications on Reusability or Salvage of Used
" Cylinder head and gaskets Parts" .
" Exhaust manifold " Aftercooler
" Gaskets and seals " Camshafts
" Gear train bearings " Camshaft followers
" Governor " Connecting rods
" Hoses and clamps " Crankshaft
" Main bearings " Gears of the gear train
" Piston rings " Gear train bushings
" Rod ends for the control linkage of the actuator " Governor
" Spark plugs " Inlet air piping
" Spark plug wires " Oil cooler
" Transformers " Oil pump
" Valve rotators " Pistons
" Water temperature regulators " Transformers
" Wiring harnesses
101614365
Rebuilding of Components v rhaul (T® End)
Rebuild the following components during the major SMCS Code: 7595-020-TE
overhaul . If the components cannot be rebuilt,
replace the components.
Scheduling a T End Overhaul
" Carburetor
Note: For information on estimating operating
" Cylinder packs hours before an overhaul, refer to Maintenance
Management Schedules, SEBU6127 .
" Exhaust bypass
 93
Maintenance Section
Overhaul (Top End)

Top end overhauls are scheduled according to Inspect the following components according to
the recession of the exhaust valve stems . This the instructions that are in Caterpillar reusability
measurement provides an accurate indication of publications . Refer to Guidelines for Reusable
the rate of valve wear. This measurement can be Parts and Salvage Operations, SEBF8029, "Index
used to predict when a cylinder head requires of Publications on Reusability or Salvage of Used
replacement. For more information, refer to this Parts" .
Operation and Maintenance Manual, "Valve Stem
Projection - Measure/Record" topic . Your Caterpillar dealer can provide these services
and components . Your Caterpillar dealer can ensure
Note : The generator or the driven equipment may that the components are operating within the
also require service when the engine overhaul is appropriate specifications .
performed .
If you elect to perform an overhaul without the
Top End Overhaul Information services of a Caterpillar dealer, be aware of the
following recommendations.
A top end overhaul involves servicing the cylinder
heads and turbochargers . Also, some other engine The following definitions explain the terminology for
components are inspected. the services that are performed during an overhaul :

Top end overhauls require more tools than Inspect - Inspect the components according to
preventive maintenance . The following tools the instructions that are in Caterpillar reusability
are needed for restoring the engine to factory publications . Refer to Guidelines for Reusable
specifications : Parts and Salvage Operations, SEBF8029, "Index
of Publications on Reusability or Salvage of Used
" Torque wrenches Parts" . The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
" Dial indicators unnecessary expenditures . New parts are not
required if the existing parts can still be used,
" Accurate measurement tools reconditioned, or repaired . If the components are
not in the reusability guidelines, refer to the Service
" Cleaning equipment Manual, "Specifications" module .

" Rebuilding equipment Rebuild -The component can be reconditioned in

order to comply with reusability guidelines .
Caterpillar dealers are equipped with these tools .
Caterpillar dealers can provide a flat rate price for a Replace - The service life of the part is exhausted.
top end overhaul . The part may fail before the next maintenance
interval . The part must be replaced with a part that
Unexpected problems may be found during a top meets functional specifications . The replacement
end overhaul . Plan to correct these problems, if part may be a new part, a CAT remanufactured
necessary. part, a rebuilt part, or a used part. Some worn
components may be exchanged with your
" Buildup in the cylinders from excessive oil Caterpillar dealer. Consult your Caterpillar dealer
consumption about repair options for your engine .

" Buildup in the cylinders from contamination of Replacing of Components

the fuel
Note : The cylinder head may be rebuilt, when
" Plugging of the aftercooler from coolant that is possible .
poorly maintained
Replace the following components during a top
s Plugging of the aftercooler from contamination end overhaul .
of the inlet air
" Alternator and fan drive belts
" Degradation of the oil cooler from hydrogen
sulfide in the fuel " Cylinder heads and gaskets

" Hoses and clamps

" Rod ends for the control linkage of the actuator

94
Maintenance Section
Overhaul (Top End)

" Spark plugs

NOTICE
" Spark plug wires Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
" Water temperature regulator can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
Rebuilding of Components cleaner.

Rebuild the following components during a top end

overhaul : NOTICE
Do not use a high pressure spray for cleaning the fins
® Carburetor of the core. A high pressure spray can damage the
surface of the fins and reduce the flow of air through
" Gas regulator the core.

® Starting motor 3. Back flush the core with cleaner.

" Turbocharger Caterpillar recommends the use of Hydrosolv

liquid cleaner. Use a two to five percent
" Water pumps concentration of the cleaner at temperatures up
to 93 °C (200 °F). Refer to Application Guide,
Note : Periodic inspection of the turbocharger NEHS0526 or consult your Caterpillar dealer for
is recommended for determining when the more information .
turbocharger will require an overhaul . In a few
applications, the turbocharger may require 4. Steam clean the core in order to remove any
rebuilding prior to the top end overhaul . An example residue . Flush the fins of the core. Remove any
is an application with loads that vary frequently. In other trapped debris .
these cases, rebuilding the turbocharger normally
occurs separately from rebuilding the cylinder 5. Wash the core with hot, soapy water. Rinse the
heads . Some applications can operate longer core thoroughly with clean water.
before the turbocharger requires rebuilding . Only
experience can determine the actual need.

Inspecting of Components Personal injury can result from air pressure .

Clean the following components. Pressure test Personal injury can result without following prop-
the components . Replace the components, if er procedure. When using pressure air, wear a pro-
necessary: tective face shield and protective clothing .
® Aftercooler core (if equipped) Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
" Oil cooler core

Note : It is difficult to clean the aftercooler core when 6. Dry the core with compressed air. Direct the air
maintenance is not performed . in the reverse direction of the normal flow.

Note : This procedure may be used for cleaning both Note : The test pressure for the oil cooler is 790 kPa
the aftercooler core and the oil cooler core . (115 psi) . The maximum differential pressure
of water for the aftercooler is 44 kPa (6 psi) .
1 . Remove the core . For the procedure, refer to the The maximum differential pressure of air for the
Service Manual, "Disassembly and Assembly" aftercooler is 5.1 kPa (0 .74 psi) .
module .
7. Inspect the core in order to ensure cleanliness.
2. Turn the core upside-down in order to remove Pressure test the core . Many shops that service
debris . radiators are equipped to perform pressure tests.
If necessary, repair the core .

6. Install the core . For the procedure, refer to the

Service Manual, "Disassembly and Assembly"
module.
 95
Maintenance Section
Overhaul Considerations

For more information on cleaning the cores, consult Most owners will save money by overhauling the
your Caterpillar dealer. engine at the intervals that are recommended in
this Operation and Maintenance Manual . It is not
Exhaust Bypass practical to wait until the engine exhibits symptoms
of excessive wear or failure . It is not less costly to
Inspect the condition of the exhaust bypass wait. A planned overhaul before failure may be the
(if equipped) . Recondition the component, if best value for the following reasons :
necessary. Refer to this Operation and Maintenance
Manual, "Exhaust Bypass - Inspect" topic " Costly unplanned downtime can be avoided .
(Maintenance Section) .
" Many original parts can be reused according to
Governor the guidelines for reusable parts .

Inspect the governor for proper operation . Make " The service life of the engine can be extended
any repairs that are necessary. without the risk of a major catastrophe due to
engine failure .
Transformers
" Achieve the best cost/value relationship per hour
The transformers produce a voltage increase . For of extended service life .
good operation, the connections must be clean and
secure . Inspect the transformers for the following Overhaul Intervals
conditions :
Note : For information on estimating operating hours
" Dirty insulator before an overhaul, see Maintenance Management
Schedules, SEBU6127.
" Loose connections
Top end overhauls are determined by the projection
" Loose connector of exhaust valve stems. Major overhauls are
determined by cylinder compression, crankcase
" Moisture blowby, oil consumption, and results of S-O-S oil
analysis .
Test the resistance of the transformers according
to the Service Manual, "Specifications" module. Some other factors that are important for
Consult your Caterpillar dealer for assistance . determining the overhaul intervals include the
following considerations :
101012990
" Performance of preventive maintenance
Overhaul Considerations
Use of recommended lubricants
SMCS Code: 7595-043
" Use of recommended coolants
Overhaul Information Use of recommended fuels
An overhaul is replacing the major worn components e Proper installation
of the engine . An overhaul is a maintenance interval
that is planned. The engine is rebuilt with certain " Operating conditions
rebuilt parts or new parts that replace the worn
parts. " Operation within acceptable limits
An overhaul also includes the following maintenance : Engine load
" Inspection of all the parts that are visible during Engine speed
the disassembly
Note : To avoid oil problems, engines that are
" Replacement of the seals and gaskets that are turbocharged and aftercooled must be operated at
removed a minimum of 60 percent of rated load .
" Cleaning of the internal passages of the engine
and the engine block
96
Maintenance Section
Power Take-Off Clutch - Check/Adjust/Lubricate

Generally, engines that are operated at a reduced " Starting motors

load and/or speed achieve more service life before
an overhaul . However, this is for engines that are " Turbochargers
properly adjusted, operated and maintained.
" Water pumps
Overhaul Inspection
Consult your Caterpillar dealer for details and for a
Refer to the Service Manual for the disassembly list of the remanufactured parts that are available .
and assembly procedures that are necessary in
order to perform the required maintenance on the Your Caterpillar dealer may be offering a variety of
items that are listed . Consult your Caterpillar dealer overhaul options .
for assistance .
A Flat Rate Overhaul guarantees the maximum price
To determine the reusability publications that are that you will pay for an overhaul . Flat rate prices on
needed to inspect the engine, refer to Guidelines for preventive maintenance programs or major repair
Reusable Parts and Salvage Operations, SEBF8029, options are available from many servicing dealers
"Index of Publications on Reusability or Salvage of for all Caterpillar Engines . Consult your Caterpillar
Used Parts" . dealer in order to schedule a before failure overhaul .

The Guidelines For Reusable Parts and Salvage Overhaul Recommendation

Operations is part of an established Caterpillar
parts reusability program . These guidelines Caterpillar recommends a scheduled overhaul in
were developed in order to assist Caterpillar order to minimize downtime . A scheduled overhaul
dealers and customers reduce costs by avoiding will provide the lowest cost and the greatest value.
unnecessary expenditures for new parts . If the Schedule an overhaul with your Caterpillar dealer.
engine parts comply with the established inspection
specifications, the parts can be reused . New parts Overhaul programs vary between dealers. To obtain
are not necessary if the old parts can be reused, specific information about the types of overhaul
repaired, or salvaged . programs and services, consult your Caterpillar
dealer.
If the parts are not within the inspection
specifications, the parts should be salvaged, i01506009
repaired, replaced, or exchanged. The use of
out-of-spec parts could result in unscheduled Ovver Take-Off Clutch -
downtime and/or costly repairs. The use of
out-of-spec parts can also contribute to increased heck/Adjust/Lubricate
fuel consumption and reduction of engine efficiency.
SMCS Code : 3055-036 ; 3055-086
Your Caterpillar dealer can provide the parts that
are needed to rebuild the engine at the least NOTICE
possible cost . New power take-offs should have the clutch adjust-
ment checked before being placed into service. The
Overhaul Programs clutch adjustment should be checked again after the
first ten hours of operation . New clutch plates have a
An economical way to obtain most of the parts "wear in" period, and the clutch may require several
that are needed for overhauls is to use Caterpillar adjustments until the new plates are "worn in".
remanufactured parts . Caterpillar remanufactured
parts are available at a fraction of the cost of new
parts. These parts have been rebuilt by Caterpillar
and certified for use. The following components are
examples of the remanufactured parts :

" Alternators

" Connecting rods

" Crankshafts

" Cylinder heads

" Oil Pumps

 97
Maintenance Section
Radiator - Clean

Personal injury can result from air pressure .

Personal injury can result without following prop-

er procedure . When using pressure air, wear a pro-
tective face shield and protective clothing .
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removing

loose debris . Direct the air in the opposite direction
g00781502 of the fan's air flow. Hold the nozzle approximately
Illustration 52 6 mm (0.25 inch) away from the fins . Slowly move
(1) Instruction plate the air nozzle in a direction that is parallel with the
(2) Serial number plate tubes. This will remove debris that is between the
tubes.
Check the clutch adjustment regularly after
"wear in" . Heavy-duty applications which have Pressurized water may also be used for cleaning .
engagements that are frequent and relatively long The maximum water pressure for cleaning purposes
periods of clutch slippage require more frequent must be less than 275 kPa (40 psi) . Use pressurized
adjustment than light-duty applications . The water in order to soften mud. Clean the core from
operating torque should be measured in order to both sides.
determine if a clutch adjustment is required .
Use a degreaser and steam for removal of oil and
Refer to the OEM information and instruction plate grease . Clean both sides of the core. Wash the core
(1) for instructions on lubrication, adjustment, and with detergent and hot water. Thoroughly rinse the
other recommendations for service. Perform the core with clean water.
maintenance that is specified on the instruction
plate . After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine .
Use a light bulb behind the core in order to inspect
Do not operate the engine with the Instruction the core for cleanliness . Repeat the cleaning, if
Plate cover removed from the clutch . Personal necessary.
injury may result.
Inspect the fins for damage. Bent fins may be
If the clutch is damaged to the point of burst fail- opened with a "comb" . Inspect these items for
ure, expelled pieces can cause personal injury to good condition: welds, mounting brackets, air lines,
anyone in the immediate area . Proper safeguards connections, clamps, and seals. Make repairs, if
must be followed to help prevent accidents. necessary.

For more detailed information on cleaning and

i01604510
inspection, refer to Special Publication, SEBD0518,
"Know Your Cooling System" .
a l t r- Clean
SMCS Code: 1353-070

Note : Adjust the frequency of cleaning according to

the effects of the operating environment.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and
other debris . Clean the radiator, if necessary.
98
Maintenance Section
Speed Sensor - Clean/Inspect

101511915 ® Longer service life for the generator set

Speed Sensor - lean/Inspect a Minimum of expensive repairs
SMCS Code: 1907-040 ; 1907-070 Your Caterpillar dealer can help you to establish
an effective Preventive Maintenance Program for
your generator set. Consult your Caterpillar dealer
for details.

Maintenance and Operation

Procedures

The high voltage that is produced by an operat-

ing generator set can cause severe injury or death.
Before performing any maintenance or repairs, en-
sure that the generator will not start.
g00784740
Illustration 53
Speed sensors Place the engine control switch in the "OFF" posi-
tion . Attach "DO NOT OPERATE" tags to all start-
1 . Remove the speed sensor from the flywheel ing controls . Disconnect the batteries or disable
housing. Check the condition of the end of the starting system. Lock out all switchgear and
the magnet. Check for signs of wear and automatic transfer switches that are associated
contaminants . with the generator.

2. Clean the metal shavings and other debris from The recommended maintenance for the engine is
the face of the magnet. listed in this Operation and Maintenance Manual,
"Maintenance Interval Schedule (Standby Generator
3. Install the speed sensor and adjust the speed Set Engines)" (Maintenance Section) .
sensor according to the engine's Specifications
module. For the recommended generator maintenance, see
the Operation and Maintenance Manual for the
101038735
generator and the control panel .

Standby enera r Maintenance and Repair

Set Maintenanc The maintenance that is recommended for Every
Recommendati ns Week can be performed by an authorized operator.
The maintenance that is recommended for the
SMCS Code: 4450-041 subsequent maintenance intervals must be
performed by an authorized service technician or
A standby generator set may not need to be used by your Caterpillar dealer.
very often. However, the generator set is usually
needed for operation in an emergency situation. Unless other instructions are provided, perform
Maintenance of the standby generator set is very maintenance and repairs under the following
important for the following reasons: conditions :
® The generator set must always be in excellent ® The engine is stopped .
operating condition .
e The starting system is disabled .
® The generator set must be ready to work under
load at any time. ® The generator does not pose an electrical shock
hazard .
Establishing a Preventive Maintenance Program will
provide these benefits :

® Maximum availability of the standby generator set

 99
Maintenance Section
Starting Motor - Inspect

Operation Inspect the starting motor for proper operation.

Listen for grinding when the engine is started .
To ensure proper operation, the generator set Inspect the teeth of the starting motor pinion and
must be exercised regularly. For instructions on the flywheel ring gear. Look for patterns of wear on
operating the generator set, see the Operation and the teeth . Look for teeth that are broken or chipped .
Maintenance Manual for the generator set control If damaged teeth are found, the starting motor
panel . pinion and the flywheel ring gear must be replaced .
For these operation procedures, follow the
instructions that are provided in this Operation and Electric Starting Motor
Maintenance Manual, "Operation Section" : starting Note : Problems with the electric starting motor can
the engine, engine operation, and stopping the
engine . be caused by the following conditions : malfunction
of the solenoid and malfunction of the electric
starting system .
Record Keeping
Inspect the electrical system for the following
Maintain a record in order to document these items : conditions :
gauge readings, maintenance that is performed,
problems, and repairs. " Loose connections

Space Heaters " Corrosion

Moisture causes damage to generators and other " Wires that are worn or frayed
electrical equipment. Make every effort to keep the
generator set as dry as possible. " Cleanliness

Generators can operate without problems in humid Make repairs, if necessary.

environments . However, problems can occur when
the generator is inactive . Moisture can condense on
the windings . This can result in poor performance.
Air Starting Motor
Also, damage to the windings can occur.
WARNING
Use space heaters in order to help keep the
windings dry. When the generator is not active, Personal injury or death can result from improper-
ensure that the space heaters are operating . When ly checking for a leak.
the generator is operating, turn OFF the space
heaters. Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tis-
101113939
sue causing serious injury, and possible death.
Starting Motor - Inspect If fluid is injected into your skin, it must be treated
SMCS Code : 1451-040; 1453-040 immediately by a doctor familiar with this type of
injury.
If the starting motor fails, the engine may not start
in an emergency situation. A scheduled inspection Inspect all of the components in the air circuit for
of the starting motor is recommended. the starting motor. Inspect all of the air lines and
connections for leaks .
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine If the teeth of the starting motor pinion and/or the
to start properly. The engine will not start if the flywheel ring gear are damaged, the air circuit for
starting motor pinion does not engage the flywheel the starting motor must be examined in order to
ring gear. The teeth of the starting motor pinion and determine the cause of the problem.
the flywheel ring gear can be damaged because
of irregular engagement .
100
Maintenance Section
Turbocharger - Inspect

Removal and Installation of the 9 Chipping and/or flaking of deposits

Starting Motor If the turbocharger must be removed for inspection,
Refer to the Service Manual, "Disassembly and use caution . Do not break deposits from the turbine
Assembly" module for information on removing the wheel. Do not attempt to clean the turbine wheel.
starting motor and installing the starting motor. For options regarding removal, installation, repair
and replacement, see the Service Manual or consult
Consult your Caterpillar dealer for assistance . your Caterpillar dealer.

Remove the exhaust outlet piping and remove

i01012850 the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil.
Turbocharger ® Inspect
2. Turn the compressor wheel and the turbine
SMCS Code: 1052-040 wheel by hand . The assembly should turn freely.
Inspect the compressor wheel and the turbine
Periodic inspection and cleaning is recommended wheel for contact with the turbocharger housing.
for the turbocharger . There should not be any visible signs of contact
between the turbine wheel or compressor
Fouling of the turbine wheels can contribute to wheel and the turbocharger housing . If there is
loss of engine power and overall loss of engine any indication of contact between the rotating
efficiency. turbine wheel or the compressor wheel and the
turbocharger housing, the turbocharger should
If the turbocharger fails during engine operation, be reconditioned .
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the 3. Check the compressor wheel for cleanliness .
turbocharger compressor wheel could allow parts If only the blade side of the wheel is dirty,
from the compressor wheel to enter an engine dirt and/or moisture is passing through the air
cylinder. This can cause additional damage to the filtering system . If oil is found only on the back
pistons, the valves, and the cylinder head . side of the wheel, there is a possibility of a failed
turbocharger oil seal .
NOTICE
Turbocharger bearing failures can cause large quan- The presence of oil may be the result of extended
tities of oil to enter the air inlet and exhaust systems. engine operation at low idle . The presence of oil
Loss of engine lubricant can result in serious engine may also be the result of a restriction of the line
damage. for the inlet air (plugged air filters), which causes
the turbocharger to slobber .
Minor leakage of a turbocharger housing under ex-
tended low idle operation should not cause problems Note : Deposits can accumulate on the turbine
as long as a turbocharger bearing failure has not oc- wheel. The turbine wheel will become unbalanced
curred . when the deposits flake off . The turbocharger
cartridge must be replaced when this occurs .
When a turbocharger bearing failure is accompanied However, remove deposits from the housing . This
by a significant engine performance loss (exhaust will prevent wear on the blades of the turbine wheel.
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or 4. Inspect the turbine wheel for deposits . If deposits
replaced . of 25 mm (1/16 inch) thickness are found or
if the turbine is in contact with the housing,
the turbocharger must be disassembled and
An inspection of the turbocharger can minimize cleaned . The deposits can be very difficult to
unscheduled downtime . Also, the chance for remove .
potential damage to other engine parts is reduced.
5. Inspect the bore of the turbine housing for
Note : Turbocharger components require clearances corrosion and deposits .
that are precise . The turbocharger cartridge must
be balanced due to high rpm. 6. Clean the turbocharger compressor housing with
standard shop solvents and a soft bristle brush.
The following conditions can cause the turbocharger
to be out-of-balance :

" The buildup of deposits

 10 1
Maintenance Section
Valve Stem Projection - Measure/Record

7. Check the clearances of the turbocharger

bearing . Compare the clearances to the Service
Manual, "Specifications" . If the clearances are
not within the specifications, the turbocharger
must be repaired .

8. Fasten the air inlet piping and the exhaust outlet

piping to the turbocharger housing .

101492440

Valve Stern Projection

Measure/Record
SMCS Code: 1105-082

Valve Recession - The valves and the valve seats

are worn over time. This causes the valves to
recede into the cylinder head. This condition is
called "valve recession" .

The exhaust valves and valve seats show the

greatest wear. The top end overhaul is scheduled
according to the recession of the exhaust valves .

It is difficult to measure the actual valve recession

in the cylinder head . A simpler method is used to
determine the valve recession :

® Measure the projection of the valve rotator

above the cylinder head . It is not necessary to
remove the rocker arms in order to obtain this
measurement .

Measure the projection of the exhaust valve rotators

with the 155-1536 Valve Recession Tool Group.
Follow the instructions that are provided with the
tool group.

Record the measurements on the Operation and

Maintenance Manual, "Valve Data Sheet" (Reference
Materials Section) .

" Measure the projection of the exhaust valve

rotators after 100 to 200 service hours. This
measurement is the baseline . The baseline is a
reference for subsequent measurements.

" Measure the projection of the exhaust valve

rotators at the first 1000 service hours. Illustration
54 shows schedules for determining subsequent
intervals.
102
Maintenance Section
Walk-Around Inspection

2 .286

1110110,0000 ONE Ron 0

(0 .090)

2 .032
(0 .080)
1 .778

1 110110 IBM
(0 .070)

onsion~
1 .524
(0 .060)

1 .270
(0 .050)

is Million I
1 .016
(0 .040)
0 .762
(0 .030)
0 .508

7Jfil 1 logo INN III

(0 .020)
0 .254
(0 .010)

Y
1000 2000 3000 4000 5000 6000 7000 9000 11 .000 13,000 15,000

g00792504
Illustration 54
(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 i01492446

in Illustration 54 that is closest to the measurement
for each cylinder . round Inspection
For example, suppose that the measurement that SMCS Code: 1000-040
was obtained at the initial 1000 hours shows a valve
recession of approximately 0.152 mm (0.0060 inch) . Inspect the Engine for Leaks and
According to Schedule (C), the next interval for
measuring that cylinder is at 5000 service hours. for Loose Connections
Another cylinder may have a valve recession of
approximately 0.254 mm (0.0100 inch). According A walk-around inspection should only take a few
to Schedule (A), the next interval for measuring that minutes. When the time is taken to perform these
cylinder is at 3000 service hours. checks, costly repairs and accidents can be
avoided.
o After 70 percent of the maximum limit has been
reached, measure the projection of the exhaust For maximum engine service life, thoroughly inspect
valve rotators at every 1000 hours of operation. the engine room before starting the engine . Look for
The 70 percent is 1 .60 mm (0.063 inch). items such as leaks, loose bolts, loose connections
and trash buildup . Make repairs, as needed .
" Plan for the top end overhaul as the projection of
the valve rotator approaches the maximum limit. " The guards must be in the proper place. Repair
Perform the top end overhaul when the projection damaged guards or replace missing guards .
of the valve rotator has increased by a total of
2.3 mm (0.09 inch) . Do not allow the recession " Wipe all caps and plugs before the engine is
of the exhaust valves to exceed this limit. The serviced in order to reduce the chance of system
valve head can break. This will cause severe contamination .
damage in the combustion chamber.

Consult your Caterpillar dealer for assistance .

 103
Maintenance Section
Walk-Around Inspection

" Inspect the exhaust system for leaks . If a leak

NOTICE is 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
i01041757
is suspected, check the fluid levels more often than
recommended until the leak is found or fixed, or until Walk-Around Inspection
the suspicion of a leak is proved to be unwarranted .
(Exercise Inspection of
NOTICE
Standby Generator Set
Accumulated grease and/or oil on an engine or deck is Engines)
a fire hazard. Remove this debris with steam cleaning
or high pressure water. SMCS Code: 1000-040

" Ensure that cooling lines are properly clamped . g WARNING

Check for leaks . Check the condition of all pipes.
NEVER use a flame to check for gas leaks . Use a
" Inspect the water pumps for coolant leaks . gas detector.

Note: The water pump seal is lubricated by coolant An open flame can ignite mixtures of air and fuel.
in the cooling system . It is normal for a small This will cause explosion and/or fire which could
amount of leakage to occur when the engine cools result in severe personal injury or death .
and the parts contract .
1 . Perform the procedures that are described in
Excessive coolant leakage may indicate the need this Operation and Maintenance Manual, "Before
to replace the water pump seal . For instructions Starting Engine" topic (Operation Section) .
on removal and installation of water pumps and/or
seals, refer to the Service Manual, "Disassembly 2. Start the engine according to the instructions in
and Assembly" module for the engine or consult this Operation and Maintenance Manual, "Engine
your Caterpillar dealer. Starting" topic (Operation Section).
" Inspect the lubrication system for leaks at the
front crankshaft seal, the rear crankshaft seal, the NOTICE
oil pan, the oil filters and the valve covers. For any type of leak (coolant, lube, orfuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
NEVER use a flame to check for gas leaks. Use a unwarranted.
gas detector.

An open flame can ignite mixtures of air and fuel. 3. Perform an inspection of the installation after
This will cause explosion and/or fire which could the engine is started . Look for leaks . Listen for
result in severe personal injury or death . unusual noises .

" Check the engine oil level when the engine

" Check the fuel system for leaks. Look for loose is operating at low idle rpm . Observe the oil
fuel line clamps . level on the "LOW IDLE" side of the oil level
gauge (dipstick).
" Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps . " Inspect the lubrication system for leaks at the
oil pan, the oil filter, and the valve covers .
" Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed " Inspect the cooling system for leaks at the
wires . hose connections .

" Inspect the ground straps for good connections " Check the fuel system for leaks with a gas
and for good condition . detector .

" Check the condition of the gauges. Replace any Inspect the piping for the air inlet system and
gauge that is damaged . Replace any gauge that the elbows for cracks and for loose clamps .
can not be calibrated .
104
Maintenance Section
Water Pump - Inspect

" Inspect the exhaust system for leaks. A water temperature regulator that fails in a
partially opened position can cause overheating or
" If the enclosure has louvers, inspect the overcooling of the engine .
louvers for proper operation.
A water temperature regulator that fails in the
" Observe the gauges. Ensure the correct closed position can cause excessive overheating .
readings for the engine rpm . Record the Excessive overheating could result in cracking of
engine oil pressure and the jacket water the cylinder head or a seizure of the pistons.
temperature.
A water temperature regulator that fails in the open
Record the data for the performance of the position will cause the engine operating temperature
generator. See the Operation and Maintenance to be too low during partial load operation. Low
Manual for the generator and the control panel. engine operating temperatures during partial loads
could cause an excessive carbon buildup inside
4. After exercising the generator set, stop the the cylinders. This excessive carbon buildup could
engine according to this Operation and result in an accelerated wear of the piston rings and
Maintenance Manual, "Engine Stopping" topic wear of the cylinder liner. Also, a low temperature
(Operation Section) . can allow moisture to condense in the oil . This can
form damaging acids.
5. Perform the procedures that are described in
this Operation and Maintenance Manual, "After NOTICE
Stopping Engine" topic (Operation Section) . Failure to replace the water temperature regulators on
a regularly scheduled basis could cause severe en-
6. Ensure that the control switches are in the correct gine damage.
position for automatic starting of the generator
set. Never operate the engine without the water tempera-
ture regulators installed .
100524084
If the water temperature regulator is installed incor-
Water Pump - Inspect rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
SMCS Code: 1361-040 ulator is installed in the original position .
A failed water pump might cause severe engine
overheating problems that could result in cracks in For the procedure to replace the water temperature
the cylinder head, a piston seizure or other potential regulators, see the Service Manual, "Disassembly
damage to the engine . and Assembly" module . Consult your Caterpillar
dealer for assistance .
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of Note : If only the water temperature regulators are
the water pump seals. Refer to the Service Manual replaced, drain the coolant from the cooling system
for the disassembly and assembly procedure. to a level that is below the water temperature
regulator housing .
Inspect the water pump for wear, cracks, pin holes
and proper operation. Refer to the Service Manual
or consult your Caterpillar dealer if repair is needed
or replacement is needed.

101023425

Water Temperature e ulat®r -

Replace
SMCS Code: 1355-510
Replace the water temperature regulators before
the water temperature regulators fail . This is a
recommended preventive maintenance practice .
Replacing the water temperature regulators reduces
the chances for unscheduled downtime .
 105
Reference Information Section
Customer Service

Reference Inf r ati n 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

101706971
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 Fax: 65-662-8302
that 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 Hong Kong
phone number that is listed below to talk with a Phone: 852-2848-0333
Field 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-Chime
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 610 817, AIG Aoyama Bldg .
Mossville, Illinois 61552-0610 2-11-16, Minami-Aoyama
Minato-ku, Tokyo 107-0062
Please keep in mind : probably, your problem will Phone: 81-3-5786-3803
ultimately be solved at the dealership, using the Fax: 81-3-5786-3809
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 f 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 Phone: 03-9953-9333
the dealer level, consult the appropriate Caterpillar Fax : 03-9335-3366
office .
106
Reference Information Section
Customer Service

101028392

Ordering Replacement Parts

SNICS Code: 4450 ; 7567

A WARNING
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 .
 107
Reference Information Section
Reference Materials

Reference Material " Owner's receipts

" 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

108
Reference Information Section
Reference Materials

101176304

Maintenance Log
SMCS Code: 1000 ; 4450
Table 31
 109
Reference Information Section
Reference Materials

101336180

Valve Data Sheet

SMCS Code: 1000

Table 32
Engine Model Serial Number Service Hours Authorization
Cylinder Valve Location Current Baseline of Baseline of
Cylinder Wear
Pressure Measure the Stem the Rotator
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

101409038 " Data Sheet, PEWP9733, "Caterpillar Fluids

Selector Dial"
Reference Material
" Special Publication, PECP6026, "One Safe Source
SMCS Code: 1000 ; 4450 (NACD)"
The following literature can be obtained through any " Special Publication, PECP6027, "One Safe Source
Caterpillar dealer. (COSA)"

Lubricants " Special Publication, PECP6028, "One Safe

Source"
" Data Sheet, NEDG6022, "Caterpillar Lubricating
Grease" Fuels
" Data Sheet, PEHP0017, "Special Purpose Grease " Data Sheet, LEKQ5404, "Fuel Specifications
(SPG) Bearing Lubricant" Changes"
" Data Sheet, PEHP0002, "Multipurpose Lithium " Data Sheet, LEKQ9360, "Internal Combustion
Complex Greawe with Molybdenum (MPGM)" Engine Fuel Gases"
" Special Publication, SEBD0640, "Oil and Your " Data Sheet, LEKQ9416, "Low Energy Gas Fuels"
Engine"
" Data Sheet, LEKQ2364, "US Stationary Engine
" Special Publication, PEDP1129, "Listen To Your Regulations/Spark Ignited Emissions"
Oil"

" Data Sheet, PEHP0004, "Natural Gas Engine Oil" Coolants

" Special Instruction, PEHP6001, "How To Take A " Data Sheet, PEHP4036, "Extended Life Coolant"
Good Oil Sample"
11 0
Reference Information Section
Reference Materials

" Data Sheet, LEKQ8567, "Water Treatment " Special Instruction, SEBF8062, "Procedure to
Recommendations for Ebullient and Solid Water Inspect and Clean Air Filters"
Cooled Engines"
" Special Instruction, SEHS7654, "Alignment-
" Special Publication, PEDP5033, "S . 0-S Coolant General Instructions"
Analysis"
" Special Publication, SEBF8029, "Index of
" Special Publication, SEBD0518, "Know Your Publications on Reuseability or Salvage of Used
Cooling System" Parts"

" Special Publication, SEBD0970, "Coolant and " Special Instruction, SMHS7001, "Assembly of Fan
Your Engine" Drive Pulley Assemblies"

Miscellaneous " Service Manual, SENR3865, "3406 Spark Ignited

Engine (4FD)"
" Specifications, SENR3130, "Torque Specifications"
" Service Manual, SENR4670, °3406 Spark Ignited
" Special Instruction, SEHS7332, "Do Not Operate Engine"
Tag"
101775229
" Special Instruction, SEHS7633, "Battery Test
Procedure" Additional Reference Material
" Special Instruction, SEHS7768, "Use of the SMCS Code: 1000 ; 4450
6V-2150 Starting/Chargineg Analyzer"
The "Engine Fluids Data Book" can be obtained
" Special Instruction, SEHS8712, "Using the from the following locations : local technological
8T-2700 Blowby/Airflow Indicator Group" society, local library, and local college . If necessary,
consult EMA at the following address :
" Special Instruction, SEHS9031, "Storage
Procedure for Caterpillar Products" Engine Manufacturers Association
Two North LaSalle Street, Suite 2200
" Special Instruction, SEHS9298, "Installation and Chicago, Illinois, USA 60602
Maintenance of Gaseous Fuel Filters" E-mail: ema@enginemanufacturers .or g
(312) 827-8700
*Special Publication, NEHS0526, "Service Facsimile : (312) 827-8737
Technician Application Guide"
The "Society of Automotive Engineers (SAE)
" Special Publication, NENG2500, "Caterpillar Tools Specifications" can be found in your SAE handbook .
and Shop Products Guide" This publication can also be obtained from the
following locations : local technological society, local
" Service Manual, SENR5359, "SR4B Generator library, and local college . If necessary, consult SAE
Service Manual" at the following address :

" Service Manual, SENR3985, "SR4 Generator SAE International

Service Manual" 400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
" Operation and Maintenance Manual, SEBU6918, Telephone : (724) 776-4841
"SR4B Generator and Control Panels"
The "American Petroleum Institute Publication No .
" Operation and Maintenance Manual, SEBU6150, 1509" can be obtained from the following locations :
"SR4 Generator and Control Panels" local technological society, local library, and local
college . If necessary, consult API at the following
" Special Instruction, SEHS9124, "Cleaning and address :
Drying of Electric Set Generators"
American Petroleum Institute
" Engine Performance, LEBQ6483, "G3400 1220 L St. N. W.
Industrial Engine Performance" Washington, DC, USA 20005
Telephone : (202) 682-8000
" Engine Performance, LEBQ6484, "G3400
Industrial Engine Performance"
 111
Reference Information Section
Reference Materials

The International Organization for Standardization

(ISO) offers information and customer service
regarding international standards and standardizing
activities . ISO can also supply information on the
following subjects that are not controlled by ISO:
national standards, regional standards, regulations,
certification, and related activities. Consult the
member of ISO in your country.

International Organization for Standardization

(ISO)
1, rue de Varembe
Case postale 56
CH-1211 Geneve 20
Switzerland
Telephone: +41 22 749 01 11
Facsimile : +41 22 733 34 30
E-mail : central@iso .ch
Web site : http://www .iso.ch

European classifications are established by the

Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).

CIMAC Central Secretariat

Lyoner Strasse 18
60528 Frankfurt
Germany
Telephone : +49 69 6603 1567
Facsimile : +49 69 6603 1566

i00382622

Warranty Information
SMCS Code: 1000

Engine Protection Plans

Extended Warranties and Service
Contracts

A wide variety of protection plans are available for

Caterpillar Engines. Consult your Caterpillar dealer
for detailed information on the specific programs
and coverages that are available .

Consult your Caterpillar dealer for information on a

plan that is tailored in order to fit your requirements .
 11 2
Index Section

Index
A Conventional Coolant/Antifreeze Cooling System
Maintenance . . .... . . ... . . .... . . .. . . . . . ... . . . ... . .... . ... . . .. . . . .... . 50
Actuator Control Linkage - Lubricate . ... . ..... . .... . . . ... 59 Adding the SCA to Conventional Coolant/Antifreeze
Check the Linkage ... . . .. . . . ... . .... . . ... . . ... . .... . . .... . . . ... 59 at the Initial Fill ... . .... . . .... . . . ... . . . .... . ... . ... . .. . . . . .... . . . 51
Additional Reference Material .... . ... . . ... . . .... . . .... . ... 110 Adding the SCA to Conventional Coolant/Antifreeze
After Starting Engine ... .... . .... . . .... . ... . . .... . .... . . ... . . ... . . 36 For Maintenance . .... . . ... . . . .... . . .... . .... . ... . .. . . . . .... . .. 51
Engaging the Driven Equipment . . . .. . . .... . . ... . . . ... . . 36 Cleaning the Cooling System of Heavy-Duty
Warm-up . . . .... . ... . . . ... . .... . ... . . . .... .... . . ... . . .... ...... . ... . . 36 Coolant/Antifreeze . .. .... . . .... . . . .... . ... . . . .. ..... . .. , . ... 52
After Stopping Engine . . ... . . ... . . ... . . ... . . ... . .... . . .... . . . .. . . . 39 Coolant Recommendations .. . . . ..... . .... . ... . ... . ...... . ... . 49
Aftercooler Core - Clean/Test (Air-To-Air Cooling System Coolant (DEAC) - Change ...... .... . 64
Aftercooler) . ... . . ... . .... . . ... . . ... . . ... . . ... . . ... . .... . . .... . . . ... . . 59 Clean the Cooling System . . . .... . . ... . . ... . .. . . .... .. .... . 64
Aftermarket Oil Additives . . ... . .... ..... . . ... . .... . . .... . ... . . . . 42 Cleaning a Cooling System that has Heavy
Air Tank Moisture and Sediment - Drain . . .... . . . ... . . .. 59 Deposits or Plugging . . ... . .. .... . . .... . ... . ... . .. . . . . .... . . . 65
Alarms and Shutoffs . . .... . ... . . . .... .... . ... . . . ... . .... . . . ... . ... 30 Drain the Cooling System . . .... . ..... . ... . ... .... . . . . ... . .. 64
Engines Without A Caterpillar Remote Control Fill the Cooling System . .. . ..... . ..... . . . . . ... ...... . . .... . .. 65
Panel (Status) ..... . ... . . .. . . . ... . . ... . . ... . .... . . .... . .... . . ... 31 Cooling System Coolant Analysis (Level II) -
Testing Alarms and Shutoffs . ... . . ... . .... . . .... . .... . . ... 30 Obtain . . ... . .... . .... . . ... . .... . ... . . . ... . . . .... . . .. . .... ... . .. .... . . . .. 66
Alternator- Inspect .. . . .. . . ... . . .... .... . . ... . . .... . ... . . . ... . . . ... 60 Cooling System Coolant Level - Check . . ... . .. .... . . . .. 66
Alternator and Fan Belts - Inspect/Adjust/ Cooling System Specifications . . ... . . ... . ... . ... . . ..... . . . .. 47
Replace . .. .... . . ... . ..... . ... . . .. . . . .... .... . ... . . . .... .... . . . ... . .... . 60 Cooling System Supplemental Coolant Additive
Alternator Belt Adjustment .. . ... . . ... . . .... .... . . . ... . . . ... 60 (SCA) - Test/Add .. . ... . . ... . . ... . . . . .... . . .. . . ... .... ... . .. . . . ... . 67
Fan Drive Belt Adjustment .. .... . . ... . . .... . ... . . . ... . ..... 61 Add the SCA, If Necessary . . .... . ... . .... . ... . .. . .. . . . ... . 67
Inspection... . ... . . .... . ... . . . ... . .... .... . . .... . .... ..... . . ... . .... . 60 S-O-S Coolant Analysis (Level I) .. . .... .. . . .. . . . . . . .... . 67
Replacement .. . . .... .... . . .. . . . .... .... . .... . .... . .... . . .... . .... . 60 Test the Concentration of the SCA... . ... ... . . . . . . . ... . 67
Automatic Start/Stop - Inspect (Generator Set) .... . 61 Crankcase Blowby - Measure/Record . . ... ... . . . . . . .... . 68
Crankshaft Vibration Damper - Inspect .. . ... .. . . . .... . . 68
Visconic Damper ... . ... . . .... . .... . . . .... . .. . .. . . . .. . . . . . . ... . .. 68
B Crushing Prevention and Cutting Prevention . ..... . .. 14
Customer Assistance . ... . ..... . .... . . . ... . . ... .... ... . . . . . . ... . 105
Batteries - Replace . . ... . . ... . .... . ... . . ... . . .... .... . . . ... . . ... . . . 61 Outside of the USA and of Canada . .... . .. . . .. ..... . 105
Battery Charger - Check .. . .... .... . . ... . . ... . .... . . . ... . .... . . . 62 USA and Canada . . . ... . .... ...... . .... . . .... ... . .. . .. . . ..... . 105
Checking After Stopping ... . ... . ... . . . .... .... . . .... . .... . .. 62 Customer Service ... . .... . . ... . .... . . . ... . . . ... ... . ... . .. . .... . .. 105
Checking Before Start-Up . . . .. . . . .. . . .... . .... . . ... . . . ... . . 62 Cylinder Pressure - Measure/Record ... . ... ... . .... . . ... 69
Battery Electrolyte Level - Check . . . . .... .... . . .... . .... . .. 62
Before Starting Engine . ... . .... .... . . ... . . .... .... . . .... . . 15,32
Air Inlet System .. . . ... . . ... . .... . ... . ... . . . .... .... . . .... . . ... . . . 32 D
Cooling System .. . . ... . . ... . .... . ... . .... . . .... .... . . . ... . . ... . . . 32
Driven Equipment ... . ... . . .... .... . ... . . ..... .... . . .... . .... . . . 32 Diesel Engine Antifreeze/Coolant (DEAC) . . . . . . .... . . 49
Electrical System . ... . ... . ..... . ... . ... . . ..... .... . . .... . .... . .. 32 Driven Equipment - Check ... . ..... . . .... . ... ... . ... . . . . . . . .... 70
Fuel System . . . ... . .... . . ... . .... . .... . ... . ..... . .... . . ... . . .... . .. 32 Driven Equipment - Inspect/Replace/Lubricate ... . . 70
Lubrication System . . .. . . ... . . .... . ... . . ... . . .... . .... . . .... . .. 33
Starting System . .... . ... . .... . . ... . . ... . .... . ... . . . ... . . . ... . ... 33
Walk-Around Inspection .. . . ... . .... . .... . . .. . . . ... . . . ... . ... 32 E
Belts - Replace . ... . . .... . ... . . ... . . ... . . ... . .... . ... .. . ... . . . ... . ... 63
Burn Prevention ... . . .... . ... . .... . . ... . . ... . .... . ... . . . ... . . . ... . ... 12 Electrical System . . . ... . .... .... . ... . . . .... . . .. . ... . .. . ... . ..... . . .. 16
Batteries .. . ... . . ... . . ... . . ... . .... . ... . . .... . .... .... . . . ... . ... .. . . . . 12 Grounding Practices .. .... . ... . . . .... .... . ... . ... ... . . .... . . .. 16
Coolant . ... . ... . .... . . .... . ... . .... . . ... . ... . . .... . ... . . . ... . . . ... . ... 12 Emergency Stopping . .... ... . . ... . . . .... .... . ... . .. .... . . ..... . .. 38
Oils . . . . . . . ... . ... . . . .. . . .... . ... . . ... . . .. . . . ... . .... . . .... . ... . . ..... . . . 12 Emergency Stop Button . . ... . .... . . .... . ... ... ... . . . .... . ... 38
Engine - Clean . .... . ... . .... . ... . . . .. . .... . . .... . .. .... ... . .. .... .... 70
Engine Air Cleaner Element - Replace .... .. . . .. .. . . .... 71
C Cleaning the Primary Air Cleaner Elements . . . ... 72
Servicing the Air Cleaner Elements . ... ... . . . . . . . . .... 71
Carburetor Air/Fuel Ratio - Check/Adjust . ... . .... . ... . 63 Engine Air Cleaner Service Indicator - Inspect . . ... . 73
Cold Weather Starting . .. . .... . ... . . ... . . .... .... . . . ... . .... . . ... 33 Test the Service Indicator . ..... . .... . ... . ... ... . .. . .. . . .... 73
Commercial Heavy-Duty Coolant/Antifreeze and Engine Air Precleaner - Clean .. . . .... . ... . .. . ... ... . . . . . ... . 74
SCA . . . . . . . ... . ... . . ... . . ... . . ... . .... . ... . . .... . .... .... . . . ... . ..... . ... 50 Engine Crankcase Breather - Clean .. . . .. .... .. . .. . . . ... . 74
Control Panel - Inspect .. . .... . ... . . ... . . .... .... . . . ... . .... . . ... 63 Engine Lifting . . ... . . ... . ... . ... . . ... . . ... .... . . . .. .... ... . .. . . . . . ... . . 24
Record the Data and Review the Data. . ... . .... . . ... 63 Engine Lifting with a Generator. . .... .... .. . ... . . . . .... . . 24
 11 3
Index Section

Engine Lifting and Storage . . . ... . .... .. ... . . ... . .... . . .. . ... . . 24 G
Engine Mounts - Check ... ... . . ... . . ... . . ... . . ... . .... . ... . ... . . 75
Engine Oil . ... . ... . .... . . .... . ... . ... . . ... . .... . ... . . . ... . .... . ... . ... . . 40 Gas Pressure Regulator - Check. . ... . ... . .... . ... . . ..... .. 83
Commercial Oils. . .. .. . . .. . . . . . . ... . .... ..... . . ... . .... . . .. . ... . . 41 Pressure of the Fuel Supply To the Carburetor .. 83
Lubricant Viscosity Recommendations .... . ... . ... . . 42 Gas Pressure Regulator Condensation - Drain ... . . 83
Sour Gas and Bio-Gas Applications ... . .... . ... . . ... . 41 Gauges and Indicators ... . ... . . ... . . ... . .. . .... . ... . . . ... . .... . . 26
Engine Oil and Filter - Change . . ... . ..... . ... . . ... . . .. . . .. .. 78 General Coolant Information . ... . ... . ... . ... . .... . . ... . . ... . . 47
Drain the Engine Oil . .... .... . ... . . ... . . .... . ... . . .... . ... . ... . 78 Additives . . .... . . ... . . ... . .... . ... . . .... ... . ... . . ... . ... . . . ... . .... . . 48
Fill the Engine Crankcase . ... . .... . ..... . ... . .... . . ... . ... . 79 Glycol . . . .... .... . . . ... . ... . .... . ... . . .... .... . ... . ... . .... . . ... . ... . . . 48
Replace the Oil Filter ... ... . . ... . . .... . .... . ... . . ... . . .. . .... . 79 Water . . . .... .... . . . ... . ... . .... . . ... . .... .... . ... . ... . .... . . ... . .... . . 47
Engine Oil Filter (Auxiliary) - Change . . ... . . ... . . ... . ... . 75 General Hazard Information . . .... .... . .. . . ... . ... . . ... . . . .... .. 9
Engine Oil Level - Check . .... . ... . ..... . .... . ... . . ... . . .. . ... . . 76 Asbestos Information .. . . ... . . ... . .... . .. . ... . . ... . . ... . . ..... 11
Engine Oil Sample - Obtain . . ... . . ... . . .... . ... . . ... . . ... . ... . 77 Containing Fluid Spillage . . . ... . ... . .... ... . . ... . . ... . . . ... . 11
Obtain the Sample and the Analysis ... . . ... . . .. .. . ... 77 Dispose of Waste Properly .... .... . ... . .... .... . ... . . . .... 12
Engine Operation .. . . . ... . .... .... . ... . . . ... ..... . ... . . ... . . .... .... 37 Fluid Penetration . .... .... . ... . . . .... ... . .... ... . . ... . . ... . . . .... 11
Operating the Engine and the Driven Pressure Air and Water... . .... . . ... .... .... . ... . . . ... . . ... . . 10
Equipment . .. .... . .... . . .... ... . ... . . .... . .... . . ... . .... . ... . . .. . . 37 Governor - Inspect . . ... . .... . .... . . .... .... . .. . . ... . .... . ... . . . . . . . 84
Partial Load Operation . ... . .... . .... . .... . . ... . .... . ... . ... . . 37 Governors and Actuators. ... . . . ... . ... . .... ... . .... . . ... . . .... . 31
Engine Performance - Test . . . ... . .... ..... . . ... . .... . ... . ... . . 80 Woodward 8290/1724 Governor . ... ... . . ... . . ... . . . ... . 31
Engine Protective Devices - Check ... . . ... . .... . . .. . ... . . 80 Woodward Flo-Tech Speed Control .... .... . ... . . . .... 31
Visual Inspection ... . . ... . . ... . ... . . .... . ... . . .... . .... .... . ... . . 80 Woodward PSG Governor . .... .... . ... . .... .... . . .. .. . .... 31
Engine Speed/Timing Sensor - Clean/Inspect... .... 81
Engine Starting . .... . . .... . .... .... . ... . ..... ..... . ... . . ... . . .. 15,32
Engine Stopping .... . .... . .... .... . ... . ..... . .... . ... . . ... . . .. 15,38 H
Engine Storage . . ..... . ... . .... .... . ... . . . .... .... . . ... . . .... .... . ... 25
Generator Storage .. . .... .... . ... . . . ... . .... . . ... . . ... . .... . ... 25 Hoses and Clamps - Inspect/Replace . ... . ..... . ... . . . .. 84
Engine Valve Lash - Inspect/Adjust .... . ... . .... . . ... . .... 81 Replace the Hoses and the Clamps ... . ..... . ... . . . .. 84
Engine Valve Lash .. . .... .... . .... . . ... . .... . . ... . . ... . .... . ... 81 Hoses and Clamps - Replace . ... . .... . ... .... . ..... . ... . . ... 85
Valve Bridge .. . . ... . . ... . . ... .... . ... . . . ... . .... . . .... . ... . .... . ... 81
Engine Valve Rotators - Inspect . ... . .... . ... .. . ... . .... . ... 81
Exhaust Bypass - Inspect .... . ... . . ..... .... . ... . . . ... . .... . ... 82
Exhaust Piping - Inspect.. .... . . .... . .... . .... . . ... . .... . ... . ... 82
Water Cooled Exhaust Manifolds .... . . ... . . .... .... . ... 82 Ignition System Spark Plug Wires - Replace
(Standard Ignition Systems) . . .... .... . ... . .... . .... . . ... . . . 85
Ignition System Spark Plugs - Check/Adjust/
F Replace ... . ... . . . . . .. . . .. . .... . .... . . ... . .... .... . ... . .... .... . . . ... . .. 85
Cleaning the Spark Plug . . ... . .... .... . ... . .... ...... . ... . . . 88
Features and Controls . . . ... . ... . . ... . .... . ..... . ... . .... . ... . . .. 29 Inspecting the Spark Plug . ... . ... . ... . . ... . ... . . .... . .... . . 87
Fire Prevention and Explosion Prevention . .. ... . .... . . 12 Installing the Spark Plug . . ... . .... .... . ... . .... . . .... . ... . . . 88
Fire Extinguisher .. . . ... . ... . .... . ... . .... . . .... . ... . ..... . .. . . .. 13 Removing the Spark Plug . .... . ... .... . ... . . .... .... . . . ... . 86
Lines, Tubes and Hoses. .... . ... . . . ... . .... . . ... . .... . ... . . . 14 Ignition System Timing - Check/Adjust . . . .... .... . . . ... . 89
Foreword .... . ... . .... . . ... . . ... . .... .... . . .... . .... . .... . .... . .... .... . ... 5 Ignition System Transformer Resistance - Test . ... . 89
California Proposition 65 Warning . .... . . ... . .... .... . ... 4 Ignition Systems .... . ... . .... . .... . .... . .... .... .... . .... . ... . . . ... . 14
Literature Information . .... .... . . .... . .... .. .. . . . ... . .... .... . ... 4 Magneto . . . .... . . ... . . ... . .... . ... .. . ... . ... . .... . ... . .... . .... . . ... . 14
Maintenance ... . . .... . ... . . ... .... . ... .. . .... .... . . .... . .. .. . ... . ... 4 Important Safety Information . ... . .... .... . ... . .... . ..... . ... . . . 2
Maintenance Intervals .. . . ... . . ... . .... . ..... . ... . .... . ... . . .. . . 4 Inlet Air System - Inspect. .... . . ... . .... .... . ... . .... . . ... . . ... . 90
Operation ... . . ... . . .... . .... . ... ..... . . ... . .... . . ... . . ... . .... .... . ... 4 Instrument Panel - Inspect... . . ... . .... .... . ... . .... . ..... . ... . 90
Overhaul . ... . . .... . .... . . ... . ... .. ... . . ... . .... . . .... . ... . .... .... . ... 5
Safety . .... . ... . ..... . .... . ... . . . .. .... . . .... . .... . . .. . . . ... . .... .... . . .. 4
Fuel Recommendations.. . ... . ... . . ... . .... . . ... . . ... . .... .. .. . . 44 J
Dry Natural Gas .... . . ... . ... . . ... . . ... . . ... . . .... . ... . . . .. . ... . . 44
Gaseous Fuel Filters ... . ... . ... . . ... . . .... . .... . ... . . ... . . .... 46 Jacket Water Heater - Check . . ... . . .. . . ... . ... . . .... . .... . . .. 90
General Fuel Information . .... . ... . . ..... .... . . .. . . . ... . .... 44
Propane . .. ... . . .... . . ... . . ... . ... . .... . ... . ..... . .... . ... . . . ... . . . . . 44
Sour Gas .. . .. . . .... . .... . . ... . .... .... . ... . . ..... .. . . . . . .. . . ... . .... 45 L
Wellhead Gas (Field Gas) .... . . . ... . ... . . ... . . .... . .... .... 45
Fuel Specifications . .... . ... . ... . . ... . ... . . ..... .... . . .. . . . .... .... 44 Lubricant Information . ... . . ... . . ... . .... .... . ... . .... . . .... ..... . . 40
Fuel System Fuel Filter Differential Pressure - Lubricant Specifications . .... .... . ... . . ... . ... . ... . . . .... .... . . . 40
Check. .... .... . ... . . . ... . ..... . ... . ... . . ... . . ... . ..... . .... . ... .. ... . . .. 83
 114
Index Section

M Reference Material ... .... . ... . .... . .... . . ... . .... . ..... ...... . . . 109
Coolants . . . . . . . . . . . . .. . . .... . .. . . .. . . .. .. . . . .. . . .. . . . .......... . . .. 109
Maintenance Interval Schedule (Naturally Aspirated Fuels . . . ... . . . .. . . . . . . ... . ... . . ... . .... .... . . . ... . .... ...... ...... . . . 109
Engines) . . .... . . . .. . . . .. . .... .... . ... . . ... . ... . ... . . . ... . .... . . . ... . . . . 57 Lubricants .... . ... . .. . . . ... . ... . .. .. . .... . . ... . .... . ........... . . . 109
Maintenance Interval Schedule (Standby Generator Miscellaneous . . . ... . .. . . .. . . .... . .... . . . .. . .... . ........... . . .. 110
Set Engines) . ... . . ... . ... . .... . ... . .... . ... . ... . . . ... . .... . . . ... . . . . 58 Reference Materials . ... . ... . ... . . .... . . ... . ..... . ........... . .. 107
Maintenance Interval Schedule (Turbocharged Refill Capacities .. . ... . . .. . . .. . .... . . .... . . ... . . .... ............ . ... . 55
Aftercooled Engines) . ... . ... . . .... .... . ... . .... . .... . . .... . . . .. 56 Cooling System . .. . ... . ... . .... . . .... . . ... . ... . . ............ . ... . 55
Maintenance Log . . . . ... . ... . ... . . . .... ... . . ... . .... .... . . . ... . . . . 108 Lubrication System . . . .. . .... . ..... . ... . .... . . .... ...... . . . ... . 55
Maintenance Records. ... . ... . . . .... ... . . ... . .... .... . . . ..... . . 107
Maintenance Section . . ... . ... . . .... . ... . ... . . .... .... . . .... . . . ... 40
Manual Stop Procedure . . ... . .... . ... . . ... . .... . .... . ..... . . . ... 38 S
Model View Illustrations . . ... . .... .... . ... . . ... . ..... . ... . . . ..... 17
Model Views and Specifications . . ... . .... . .... . . ... . . . .... . 17 S-O-S Coolant Analysis . . . .. . . .... . . . ... . .... .... . . . . .. .. . . .... . 54
Mounting and Dismounting . .... .... . ... . .... .... . . . ... . . . .... . 14 S-O-S Coolant Analysis (Level I) . .. . . .... . . . . . . . . . ... . . . 54
S-O-S Coolant Analysis (Level II) .. . . ... . . . . . . . . . . ... . . . 54
S .0-S Oil Analysis .... . . .. . ... . .... . . . ... . .... . .... . . . . . . . . . . ... . . . 43
Condemning Limits of the Oil ... . .... . .... . . . . . . . . . . ... . .. 43
Safety Messages . . .... . .. . . .... .... . . .... . . ... . ... . . . . . . . . . . . ... . .... 6
Operation Section .. . . ... . .. . . ..... .... . ... . .... . ... . .... . . . . .... . .. 24 Safety Section . . ... . . . .. . .. . . .... .... . . . ... . . ... . ... . . . . . . . . . . . ... . . ... 6
Ordering Replacement Parts .... . ... . .... . . ... . . ... . .. .... . 106 Specifications . . . ... . .. . . . . .. . ... . .... . . . ... . .... . .... . . . . . . . . . . ... . . . 21
Overhaul (Major) .... . . .. . ... . .... . . .... . .. . . .... .... . ... . . . ..... . ... 90 Speed Sensor - Clean/Inspect . . ... . . ... . . ... . . . . . . . . . . ... . . . 98
Major Overhaul Information . . . ... . .... .... . ... . . . .... .. . .. 91 Standby Generator Set Maintenance
Scheduling a Major Overhaul . .. . . .... . ... . . ... . . . . ... . ... 90 Recommendations . . .. . . ... .... . . . .... . . . . .. .... . . . .. . . . . . . ... . .. 98
Overhaul (Top End) ... . ... . .... . . .... ... . . ... . .... . ... . . . ..... . ... 92 Maintenance and Operation Procedures . . . . . ... . .. 98
Scheduling a Top End Overhaul .. . . ... . . ... . . ..... . . ... 92 Starting Motor - Inspect ... . ... . . . ..... . .... .... . . . .. . . . . . . ... . . . 99
Top End Overhaul Information . .... . . ... . . ... . ...... . ... . 93 Air Starting Motor. . ... . ... . ... . . . ..... . .... . ... . . . .. . . . . . . ... . . . 99
Overhaul Considerations ... . .... . ... . .... . .... . ... . . ...... .... . 95 Electric Starting Motor . . ... . . . ... . . . .... .... . .... . . . . . .... . . . 99
Overhaul Information . ... . . .... . ... . .... . ... . .... . . .... . . ..... 95 Removal and Installation of the Starting
Motor .. . .... . . .... .... . ... . .... .... . . . ... . . . ... . .... . ..... . . . . .... . 100
Starting the Engine . . ... . .... .... . . .... . . . ... . .... . ..... . . . ..... . .. 34
P Automatic Starting .. . .... .... . . . ... . . . ... . .... . . .... . . . . . ... . .. 34
Manual Starting . . . ... . . .. . . ... . . .... . . .... . .... . . ... ... . . ... . . . .. 34
Performance Parameters .. .... . . ... . ... . . .... . ... . . ..... . .... . . 29 Operation of the Generator Set Control Panel . .. 34
Air/Fuel Ratio . . . .... . ... . .... .... . . .. . .... . . .... . ... . ..... . . .... . . 29 Starting with Jump Start Cables . . . ... . ... . . ..... . . . ..... . . . 35
Fuel Consumption . ... . ... . .... . . ... .... . . .... . ... . .... .. . . .... . 29 Supplemental Coolant Additive (SCA) . . . ..... . . . ..... . .. 50
Throttle Angle and Exhaust Bypass Synthetic Base Stock Oils . . . . .... . . .... . .... . . ... .. . . . ..... . .. 42
(Wastegate) .. . . .. . . ... . ... . . ... . . ... . .... . ... . . . ... . .... . . ..... . . 30
Plate Locations and Film Locations... . . ... . . .... . . .... . . . 22
Information Plate . ... . .... ..... . . ... . ... . .... . . ... . ..... . . .... . .. 22 T
Serial Number Plate . ... .... . . . ... . ... . .... . . ... . . .... . . .... . . . 22
Power Take-Off Clutch - Check/Adjust/Lubricate . . . 96 Table of Contents .. . ... . .... . ... . ..... . . . .... . ... . .. ... . .. . . ... . . . .... 3
Product Description ... . .... .... . . . ... . ... . .... . .... . . .... . . .... . . . 20 Turbocharger - Inspect... . ... . . .... . . . .... . .... . . ... ... . . .. ... . 100
Cooling System . . . ... . .... .... . . .... ... . . .... . ... . ..... . . . .... . .. 20
Engine Service Life . .... .... . ... . . ... . ..... . ... . .... . . ...... . .. 20
Ignition System . . . ... . .. . ... .. . ... . .... ...... . ... . .... . . .... . . . .. 20 V
Inlet Air and Fuel System . .. ... ... . . .... . .... . .... . .. .... . .. 20
Lubrication System . ... . ... . . ... . . ... .... . . . ... . .... . . .... . . . .. 20 Valve Data Sheet .. . ... . .... . ... . ..... . . . .... . .... . . ... ... . . . . ... . 109
Product Identification Information .... . . . ... . .... . ..... . . ... 22 Valve Stem Projection - Measure/Record .. .. . . . . ... . 101
Product Information Section ... . .... .... . . . ... . .... . . .... . . . .. 17

W
R
Walk-Around Inspection . ... . ..... . . . .... . ... . . . ... . .. . .. . ... . 102
Radiator - Clean . . . ... . .... .... . ... . . . .. . . .... . ... . . .... . .... . . . ... . 97 Inspect the Engine for Leaks and for Loose
Reference Information . . .... . ... . . . .. . . .... . ... . . .... . .... . . . ... . 23 Connections ... . . .. . . ... . .... . .... . . . . .... . ... . . . ... . . . . . . . . .. . 102
Reference Information Section .. . . ... . . ... . . ... . . .... . . . .. 105 Walk-Around Inspection (Exercise Inspection of
Standby Generator Set Engines) .. .... . . . ... . . . . . . . ... . 103
Warranty Information . .... .... . ..... . . . .... . ... . . . ... . .. . . . . .... 111
Engine Protection Plans. . ... .. . . . .... .... . . . ... . . . . . . . ... . 111
Water Pump - Inspect.... .... . .... . . . . .... . ... . . . ... . .. . . . . .... 104
Water Temperature Regulator - Replace . . . ... . .. . . .. 104
Water/Supplemental Coolant Additive (SCA) .... .... 52
Cooling Systems with Larger Capacities . . ... . . ... . 53
116
Index Section
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 :
02002 Caterpillar
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