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Operation and Maintenance Manual G3408C and G3412C Engines 6ZM1-Up 6ZM1-Up (Engine) 3WR1-Up (Engine) (Engine) 9RR1-Up (Engine) 6FW1-Up (Engine) (Engine) 8LW1-Up (Engine) BAZ1-Up (Engine) (Engine)
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Important Safety Information
Most accidents that t hat involve product operation, maintenance and repair are caused by failure to obse basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazard situations before an accident occurs. A person must be alert to potential hazards. This person should have the necessary necess ary 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 or perform any lubrication, maintenance or repair on this product, until you ha read and understood understood the operation, operation, lubrication, maintenance and repair information. information. Safety precautions and warnings are provided in this manual and on the product. If these hazard war are not heeded, heeded , bodily injury or death could occur to you or to other persons. The hazards are identi fied by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows: Attention! Attention! Become Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictori presented.
Operations Operations that that may cause product damage are identi fied by “NOTICE” labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazar The warnings 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 speci fically recommended by Cate is used, you must satisfy yourself that it is safe for you and for others. You should also ensure the product will w ill not be damaged or be made unsafe by the operation, lubrication, maintenanc repair procedures that you choose.
The information, information, speci fications, and illustrations in this publication are on the basis of information tha cations, torques, torques, pressures, pressures, was availabl available at the time that the publication was written. The speci fications, measurements, adjustments, illustrations, and other items can change at any time. These changes c affect the service that is given to the product. Obtain the complete and most current information befor start any job. job. Caterpillar dealers have the most current information Sign available. up to vote on this title
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Important Safety Information
Most accidents that t hat involve product operation, maintenance and repair are caused by failure to obse basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazard situations before an accident occurs. A person must be alert to potential hazards. This person should have the necessary necess ary 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 or perform any lubrication, maintenance or repair on this product, until you ha read and understood understood the operation, operation, lubrication, maintenance and repair information. information. Safety precautions and warnings are provided in this manual and on the product. If these hazard war are not heeded, heeded , bodily injury or death could occur to you or to other persons. The hazards are identi fied by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows: Attention! Attention! Become Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictori presented.
Operations Operations that that may cause product damage are identi fied by “NOTICE” labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazar The warnings 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 speci fically recommended by Cate is used, you must satisfy yourself that it is safe for you and for others. You should also ensure the product will w ill not be damaged or be made unsafe by the operation, lubrication, maintenanc repair procedures that you choose.
The information, information, speci fications, and illustrations in this publication are on the basis of information tha cations, torques, torques, pressures, pressures, was availabl available at the time that the publication was written. The speci fications, measurements, adjustments, illustrations, and other items can change at any time. These changes c affect the service that is given to the product. Obtain the complete and most current information befor start any job. job. Caterpillar dealers have the most current information Sign available. up to vote on this title
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Table o
Table of Contents
Reference Materials Materials ............................. ................................... ......
Index Section Foreword Foreword ........................ ..................................... ......................... ........................ ................ .... 4
Index ....................... ................................... ........................ ...................... ..........
Safety Section Section Safety Messages ........................ ................................... ....................... ................. ..... 6 General General Hazard Information ........................ ................................. ......... 10 Burn Prevention ........................ .................................... ......................... ................ ... 12 Fire Prevention and Explosion Prevention ............ ............ 13 Crushing Crushing Prevention and Cutting Prevention ........ ........ 14 Mounting Mounting and Dismounting Dismounting ..................... ................................ .............. ... 15 Ignition Systems ....................... ................................... ........................ ................ .... 15 Before Starting Engine ................................. .......................................... ......... 15 Engine Starting ...................... .................................. ........................ ................... ....... 16 Engine Stopping ....................... ................................... ....................... ................ ..... 16 Electrical Electrical System ........................ ................................... ....................... ............... ... 16
Product Product Information Information Section Model Views and Specifications ........................... 18 Product Identi fication Information Information ...................... ........................ .. 24
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Operation Section Lifting and Storage .................... ................................ ........................ ................ .... 26 Gauges and Indicators Indicators ...............
28
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4 Foreword
S
Foreword Literature Information This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literatur e holder or literature storage area. Read, study and keep it with the literature and engine information. English is the primary language for all Caterpillar publications. The English used facilitates translation and consistency in electronic media delivery. Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Caterpillar dealer for the latest available information.
Use service hours to determine intervals. C intervals shown (daily, annually, etc) may b instead of service meter intervals if they pro convenient schedules and approximate the service meter reading.
Recommended service should always be performed at the service hour interval. The operating environment of the engine also g the maintenance schedule. Therefore, und extremely severe, dusty, wet or freezing co operating conditions, more frequent lubrica maintenance than is speci fied in the mainte schedule may be necessary.
The maintenance schedule items are organ a preventive maintenance management the preventive maintenance program is foll periodic tune-up is not required. The implem of a preventive maintenance manageme should minimize operating costs through c avoidances resulting from reductions in uns downtime and failures.
Maintenance Intervals
You're Reading a Preview
Safety
Perform maintenance on items at multiples
requirement. Each level and/or ind Unlock full access withoriginal a free trial.
items in each level should be shifted ahead This safety section lists basic safety precautions. depending upon your specific maintenance In addition, this section identi fies hazardous, Download With Free Trial and application. We recommend operation warning situations. Read and understand the basic the maintenance schedules be reproduced precautions listed in the safety section before displayed near the engine as a convenient r operating or performing lubrication, maintenance and We also recommend that a maintenance re repair on this product. maintained as part of the engine’s permane Sign up to vote on this title See the section in the Operation and Maint Operation useful Useful NotRecords” Manual, “Maintenance for inform regarding documents that are generally acc Operating techniques outlined in this manual are as proof of maintenance or repair. Your aut basic. They assist with developing the skills and
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Overhaul Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval. Major repairs are best left to trained personnel or an authorized Caterpillar dealer. Your Caterpillar dealer offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available from your Caterpillar dealer. Consult with your dealer for information regarding these options.
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6 Safety Section Safety Messages
S
Safety Section i02803087
Safety Messages SMCS Code: 1000; 7405 There may be several speci fic safety messages on your engine. The exact location and a description of the messages are reviewed in this section. Please become familiar with all of the messages. Ensure that all of the messages are legible. Clean the messages or replace the messages if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap for cleaning the messages. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the messages. The messages that are loosened could drop off of the engine. Replace any message that is damaged or missing. If a message is attached to a part of the engine Reading a Preview that is replaced, install a new message on You're the replacement part. Your Caterpillar dealer can provide Unlock full access with a free trial. new messages. Do not operate or work on the engine unless the Download With Free Trial instruction and warnings in the Operation and Maintenance Manual are understood. Failure to follow the instructions or failure to heed the warnings could result in injury or death. Proper care is your responsibility. Sign up to vote on this title Note: Your engine will have “Type 1” safety Useful Not useful messages or “Type 2” safety messages.
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Safe Safety
Type 1
You're Reading a Preview Unlock full access with a free trial. Illustration 1
1 Universal Safety Message
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The safety message for reading the manual before operating the unit is located on the outside of the door of the control panel.
Do not operate or work on this engine o tor set unless you have read and under Opera instructions and warnings in the Sign up to vote on this title Maintenance Manuals. Useful Not useful Failure to follow the warnings and could result in injury or death. Co llar dealer for
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8 Safety Section Safety Messages
Illustration 3
S
g00107407
Rotating gears can cause entanglement of fingers or entanglement of hands. Do not service this component without first reading the Operation and Maintenance Manual.
Type 2 You're Reading a Preview Unlock full access with a free trial.
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Safe Safety
Illustration 5 View of the left side of a typical G3408 or G3412 Engine (1) Universal warning
1 Universal Safety Message
(2) Shock hazard
(3) Hazardous environment
You're Reading a2Preview Shock Hazard
full access withThe a free trial. message for shock hazards is lo The universal safety message is located onUnlock the base safety of the front valve cover on each side of the engine. on the base of the back valve cover on eac of the engine.
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10 Safety Section General Hazard Information
S
3 Hazardous Environment (CSA) The safety message for hazardous environment is located on the front crankcase cover on the left side of the engine.
Do not allow unauthorized personnel on or around the engine when the engine is b serviced.
Engine exhaust contains products of comb which may be harmful to your health. Alway engine and operate the engine in a well ve area. If the engine is in an enclosed area, v engine exhaust to the outside.
Cautiously remove the following parts. To h prevent spraying or splashing of pressurize hold a rag over the part that is being remov
• Filler caps • Grease fittings • Pressure taps Illustration 8
g01397609
• Breathers • Drain plugs
Use caution when cover plates are remove Do not disconnect equipment unless power has Gradually loosen, but do not remove the la been disconnected or the area is known to be nonYou're Reading abolts Preview or nuts that are located at opposite en hazardous. the cover plate or the device. Before remov Unlock full access with a free trial. last two bolts or nuts, pry the cover loose in relieve any spring pressure or other pressu i02602865
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General Hazard Information SMCS Code: 1000; 4450; 7405
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Safe General Hazard In
• Use all cleaning solutions with care. • Report all necessary repairs. Unless other instructions are provided, perform the maintenance under the following conditions:
Always use a board or cardboard when you for a leak. Leaking fluid that is under press penetrate body tissue. Fluid penetration ca serious injur y and possible death. A pin hol cause severe injury. If fl uid is injected into y you must get treatment immediately. Seek from a doctor that is familiar with this type o
• The engine is stopped. Ensure that the engine cannot be started.
Containing Fluid Spillage
• Disconnect the batteries when maintenance
is performed or when the electrical system is serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks.
• Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.
California Proposition 65 Warning Some engine exhaust constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Care must be taken in order to ensure that are contained during performance of inspe maintenance, testing, adjusting and repair engine. Prepare to collect the fluid with sui containers before opening any compartme disassembling any component that contains
Refer to Special Publication, NENG2500, “ Dealer Service Tools Catalog” for the follow
• Tools that are suitable for collecting fl
equipment that is suitable for collecting
• Tools that are suitable for containing
fl
equipment that is suitable for containing
Pressurized Air and Water You're Reading a Preview
Obey all local regulations for the disposal o Pressurized air and/or water can cause debris Unlock full access with a free trial. and/or hot water to be blown out. This could result in Asbestos Information personal in jury.
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When pressurized air and/or pressurized 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) when the air nozzle is deadheaded. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).
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12 Safety Section Burn Prevention
S
Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fi bers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated.
Dispose of Waste Properly
If dust that may contain asbestos is present, there are several guidelines that should be followed:
• Never use compressed air for cleaning. • Avoid brushing materials that contain asbestos.
Illustration 13
• Avoid grinding materials that contain asbestos.
Improperly disposing of waste can threaten environment. Potentially harmful fluids sho disposed of according to local regulations.
• Use a wet method in order to clean up asbestos materials.
• A vacuum cleaner that is equipped with a high
ef ficiency particulate air fi lter (HEPA) can also be used.
Always use leakproof containers when you fluids. Do not pour waste onto the ground, drain, or into any source of water.
You're Reading a Preview
• Use exhaust ventilation on permanent machining Unlock full access with a free trial. jobs.
Burn Prevention
other • Wear an approved respirator if there is noDownload With Free Trial SMCS Code: 1000; 4450; 7405 way to control the dust.
• Comply with applicable rules and regulations
for the work place. In the United States, use Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of asbestos.
Do not touch any part of an operating eng Allow the engine to cool before any mainte is performed on the engine. Relieve all pre in theSign air system, the hydraulic system, up to voteinon this title lubrication system, in the fuel system, or in Useful before useful system Notany cooling lines, fittings or items are disconnected.
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Safe Fire Prevention and Explosion
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.
If the application involves the presence of gases, consult your Caterpillar dealer for ad information about suitable protection device
Oils
Remove all fl ammable materials such as debris from the engine. Do not allow any materials to accumulate on the engine.
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 personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended. i01372262
Fire Prevention and Explosion Prevention SMCS Code: 1000; 4450; 7405
Store fuels and lubricants in properly mark containers away from unauthorized person oily rags and any flammable materials in containers. Do not smoke in areas that are storing fl ammable materials. Do not expose the engine to any
flame.
Exhaust shields (if equipped) protect hot ex components from oil or fuel spray in case o a hose, or a seal failure. Exhaust shields m installed correctly.
Do not weld on lines or tanks that contain fluids. Do not flame cut lines that contain fluid. Clean any such lines thoroughly with nonflammable solvent prior to welding or cutting.
You're Reading a Preview
Wiring must be kept in good condition. All e wires must be properly routed and secure Check all electrical wires daily. Repair any that are Download With Free Trialloose or frayed before you operate engine. Clean all electrical connections all electrical connections.
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Eliminate all wiring that is unattached or unn Do not use any wires or cables that are sm Sign up to vote on this title the recommended gauge. Do not bypass a and/or Usefulbreakers. circuit Not useful
Arcing or sparking could cause a fire. Sec connections, recommended wiring, and
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14 Safety Section Crushing Prevention and Cutting Prevention
S
Repair any lines that are loose or damaged can cause fires. Consult your Caterpillar de repair or for replacement parts.
Check lines, tubes and hoses carefully. Do your bare hand to check for leaks. Use a b cardboard to check for leaks. Tighten all co to the recommended torque.
Replace the parts if any of the following co are present:
• End fittings are damaged or leaking. • Outer coverings are chafed or cut. • Wires are exposed. • Outer coverings are ballooning. • Flexible part of the hoses are kinked. Illustration 15
g00704135
• Outer covers have embedded armoring.
Gases from a battery can explode. Keep any open • End fi ttings are displaced. flames or sparks away from the top of a battery. Do not smoke in battery charging areas. You're Reading aMake Preview sure that all clamps, guards, and hea correctly. During engine opera are installed Never check the battery charge by placing Unlock a metal full access with a free trial. will help to prevent vibration, rubbing again object across the terminal posts. Use a voltmeter or parts, and excessive heat. a hydrometer.
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Improper jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for speci fic instructions.
Crushing Prevention and Cutting Prevention
Do not charge a frozen battery. This may cause an explosion.
Sign up to vote on this title SMCS 4450; 7405 Useful Not useful Code: 1000;
The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the
Support the component properly when wor the component is performed.
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Safe Mounting and
i01372247
Mounting and Dismounting SMCS Code: 1000; 4450; 7405 Inspect the steps, the handholds, and the work area before mounting the engine. Keep these items clean and keep these items in good repair. Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine. Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds. Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.
If the wiring harness is reconnected with th the AUTOMATIC position or the MANUAL position, the storage capacitor of the ignitio may discharge. If the wiring harness is reco with the ECS in the AUTOMATIC position MANUAL START position, the storage cap the ignition system may fi re a spark plug. T plug will ignite any gas which is in the cylind crankshaft can rotate and the crankshaft ca damaged. The driven equipment can also r the driven equipment can also be damaged injury or damage to the equipment may be
Gas that has accumulated in the exhaust s may also be ignited.
Before Starting Engine SMCS Code: 1000 Inspect the engine for potential hazards.
Before starting the engine, ensure that no o Do not carry tools or supplies when you mount the You're Reading aunderneath, Preview or close to the engine. Ensure engine or when you dismount the engine. Use a hand area is free of personnel. line to raise and lower tools or supplies. Unlock full access with a free trial.
Ensure that the engine is equipped with a l system that is suitable for the conditions. En Download With Free Trialwork properly. all lights i01640342
Ignition Systems SMCS Code: 1550
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded
All protective guards and all protective cove be installed if the engine must be started in to perform service procedures. To help pre accident caused bytitle parts inrotation Signthat up toisvote on this around the parts carefully. Useful Not useful Do not bypass the automatic shutoff circuit disable the automatic shutoff circuits. The c
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16 Safety Section Engine Starting
S
i02136012
Engine Starting SMCS Code: 1000 If a warning tag is attached to the engine start switch or to the controls, DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started. All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully. If there is a possibility that unburned gas remains in the exhaust system, refer to the purge procedure in this Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Start the engine from the operator’s compartment or from the engine start switch.
Use the Emergency Stop Button (if equippe in an emergency situation. Do not use the E Stop Button for normal engine stopping. Af emergency stop, DO NOT start the engine problem that caused the emergency stop h corrected.
On the initial start-up of a new engine or an that has been serviced, make provisions to the engine if an overspeed occurs. This m accomplished by shutting off the fuel suppl engine, or shutting off the ignition system.
Electrical System SMCS Code: 1000; 1400
Never disconnect any charging unit circuit o circuit cable from the battery when the char is operating. A spark can cause the combu gases that are produced by some batteries
Check the electrical wires daily for wires th Always start the engine according to the procedure or frayed. Tighten all loose electrical You're Reading aloose Preview that is described in the Operation and Maintenance before the engine is operated. Repair all fr Manual, “Engine Starting” topic in the Operation full access withelectrical a free trial.wires before the engine is started Section. Knowing the correct procedure willUnlock help to prevent major damage to the engine components. Knowing the procedure will also help to prevent Grounding Practices Download With Free Trial personal injury. Proper grounding is necessary for optimum To ensure that the jacket water heater (if equipped) performance and reliability. Improper groun and/or the lube oil heater (if equipped) is working result in uncontrolled electrical circuit paths properly, check the water temperature and the oil unreliable electrical circuit paths. Sign up to vote on this title temperature during heater operation. Uncontrolled useful paths can res Usefulelectrical Notcircuit Engine exhaust contains products of combustion damage to main bearings, to crankshaft jou which can be harmful to your health. Always start the surfaces, and to aluminum components. Un engine and operate the engine in a well ventilated electrical circuit paths can also cause elect
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Safe Electric
Rubber couplings may connect the steel piping of the cooling system and the radiator. This causes the piping and the radiator to be electrically isolated. Ensure that the piping and the radiator is continuously grounded to the engine. Use ground straps that bypass the rubber couplings. Ensure that all grounds are secure and free of corrosion.
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18 Product Information Section Model Views and Speci fications
S
Product Information Section Model Views and Specifications i02789044
Model View Illustrations SMCS Code: 1000; 4450 S/N: 6ZM1-Up S/N: BAZ1-Up The illustrations show various typical features of G3400C Engines. The illustrations do not show all of the options that are available. Your engine may look like the following engine.
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Product Informatio Model Views and Spe
You're Reading a Preview Unlock full access with a free trial.
Illustration 17 View of the right side of a G3412 Engine (12) Sensor for nitrous oxide (13) Buffer for the sensor for nitrous oxide (14) Oil sampling valve
(15) Download Oil filters With (16) Oil level gauge (17) Turbocharger
Free Trial
(18) Exhaust outlet
i02789109
Model View Illustrations SMCS Code: 1000; 4450 The illustrations show various typical features of
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20 Product Information Section Model Views and Speci fications
S
You're Reading a Preview Illustration 18
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Typical engine (1) Crankcase breather (2) Oil filler (3) Electronic ignition system module (4) Lifting eyes
(5) Oil level gauge Download (6) Starting motor (7) Oil filters (8) Oil drain
With Free Trial
(9) Oil sampling valve (10) Inlet for the water pump (11) Vibration damper
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Product Informatio Model Views and Spe
You're Reading a Preview Illustration 19
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Typical engine (12) Manual governor control lever (13) Air cleaner (14) Air fi lter service indicator (15) Turbocharger
(16) Download Exhaust With Free (17) Gas pressure regulator (18) Gas shutoff valve (19) Junction box
i02798920
Product Description SMCS Code: 1000; 4450
Trial
(20) Emergency stop button (21) Flywheel housing (22) Auxiliary water pump
FuelSign System up to vote on this title
Useful Not useful low For the pressure gas fuel system, the c is located after the air cleaner. Filtered air an mixed in the carburetor. The mixture is com
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22 Product Information Section Model Views and Speci fications
The engines are equipped with protection from detonation. A detonation sensor is located on each side of the cylinder block. The ignition timing is retardedfor all cylinders when excessive detonation is sensedfor any cylinder. If the maximum retarded position is attained and detonation continues to occur, the ECM shuts down the engine.
S
Specifications SMCS Code: 1000 Table 1
G3400C Engine Specifications
Lubrication System The engine lubrication oil is circulated by a gear-driven pump. The oil is cooled and filtered. A bypass valve provides unrestricted fl ow of lubrication oil to the engine parts if the engine oil fi lter elements become plugged.
Cooling System The standard cooling system has a gear-driven pump. The cooling system has two temperature regulators that regulate the outlet temperature of the coolant. The temperature depends on the application. Jacket water coolant temperature is limited from 93 to 99 °C (200 to 210 °F).
Item Rated speed (rpm) Cylinders and arrangement Bore
G3408C Engine
G34
1000 to 1800 65 degree V-8
65
137 mm (5.4 inch
Stroke
152 mm (6 in
Compression Ratio
11.3:1 or 8.5:1
Aspiration
Naturally Aspirated Turbocharged Aftercoole
Total displacement
18 L (1098 in3)
27
You're Reading a Preview Firing order 1-8-4-3-6-5-7-2 1-4For engines with a Separate Circuit Aftercooler 10-3 (SCAC), the air is cooled by a heat exchanger. The Unlock full access with a free trial. water that cools the air in the heat exchanger is in Rotation Counterclockwise (flywheel end) a circuit that is separate from the jacket water. The aftercooler coolant is pumped by an auxiliary water (1) Separate Circuit Aftercooling (SCAC) Download With Free Trial pump. The SCAC is required to operate at one of the following temperatures. The engine rating depends on the temperature and the application.
• 32 °C (90 °F) • 54 °C (130 °F)
Engine Service Life
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Product Informatio Model Views and Spe
Illustration 21
g01376793
G3412C Engine design (A) Inlet valves (B) Exhaust valves (C) Flywheel
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24 Product Information Section Product Identification Information
S
Product Identification Information i01505053
Plate Locations and Film Locations SMCS Code: 1000; 4450
Engine Identification Caterpillar engines are identified with serial numbers, with performance specification numbers, and with arrangement numbers. In some of the cases, modification numbers are used. These numbers are shown on the Serial Number Plate and the Information Plate that are mounted on the engine. Caterpillar dealers need these numbers in order to determine the components that were included with the engine. This permits accurate identi fication of replacement part numbers.
Illustration 23 Typical Serial Number Plate
The following information is stamped on the Number Plate: engine serial number, mode arrangement number.
Information Plate
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Serial Number Plate
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Illustration 24 Location of the Information Plate
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Product Informatio Product Identification
The following information is stamped on the Information Plate: maximum altitude, high idle, horsepower, full load rpm, and other information.
Table 2
Reference Numbers Engine Model
i02135788
Reference Information
Serial Number Arrangement Number Packaging Arrangement
SMCS Code: 1000; 4450
Turbocharger
Identification of the items in Table 2 may be needed in order to obtain parts and service. Some of the numbers are on the engine Serial Number Plate and/or Information Plate. Locate the information 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.
Fuel Filter Element Lubrication Oil Filter Element Auxiliary Oil Filter Element Air Cleaner Element Fan Drive Belt Alternator Belt Capacity of the Lubrication System Oil type
The packaging arrangement may also be called a Capacity of the Cooling pricing arrangement or a customer arrangement. This System is the total package with attachments and options You're Reading a Preview that are not included in the engine arrangement. Performance Specification Unlock full access with aNumber free trial.
The performance speci fication can be used by Low Idle rpm your Cater pillar dealer with the Technical Marketing Download With Free Information system. Before the engine leaves the HighTrial Idle rpm factory, the engine performance is tested. Detailed Full Load rpm performance data is recorded. The performance specification number can be used for obtaining the Power Rating data.
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26 Operation Section Lifting and Storage
S
Operation Section
Engine Lifting with a Genera
Lifting and Storage
NOTICE Do not use the engine lifting eyes to remo gine and generator together. i01536259
Product Lifting SMCS Code: 7000; 7002
A lifting plate is provided with the package set. Instructions for lifting the package gene are stamped on the lifting plate.
Consult your Caterpillar dealer for informa regarding proper fi xtures and lifting devices
Lifting packaged generator sets will not be lift the unit with a single point lift. A counterw be added between the package frame rails the application requires frequent relocation unit. For complete information about addin counterweight, consult your Caterpillar dea
The single point lifting eye is secured from factory before the enclosure is shipped. The orientation of the single point lifting eye will to look through the eye when you stand at t enclosure. The lifting eye may stretch w You're Reading athe Preview package is lifted. This may cause the lockin g00103219 Illustration 26 to loosen. This could cause the lifting eye t Unlock full access with a free trial. Ensure that the lifting eye is correctly orient NOTICE packaged generator set. Ensure that the lif Never bend the eyebolts and the brackets. Only load is tightened Trial to the correct torque before yo the eyebolts and the brackets under tension.Download Remem- With Free packaged generator set. ber that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes 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.
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Operatio Lifting an
i02784832
Product Storage SMCS Code: 7002 Code: 7002 If the engine will wi ll 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, surface, which will increase engine wear which can reduce engine service life. To help prevent preven t excessive engine wear, use the following guidelines: lubrication recommendatio recommendations ns all of the lubrication • Complete all of
that are listed in this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance (Maintenance Section).
temperatures are expected, expected, check the • If freezing temperatures
cooling cooling system system for adequate protection against freezing. freezing. See the Special Special Publication, Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel, and Coolant Coolant Recommendations”. Recommendations”.
If an engine is out out of operation operation and if use of the engine engine is not planned, planned, special precautions should be made. If the engine will be stored for more than one month, a complete protection protection procedure procedure is recommended. recommended. Your Caterpillar dealer will have instructions for preparing preparing the engine for extended storage periods. For more detailed detailed information on engine storage, storage, see Special Instruction, SEHS9031, “Storage Procedure pillar Products”. Products”. for Cater pillar
Generator Generator Storage For information on generator storage, see the
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28 Operation Section Gauges and Indicators Indicators
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S
Gauges and Indicators i01836629
Gauges and Indicators SMCS Code: 7450 Code: 7450 performance. Gauges provide provide indications of engine performance. Ensure that the gauges are in good working order. Determine the normal operating range by observing the gauges over over a period of time. Noticeable changes in gauge readings can indicate potential potential gauge gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within speci fications. Determine and and correct the cause of any signi ficant change in the readings. Consult your Caterpillar dealer for assistance. assistance. Your engine may not have the same gauges or all of the gauges that are described below. NOTICE If no oil pressure is indicated, STOP the engine. The engine engine will will be damage damaged d from operating operating without without oil pressure. Engine Engine Oil Pressu Pressure re – This gauge indicates indicates the pressure pressure of the engine oil. This pressure will be highest after a cold engine is started. The pressure will decrease as the engine warms up. The pressure will increase when the engine rpm is increased. The pressure will stabilize when the engine rpm and temperature are stable. For G3400 Engines, the typical oil pressure at rated rpm is 275 to 600 kPa (40 to 87 psi).
Jacket Jacket Water Water Coolant Tempe This gauge indicates the tempera engine coolant coolant at the outlet for th water. The temperature may vary accordin load. The temperature should never be allo exceed the boiling bo iling temperature of the press cooling system. The operating range is 88 (190 to 205 °F). Higher temperatures may under certain certain conditions.
The engine should operate within the norm temperature range. The sensor for jacket w re must be fully submer coolant temperatu temperature to detect the temperature correctly. If the e is operating above the normal temperature perform the the following procedure:
1. Reduce the load and/or the engine rpm. 2. Inspect the cooling system for leaks.
3. Determine if if the engine must be shut d immediately or if the engine can be coo reducing the load and/or rpm.
Inlet Manifold Air Tempera Temperature ture gauge indicates the inlet manifold temperature temperature to the cylinders.
NOTICE High inlet manifold air temperature increas of detonation. Detonation can cause dama engine. Ensure that the aftercooling system ing properly. Sign up to vote on this title
Useful air Not useful The inlet manifold temperature depend the engine’s aspiration and the water temp regulator for the separate circuit aftercoole
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Operatio Gauges and
Table 3
Table 4
Maximum Inlet Manifold Air Temperatures for G3400 Engines Aspiration
Water Temperature Regulator
Naturally aspirated
n/a
Maximum Inlet Manifold Manifold Air Temperature 25 °C (77 °F)
Separate Circuit Aftercooling
32 °C (90 °F)
Separate Circuit Aftercooling
54 °C (130 °F) (2)
(2) (2)
Factors for Converting Service Meter U to Clock Hours
(1) (1)
43 °C (110 °F) 65 °C (150 °F)
(1)
This temperature is for an engine at an altitude of 152 m (500 ft) above sea level. A greater temperature or a higher altitude requires derating. (2) Water inlet to the aftercooler
Inlet Manifold Air Pressure (TA Engines) and Inlet Manifold Vacuum (NA Engines Engines)) – For TA engines, this gauge indicates the air pressure (turbocharger boost pressure) in the air plenum (air inlet manifold) after the aftercooler. For NA engines, this gauge is the pressure of the inlet manifold vacuum. For all engines, this pressure is relative to the load. This pressure may be used for estimating power output. Several factors affect the inlet manifold air pressure. All of these factors must be accounted for when power is estimated from inlet manifold air pressure: pressure: air restriction, restriction, exhaust exhaust restriction, restriction, coolant coolant temperature, temperature, ambient air temperature, temperature, variation of the fuel, air/fuel ratio, ignition timing, and condition of the valves. For more information, see the performance curves in the Engine Performance manual. The manual is available available from your Caterpillar Caterpillar dealer. dealer. Tachometer achometer
This gauge indicates the
Operating Speed
Factor
Engines That Are Rated From 1000 RPM to 1 1000 rpm
1.2
1200 rpm
1.0
1400 rpm
0.8
Engines That Are Rated From 1500 RPM to 1 1500 rpm
1.2
1600 rpm
1.1
1800 rpm
1.0
For example, an engine that is rated at 180 has been operating at 1500 rpm. To determ number of clock hours, multiply the number meter units by the correct factor. In this exa service meter unit is equivalent to 1.200 clo
Fuel Filter Differential Differential Pressure Pressure gauge is provided by the custome gauge indicates the difference in pressure between the inlet side and the ou of the fuel fi lter. As the fuel filter elemen plugged, the difference in pressure betwee sides of the fuel filter increases. Service th differential pressure pressur filter when the fuel fi lter differential 34 kPa (5 psi).
Air Cleaner Differential Differential Press Sign This up togauge vote onindicates this title the differenc pressure between the inlet side a Useful Not useful side engine of the air filter element. The pr is measured from the turbocharger air inlet air filter element becomes plugged, the diff
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30 Operation Section Gauges and Indicators
S
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 r apidly 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.
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Operatio Features an
Features and Controls i02536544
Performance Parameters SMCS Code: 1000
To optimize the inlet air temperature, use du a heat exchanger. This will help to avoid ex to hot air from a generator. For more inform see Application and Installation Guide, LEK “Air Intake”. Consult your Caterpillar deale assistance.
Temperature of the Fuel Supply
Fuel Consumption Optimum fuel consumption can be obtained by fine tuning the air/fuel ratio and ignition timing. In order to make fine tuning feasible, the engine must have stable operating parameters. The parameters must not exceed the following tolerances.
Changes in the temperature of the fuel supp the air/fuel ratio. Warmer fuel is less dense fuel. This results in a leaner mixture that ca noticeable r eduction of power. The recomm temperature differential of the air and the f 2.8 °C (5 °F).
The maximum fuel temperature depends o temperature regulator (if equipped) of the a
Table 5
Performance Parameters of the Engine Parameter
Tolerance
• For engines with a 32 °C (90 °F) afterco
maximum temperature of the air/fuel mix 43 °C (110 °F).
Jacket Water Coolant Temperature
± 6 °C (± 10 °F)
Inlet Manifold Air Temperature
± 6 °C (± 10 °F)
Temperature of the Gas
± 6 °C (± 10 °F)
Fuel Energy Content
more Unlock full access withFor a free trial.information, see Application and I ± 31.6 kJ (± 30 Btu)
Load
± 5%
Air/Fuel Ratio
• For engines with a 54 °C (130 °F) afterco
maximum temperature of the air/fuel mix 65 °C (150 °F). You're Reading a Preview
Download With Free Trial Fuel Supply Pressure
The correct air/fuel ratio is very important for the following considerations:
• Margin of detonation • Control of emissions
Guide, LEKQ7260, “Low BTU Engines”. Co Caterpillar dealer for assistance.
Fluctuations of the fuel pressure can chang air/fuel ratio. For low pressure gas fuel sys (10 kPa (1.5 psi) to 34.5 kPa (5 psi) fuel pre Sign up to vote on this title the regulator on the engine), the maximum Useful in useful that is allowed theNot fuel pressure is ± 1.7 (± 0.25 psi). If more than one engine is usi fuel supply line, ensure a stable fuel pressu
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32 Operation Section Features and Controls
S
A water manometer is used to measure the pressure differential. This measurement is taken when the 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 2O). If the performance of the gas pressure regulator is erratic, the gas pressure regulator may require service.
Throttle Angle and Exhaust Bypass (Wastegate) A throttle angle of approximately 70 degrees is recommended for full load operation. The following factors affect the angle of the throttle:
• LHV of the fuel • Air/fuel ratio • Setting of the exhaust bypass (wastegate) • Altitude • Ignition timing
You're Reading a Preview
Unlock full access with a free trial. After the desired exhaust emissions are achieved, the exhaust bypass is adjusted in order to achieve full load operation with the desired throttle angle. Download With Free Trial Excess boost generates back pressure in the exhaust manifold. This raises pumping losses which increase fuel consumption.
Ensure that the angle of the throttle plate is properly set. This will maintain the margin for detonation. This will also enable the engine to accept load changes without lugging down and shutting off.
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Operatio Features an
i02791455
Sensors and Electrical Components SMCS Code: 1900; 7400
You're Reading a Preview Illustration 27
Unlock full access with a free trial.
Left side and rear views of a typical G3408 or G3412 Engine (1) Detonation sensor
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(2) Speed sensor
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34 Operation Section Features and Controls
S
The control module uses the signal from th manifold pressure sensor in order to determ engine load. (5) Speed/timing sensor
The speed/timing sensor provides informat control module about the position of the cra and the engine rpm. The control module us information in order to determine the ignitio (6) Inlet manifold temperature sensor
Illustration 29
g01394803
Partial view of the top of a typical G3408 orG3412 Engine
The inlet manifold temperature sensor prov signal to the EIS that indicates the tempera air/fuel mixture in the inlet manifold. The EIS information in order to control the air/fuel ra
(6) Inlet manifold temperature sensor
The sensors provide signals to the control module. The control module uses the signals in order to provide the signals to the transformers at the appropriate time.
Alarms and Shutoffs SMCS Code: 7400
(1) Detonation sensors
This section contains some general informa function of typical engine protective dev You're Reading athe Preview Detonation sensors produce voltage signals that are proportional to the level of detonation. The control operation of all alarms and shutoffs ut Unlock full access withThe a free trial. module uses the signals from the detonation sensors components which are actuated by a sensi in order to determine the level of detonation. To The alarms and shutoffs are set at critical o eliminate detonation, the control module willDownload retard With Free Trial temperatures, pressures, or speeds in ord the ignition timing. protect the engine from damage. (2) Speed sensor The engine speed sensor provides a signal to the electronic ignition system that indicates the speed of the engine. The electronic ignition system uses the signal in order to govern the speed of the engine. The speed sensor (magnetic pickup) is installed in the left side of fl ywheel housing.
Alarms function in order to warn the opera when an abnormal operating condition occ Shutoffs inon order shut down the Signfunction up to vote this to title when a more critical abnormal operating co useful Useful Not help to prevent damag occurs. The shutoffs equipment.
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Operatio Features an
Become familiar with the following information:
• Types of the alarm and shutoff controls • Locations of the alarm and shutoff controls • Conditions which cause each control to function • Resetting procedure that is required before starting the engine
On G3400 Engines, protective devices are available for the following faults:
• Low oil pressure • High coolant temperature • Overspeed • Low coolant level Further protection is supplied by an emergency stop button. Three basic protection systems are available:
You're Reading a Preview
• Self-powered shutoff
Unlock full access with a free trial.
• Automatic start/stop system • Customer supplied shutoff
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Note: For an energize-to-shutoff system, the gas shutoff valve must be energized to shut off gas to the engine. For an energize-to-run system, the gas shutoff valve must be energized in order to supply gas to the engine. The self-powered system can be used with an air starting motor or an electric starting motor. An
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36 Operation Section Features and Controls
S
Table 6
G3400 Engine Protection Systems Item
Type of System
Shu Settin
Self-Powered
Automatic Start/Stop
Customer Supplied (1)
High jacket water coolant temperature
Yes
Yes
Yes
105
Low oil pressure (high rpm)
Yes
Yes
Yes
275
Low oil pressure (low rpm) Overspeed (1800 rpm)
100 kP No
Yes
(2)
Yes
2
Overspeed (1400 rpm) High inlet manifold air temperature 32 °C (90 °F)
168 No
No
Yes
43 °C
(3)
High inlet manifold air temperature 54 °C (130 °F) Emergency stop (1) (2) (3)
66 °C
Yes
Yes
Yes
The customer is responsible for supplying the shutoffs and the wiring. Overspeed protection is available as an option. The customer is responsible for supplying the protection for either high inlet manifold temperature or high aftercooler water temp
You're Reading a Preview i02791234
Control Panel SMCS Code: 7451
Control Panel for Stopping
Unlock full access with a free trial.
Download With Free Trial
Your engine may be equipped with one of the following control panels.
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Operatio Features an
The amber “WARNING” indicator (1) fl ashes or the amber “WARNING” indicator illuminates continuously in order to indicate the occurrence of an abnormal operating condition. A warning is not severe enough to cause a shutdown. However, this signi fies a serious problem. If a warning occurs, a diagnostic code for the condition is logged in the ECM. Correct the cause of the warnings as soon as possible in order to avoid problems with operation. The red “SHUTDOWN” indicator (2) illuminates continuously when an adverse operating condition causes a shutdown. A diagnostic code for the condition is logged in the ECM. If the engine is shut down due to parameters that are out of acceptable limits, the red indicators on the“SHUTDOWN” indicator will also illuminate. The green “POWER ON” indicator (3) illuminates continuously when power is supplied to the control panel. Illustration 31
The red “EMERGENCY STOP” button (4) is used to (6) “WARNING” indicator stop the engine in an emergency situation. When the (7) “ SHUTDOWN” indicator button is pressed, the status control module shuts off (8) “POWER ON” indicator (9) “DIAGNOSTIC RESET” switch the fuel via the gas shutoff valve. The module also You're Reading a Preview (10) Engine control switch terminates the ignition. The “EMERGENCY STOP” (11) Status control module button must be reset before the engine will start. (12) “EMERGENCY STOP” button Unlock full access with a free trial.
The “DIAGNOSTIC RESET” switch (5) is used The yellow “WARNING” indicator (6) fl ashe to clear diagnostic codes from the engine control lighted in order to indicate the occurrence Download With Free Trial module (ECM). The switch can not clear individual abnormal operating condition. A warning is n codes. Use of the switch will clear all of the codes that enough to cause a shutdown. However, this are active in the ECM. Do not clear the codes until a serious problem. If a warning occurs, a di the problems that caused the codes are addressed. code for the condition is logged in the engin module. theon cause of the warnings SignCorrect up to vote this title as possible in order to avoid problems with Remote Control Panel (Status) Useful Not useful The red “SHUTDOWN” indicator (7) illumin This section contains some general information about continuously when an adverse operating the Remote Control Panel (Status). For more detailed
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38 Operation Section Features and Controls
S
Status control module (11) has several engine monitoring and control functions. “EMERGENCY STOP” button (12) is used to stop the engine in an emergency situation. When the button is pressed, the status control module shuts off the fuel via the gas shutoff valve. The module also terminates the ignition. The “EMERGENCY STOP” button must be reset before the engine will start.
Status Control Module The status control module receives information from the following sources:
• The operator • Magnetic pickups • Transducers (oil pressure and water temperature) • Optional remote sources
Illustration 32
(13) Liquid crystal display (LCD) (14) Switch (15) “LOW OIL PRESSURE” indicator (16) “EMERGENCY STOP” indicator You're Reading a(17) Preview “AUXILIARY SHUTDOWN” indicator When the status control module receives a signal to (18) “HIGH COOLANT TEMPERATURE” indicator flow to start the engine, the module enables fuel toUnlock “OVERSPEED” indicator full access with(19) a free trial. (20) “OVERCRANK” indicator the engine. The module activates the starting motor.
The basic performance of the status control module includes the following functions:
After the rpm for crank termination is achieved, the Liquid Crystal Display (LCD) – Symbols module deactivates the starting motor. Download With Free Trial following parameters are located under LC The LCD provides a digital display of the st When the status control module receives a signal to these parameters. When the status of a par stop the engine, the module shuts off the fuel. The displayed, an arrow at the bottom of the LC module sends a signal to the engine control module. the corresponding symbol. The display can The engine control module terminates the ignition. Sign up to vote on this title metric units or English units. Useful Not useful Hour meter – When the arrow p this symbol, the hours of engine o are displayed.
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Operatio Features an
The parameters are displayed sequentially. To lock the display onto one of the parameters, press switch (14). To resume the sequential display, press the switch again. The LCD is also used to display diagnostic codes. A diagnostic indication signifies that the system has detected the failure of components that are associated with the status control module. When a diagnostic code is displayed, the arrow that indicates the display of the parameters will be missing. A flashing “DIAG” will be displayed. If more than one diagnostic code is present, the diagnostic codes will be displayed in sequence. To clear the diagnostic codes from the LCD, turn the engine control switch to the “OFF/RESET” position. For information on diagnostic codes, see these publications:
“HIGH COOLANT TEMPERATU If the coolant temperature exceed setpoint, the fuel will be shut off. I (18) will flash.
“OVERSPEED” – If the engine r exceeds the setpoint for overspee and the ignition will be shut off. In (19) will flash.
“OVERCRANK” – If the engine start within a programmed amoun time or if the number of cranking’ cycle) is exceeded, the status control modu deactivate the starting sequence. Indicator flash. The engine control switch must be tu the “OFF/RESET” position before another a start the engine can be made.
• Systems Operation/Testing and Adjusting,
SENR6420, “Control Panel (Status-Timing)”
Engine Control Switch
• Electronic Troubleshooting, SENR6535, “G3400 Engines”.
You're Reading a Preview
The status control module has six indicators (Illustration 32) that indicate engine shutdowns. The Unlock full access with a free trial. shutdowns that are associated with the indicators are described below.
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“LOW OIL PRESSURE” – There are two setpoints for low oil pressure. The setpoints depend on the engine rpm. One setpoint is for engine rpm that is below the oil step speed setting. The other setpoint is for engine rpm that is above the oil step speed setting. If the engine oil pressure decreases below the setpoint, the fuel to the engine will be shut off. Indicator (15) will fl ash.
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IllustrationUseful 33
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Engine control switch in the “OFF/RESET” position
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40 Operation Section Features and Controls
S
“OFF/RESET” – When the engine control switch is turned to this position (12 o’clock), the fault indicators on the status control module are reset and the engine shuts down immediately. The power to the engine control module and the status control module is shut off. This method is not recommended for normal stopping. “AUTO” – When the engine control switch is in this position (3 o’clock), the system is con figured for remote operation. When the remote start/stop initiate contact closes, the engine will start. When the remote start/stop initiate contact opens, the engine will shut down. If the cooldown cycle is programmed, the engine will operate for the cooldown period before the engine stops. “MAN. START” – When the engine control switch is turned to this position (6 o’clock), the engine will start. The engine will continue to operate when the switch is in this position. However, if a setpoint for a shutdown is exceeded, the engine will shut down.
Illustration 34 (21) Control module
“COOLDOWN/STOP” – This is the preferred (22) Manifold air pressure sensor method for normal stopping. When the engine control (23) NO sensor (24) Speed sensor (magnetic pickup) switch is turned to this position (9 o’clock), the You're Reading a Preview (25) Fuel valve engine will continue to operate until a programmable cooldown cycle has elapsed. The cooldown cycle Unlock full access withThe a free trial. module for the air/fuel ratio con control can be programmed for a 0 to 30 minute period. The shown below. default setting is fi ve minutes. x
Download With Free Trial Electronic Control Group for the Air/fuel Ratio The engine electronic control group for the air/fuel ratio is a digital control for use with low emission engines that use natural gas with one gas pressure regulator and a carburetor. This system can be configured in the fi eld with the keypad that is on the control module. The settings of the control module
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The inlet manif old air pressure is a measure of engine load. The measure of NO x in the engine exhaust is one measure of the exhaust emissions. The engine speed is monitored by a speed sensor. The control uses the information from these inputs in order to determine the setpoint of the desired emissions level. The control uses the information from these inputs in order to maintain engine operation at that setpoint. For more information about the controls for the air/fuel ratio, refer to the following publications:Systems Operation, KENR5186, “G3408C and G3412C Engines Air /Fuel Ratio Control (NOx Feedback)” and Troubleshooting, RENR5916, “Air/Fuel Ratio Control”. i00973195
Engine Speed Governing SMCS Code: 1908 A variety of governors and actuators are available for different engine applications. For information on governors and actuators, see the Service Manual. Consult your Caterpillar dealer for assistance. You're Reading a Preview Unlock full access with a free trial.
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42 Operation Section Engine Starting
S
Engine Starting
• Ensure that the air inlet piping and the ai are in place.
i02142937
Before Starting Engine
• Ensure that all clamps and connections a • Inspect the air cleaner service indicator
SMCS Code: 1000; 1400; 1450 Note: Certain procedures are required before an engine is started for the fi rst time. Refer to the Special Instruction, REHS0371, “Installation and Initial Start-Up Procedure for G3300 and G3400 Engines”. Perform the required daily maintenance and other periodic maintenance before starting the engine. This can prevent major repairs at a later date. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section).
equipped). Service the air cleaner filter e when the yellow diaphragm enters the re the red piston locks in the visible position
• Inspect fl exible piping for cracks and leak
Cooling System
• Inspect the cooling system for leaks or lo
connections. Inspect the condition of all t and pipes for the cooling system. Ensure connections are properly clamped.
• Inspect the water pumps for evidence of
Walk-Around Inspection
• Check the coolant level. Add coolant, if n
For information on the proper coolant to NOTICE this Operation and Maintenance Manual For any type of leak (coolant, lube, or fuel) clean up the Capacities and Recommendations” (Main fluid. If leaking is observed, find the source and correct Section). Reading a Preview the leak. If leaking is suspected, check the flYou're uid levels more often than recommended until the leak is found engines with separate circuit aftercoo Unlocktofull free trial. or fi xed, or until the suspicion of a leak is proved beaccess with•a For the water supply. unwarranted.
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To obtain maximum service life for your engine, make a thorough inspection before starting the engine. Make a walk-around inspection of the installation. Look for items such as oil or coolant leaks, loose bolts and trash buildup. Remove any trash. Make repairs, if necessary.
• Inspect the drive belts for cracks and wear. The guards must be in the proper place. Repair
Driven Equipment
• Check the oil levels of the driven equipm
Perform any maintenance that is require literature driven equipment. Refer to the Sign upby tothe voteOEM on this provided of title the driven equipm Useful Not useful • If the engine is equipped with a clutch, en the clutch is disengaged.
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Operatio Engin
Fuel System
Starting System
NEVER use a flame to check for gas leaks. Use a gas detector.
Note: If the engine is equipped with a syst external support, prepare the system befor the engine. Ensure that all of the systems fo support are enabled. Perform all prestart ch the control system.
An open fl ame can ignite mixtures of air and fuel. This will cause explosion and/or fi re which could result in severe personal injury or death.
Air Starting Motor
• Drain moisture and sediment from the air from any other air piping.
• Check the fuel system for leaks with a gas detector. •
Inspect the fuel lines for loose fi ttings. Ensure that the fuel lines are properly clamped.
• Ensure that the fuel is supplied to the engine at the
• Check the oil level in the lubricator. Kee
lubricator at least half full. Add oil, if nece For temperatures above 0 °C (32 °F), us nondetergent 10W oil. For temperatures 0 °C (32 °F), use air tool oil.
correct pressure for the engine.
• Check the air pressure for starting. The a
motor requires a minimum of 690 kPa (1 The maximum allowable air pressure is 1 (150 psi). Open the air supply valve.
Lubrication System
Electric Starting Motor You're Reading a Preview • Disconnect any battery chargers that are
Unlock full access with a protected free trial. against the high current drain
created when the electric starting motor e
Download With Free Trial Inspect the wiring, the electrical cables, an battery for the following conditions:
• Loose connections Illustration 36 Oil level gauge (dipstick) (1) “ADD” mark (2) “FULL” mark
g00760044
are worn or frayed • Wires Signthat up to vote on this title
• Corrosion
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44 Operation Section Engine Starting
S
i01857649
Cold Weather Starting SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900 Note: Oil pan immersion heaters are not recommended for heating the lube oil. To ensure the compatibility of the components, only use equipment that is recommended by Caterpillar. A jacket water heater is required for starting in temperatures as low as 0 °C (32 °F). The jacket water heater can maintain the water temperature at approximately 32 °C (90 °F). The heated water will help to keep the oil in the engine block warm enough to fl ow when the engine is started. A jacket water heater is required for starting when the temperature is less than 16 °C (60 °F). For air starting motors, a larger volume of starting air and/or a higher air pressure may be necessary in order to start the engine at colder temperatures. For electric starting, extra battery capacity may be necessary.
Unburned gas in the air inlet and exhaus may ignite when the engine is started. injury and/or property damage may resu
Before starting an engine that may burned gas, purge the unburned gas fro inlet and exhaust system. Refer to the purging unburned gas in the “Starting section.
Do not start the engine or move any of the if there is a “DO NOT OPERATE” warning similar warning tag attached to the start sw the controls.
Ensure that no one will be endangered bef engine is started and when the engine is sta
Perform the procedures that are described Operation and Maintenance Manual, “Befor Engine” (Operation Section).
You're Reading aPurging Preview Unburned Gas
Consult your Caterpillar dealer for more information following events cause unburned gas t Unlock full access withThe a free trial. on the starting aids that are available for cold weather in the air inlet and in the exhaust manifold: starting.
Download With Free Trial stop • Emergency i02799025
Starting the Engine
• Engine overspeed
SMCS Code: 1000; 1450
to sta • Unsuccessful successive attempts
Engine exhaust contains products of combustion
Not useful Useful remain Unburned gas may in the air inlet an system after several unsuccessful attempt the engine. The unburned gas may increas
engine Sign up to vote on this title
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Operatio Engin
5. Turn the manual gas shutoff valve to the OPEN position. 6. Continue with your previous procedure.
Operation of the Generator Set Control Panel
3. The method that is used for starting dep the equipment:
a. For electric starting, press the “STAR or turn the start/stop switch to the “ST position.
For information on operation for a speci fic generator set control panel, refer to the Operation and Maintenance Manual for the generator and the control panel.
Automatic Starting
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.
Illustration 37 “START” valve on an air starting motor
b. For starting with air, push the “STAR If the engine control switch is in the “AUTO” position, Release the valve as soon as the eng the engine will automatically start when theYou're remoteReading a Preview Shut off the air supply to the starting m start/stop initiate contact closes. The engine will Unlock accelerate to rated rpm when the oil pressure is full access with a free trial. Note: After starting an industrial engine, m suf ficient. governor control lever to the position for low
Manual Starting
Download With Free Trial
1. Ensure that fuel is supplied to the engine. Ensure that no gas is leaking. 2. Ensure that the driven equipment is unloaded. a. For generator set engines, open the main circuit breaker.
4. Allow the engine to idle for three to fi The engine speed should stabilize at low Check all of the pressure gauges. Inspe engine for leaks and listen for unusual n the rpm m When all systems are normal, Sign up to vote on this title increased. Useful Not useful
Starting Failure
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46 Operation Section Engine Starting
S
i02070307
Starting with Jump Start Cables SMCS Code: 1000; 1401; 1402; 1900
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. If the installation is not equipped with a backup battery system, it may be necessary to start the engine from an external electrical source.
3. Connect one negative end of the jump s to the negative cable terminal of the ele source. Connect the other negative end jump start cable to the engine block or t chassis ground. This procedure helps to potential sparks from igniting combus that are produced by some batteries.
4. Charge the batteries. The engine will no to run after starting if the batteries have charged. 5. Start the engine.
6. Immediately after the stalled engine is s disconnect the jump start cables in rever
Refer to the Electrical Schematic for your e Consult your Caterpillar dealer for more info
Many batteries which are considered unusable are still rechargeable. After jump starting, the alternator After Starting Engine may not be able to fully recharge batteries that are severely discharged. The batteries must be SMCS Code: 1000 charged to the proper voltage with a batteryYou're charger. Reading a Preview For information on testing and charging, refer to For new installations and engines that are r the Special Instruction, SEHS7633, “Battery Testfull access withrebuilt, carefully monitor the engine in orde Unlock a free trial. Procedure”. any unusual engine performance.
Download With Free Trial rpm can be increased from low The engine NOTICE to rated rpm after one minute. Using a battery source with the same voltage as the electric starting motor. Use ONLY equal voltage for It may be necessary to apply some load in jump starting. The use of higher voltage will damage attain normal operating temperatures. The the electrical system. can ramp thetoload For automatic Sign up votemanually. on this title programmable logic control can be used. Do not reverse the battery cables. The alternator can Useful Not useful be damaged. Attach ground cable last and remove first. Engaging the Driven Equipm
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Operatio Engine
Engine Operation i02061036
Engine Operation
For example, an engine is operating at 20 p of the rated torque. The engine may be ope this load factor for a maximum of one-half h the one-half hour, operate this engine for a hours at a load factor of more than 70 perce
To keep engine maintenance at a minimum the guidelines that are listed in Table 7.
SMCS Code: 1000 Proper operation and maintenance are key factors in attaining the maximum service life and economy for the engine. Follow the instructions in this Operation and Maintenance Manual in order to minimize operating costs and maximize the service life of the engine. Observe the gauges frequently while the engine is operating. Record the data from the gauges in a log regularly. Compare the data to the speci fications for normal engine operation. Comparing the data over time will help to detect changes in engine performance.
Table 7
Time Limits For Low Load Operatio Engine Torque
NA Engines
0 to 30%
1/2 hour
31 to 60%
2 hours
61 to 70%
24 hours
71 to 100%
Continuous
(1)
TA
C
For continuous operation of TA engines, the man pressure should be greater than the atmospheric p
Investigate any signi ficant change in the gauge readings. Monitor the engine operation and take action when discrepancies are found.
You're Reading a Preview
Operating the Engine and the Unlock full access with a free trial. Driven Equipment Download With Free Trial 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
Cont
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48 Operation Section Engine Stopping
S
Engine Stopping i02143005
Emergency Stopping
For the junction box, the emergency stop b the OUT position for normal engine operati emergency stop, push the emergency stop The button must be reset before the engine started.
To reset the button, turn the button clockwi spring-loaded button will return to the OUT
SMCS Code: 1000; 7418 NOTICE Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure.
Manual Stop Procedure SMCS Code: 1000; 7418
Ensure that any system that provides external support to the engine is secured after the engine is stopped. NOTICE Do not start the engine until the problem necessitating the emergency stop has been located and corrected.
NOTICE Stopping the engine immediately after the e been operating under a load can result in and accelerated wear of the engine compon Allow the engine to gradually cool before engine.
Pressing the Emergency Stop Button may cause Note: Remove the load at a rate that will a unburned gas to remain in the air inlet and in the You're Reading adetonation. Preview exhaust manifold. Disengage the driven equipment. Unlock full access with1.a free trial.
a. For generator set engines, open the system Unburned gas in the air inlet and exhaust circuit breaker. Download With Free Trial may ignite when the engine is started. Personal injury and/or property damage may result. b. For industrial engines, unload the com or pump. Disengage the clutch (if equ Before starting an engine that may contain unPlace the transmission and/or other burned gas, purge the unburned gas from the air attachments the title power take-off in Sign up to vote for on this inlet and exhaust system. Refer to the topic on NEUTRAL. purging unburned gas in the “Starting the Engine” Useful Not useful section. Note: Extended idling can cause excessive consumption and related problems. See th
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Operatio Engine
i02416955
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 Follow the guidelines for antifreeze/coolant mixtures that are recommended in this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic. Failure to do so can cause engine damage.
You're Reading a Preview
• Allow the engine to cool. Check the coolant level.
Unlock full access with a free trial.
• If freezing temperatures are expected, check the coolant for protection against freezing. The cooling Download With Free Trial 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.
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50 Maintenance Section Refill Capacities
S
Maintenance Section
Lubricant Capacities
Refill Capacities
The capacity of the lubrication system inclu capacity of the oil filters that are installed a factory.
Optional auxiliary fi lters require additional o i02524752
Refill Capacities and Recommendations
-
SMCS Code: 1348; 1395; 7560
Lubrication System Lubricant Recommendations Due to significant variations in the quality and in the performance of commercially available oils, Caterpillar makes the following recommendations:
• Cat NGEO (Natural Gas Engine Oil)
Illustration 39
Oil pan for G3400CEngines • Cat NGEO EL350 (Natural Gas Engine Oil) You're Reading a Preview (1) Standard oil pan
The proper SAE viscosity grade of oil is determined Unlock full access withTable a free9 trial. by the minimum ambient temperature during cold engine start-up, and the maximum ambient Approximate Refill Capacity for the G3 temperature during engine operation. To determine Download With Free Trial Engine Lubrication System the oil viscosity that is required for starting a cold Compartment or System Liter soaked engine, refer to the minimum temperature in Table 8. To select the oil viscosity for operation at Engine crankcase 150 the highest anticipated ambient temperature, refer Standard oil pan to the maximum temperature in the Table. Use the Sign up to vote on this title highest oil viscosity that is available in order to meet Table 10 the required temperature during start-up. Useful Not useful
Approximate Refill Capacity for the G3 Engine Lubrication System
Table 8
Engine Oil Viscosity
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Maintenanc Refi
• Composition • Contaminants
Coolant/antif reeze is normally composed o elements: water, glycol, and additives. Each must meet speci fic guidelines.
• Heat value
Water
• Methane number
Deionized water or distilled water is recommended for use in engine cooling If distilled water or deionized water is not a use water with the properties that are listed 11.
• Specific gravity Field gas can have varying characteristics of combustion. Field gas can contain numerous harmful impur ities. The impurities can alter the BTU content. The impurities can also alter the methane number. The impurities include everything from water up to complex hydrocarbons that can lead to detonation and severe engine damage. To minimize these effects, Caterpillar recommends the following guidelines: 1. Evaluate the fuel with the Caterpillar Methane Number Program, LEKQ6378.
Table 11
Caterpillar Minimum Acceptable Water Requ Property
Maximum Limit
Chloride (Cl)
40 mg/L (2.4 grains per US gal)
Sulfate (SO4)
100 mg/L (5.9 grains per US gal)
Total Hardness
170 mg/L (10 grains per US gal)
Methane values below 30 are not recommended Total Solids for use in a Caterpillar engine. Fuels with a methane number that is below 30 must first be You're Reading a Preview Acidity processed in order to remove harmful impurities in the fuel and raising the methane number into the Unlock full access with a free trial. acceptable range.
340 mg/L (20 grains per US gal) pH of 5.5 to 9.0
NOTICE Use of water that does not meet the recom gured 2. If necessary, use an engine that is con fiDownload With Free Trial for the cooling system will damage the co for a fuel that has a high energy. Consult the appropriate manual for the engine in order to determine the recommended engine timing. 3. Reduce the oil change interval according to the results of the oil analysis. For further information on fuels, see Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations”.
Do not use these types of water in the coolin sea water, softened water that has been co with salt, hard water, and tap water. Sign up to vote on this title Only use water that meets the recommend Useful Not useful the cooling system.
If you are not sure about the properties of y
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52 Maintenance Section Refill Capacities
Glycol
S
Table 12
Recommended Coolant/Antifreeze and S Life of the Coolant/Antifreeze
NOTICE Do not use Extended Life Coolant (ELC) with Caterpillar Gas Engines.
Coolant/Antifreeze Cat NGEC
Service
Three Yea
ELC was not formulated for use in Caterpillar Gas Engines.
Cat DEAC
Use only the coolant/antifreeze that is recommended.
Commercial Heavy-Duty Coolant/Antifreeze that meets “ASTM D6210”
Two Y
Preferred – Cat NGEC (Natural Gas Engine Coolant)
Commercial Heavy-Duty Coolant/Antifreeze that meets “ASTM D4985”
One Yea
Alternatively, use Cat DEAC (Diesel Engine Antifreeze/Coolant) or a commercial heavy-duty coolant/antifreeze that meets “ASTM D6210” or “ASTM D4985” specifications.
(1)
Cat SCA and Water
Two Y
Commercial SCA and Water
One Y
The service life of coolant is also limited by use (se Refer to the speci fic engine’s Operation and Maint Manual, “Maintenance Interval Schedule”.
NOTICE Do not use a commercial coolant/antifreeze that only meets the ASTM “D3306” speci fication. This type of coolant/antifreeze is made for light duty automotive applications.
Additives
Note: The preferred coolant/antifreeze and the acceptable mixture of SCA and water require different concentrations of SCA. Refer to the Special Publication, SEBU6400, “Supplemental Coolant Additive (SCA)” topic.
an SCA at the initial fi ll. Commercial hea coolant/antifreeze that meets “ASTM D621 or “ASTM D4985” fications Sign up to votespeci on this title may requ treatment with an SCA at the initial fi ll. Rea Useful that Notare useful instructions or the provided by the the product.
Preferred – Cat Supplemental Coolant Ad You're Reading a(SCA) Preview Use only the coolant/antifreeze that is recommended. – A commercial SCA that pro Unlock full access withAcceptable a free trial. 1200 mg/L (70 grains per US gal) or 1200 Acceptable – In applications that do not require nitrites in the fi nal mixture of coolant/antifre protection from boiling or from freezing, a mixture of With Free Trial Download Cat SCA and water that meets the properties that are Note: A 50/50 concentration of Cat NGE listed in Table 11 is acceptable. Cat DEAC does not require a treatment
Table 12 is a list of the coolant/antifreeze that is
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Maintenanc Refi
Coolant Capacities 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 includes the following components: engine, expansion tank, heat exchanger, radiator, and piping. Refer to the speci fications that are provided by Caterpillar or by the OEM of the equipment. Record the Total Cooling System capacity in the appropriate Tables: Table 13
Approximate Refill Capacities for the G3408C Engine Cooling System
Compartment or System Engine only
Liters 55.5
US Gal
14.5
External system(1) Total cooling system(2) (1)
The external system includes a radiator and piping. Refer to Caterpillar specifi cations or refer to the OEM speci fications. Enter the external system capacity in this row. (2) Add the “engine only” capacity to the “external system” You're Reading capacity. Enter the total in this row.
Unlock full access with a free trial.
Table 14
Approximate Refill Capacities for the G3412C Engine Cooling System Download Compartment or System Engine only
a Preview
Liters
US Gal
75
20
With Free Trial
External system(1) Total cooling system(2) (1)
The external system includes a radiator and piping. Refer to Caterpillar specifi cations or refer to the OEM speci fications. Enter the external system capacity in this row. (2) Add the “engine only” capacity to the “external system”
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54 Maintenance Section Maintenance Interval Schedule
S
i02752300
Maintenance Interval Schedule (Standard) SMCS Code: 1000; 4450; 7500 Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the installation of new components due to normal wear and aging. The performance of this product may be diminished if proper maintenance intervals and procedures are not followed. Components may experience accelerated wear if proper maintenance intervals and procedures are not followed.
Cooling System Coolant Sample (Level 1) Obtain ..................................................... Cooling System Supplemental Coolant Add (SCA) - Test/Add .................................. Crankshaft Vibration Damper - Inspect ...... Engine - Clean .......................................... Engine Oil and Filter - Change .................. Engine Valve Lash - Inspect/Adjust ........... Engine Valve Rotators - Inspect ................ Exhaust Piping - Inspect ............................ Gas Pressure Regulator - Check ............... Hoses and Clamps - Inspect/Replace ....... Ignition System Spark Plugs - Check/Adju Replace ............................................... Ignition System Timing - Check/Adjust ...... Radiator - Clean ....................................
Initial 750 Service Hours
Valve Stem Projection - Measure/Record ..
Every 1500 Service Hours Use whichever of the following that occurs fi rst in order to determine the maintenance intervals: fuel Actuator Control Linkage - Lubricate ......... consumption, service hours, and calendar time . Carburetor Air/Fuel Ratio - Check/Adjust Products that operate in severe operating conditions Crankcase Blowby - Measure/Record ....... may require more frequent maintenance. You're Reading aCylinder PreviewPressure - Measure/Record ........
Engine Crankcase Breather - Clean .......... allfull access withEngine Before each consecutive interval is performed, Unlock a free trial. Protective Devices - Check ........... maintenance from the previous intervals must be Engine Speed/Timing Sensor - Clean/Inspe performed. Speed Sensor - Clean/Inspect ...................
When Required
Download With Free Trial
Every 3000 Service Hours
Batteries - Replace ............................................... 58 Engine Air Cleaner Element - Replace ................. 68 Overhaul Considerations ...................................... 86 Valve Stem Projection - Measure/Record ............. 92
Daily Air Tank Moisture and Sediment Drain
57
Cooling System Coolant Sample (Level 2) Obtain ..................................................... Driven Equipment Check ......................... Sign up to vote- on this title Ignition System Transformer Resistance - T Not useful Inlet Air Useful System - Inspect ........................... Starting Motor - Inspect ............................. Water Pump - Inspect ................................
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Maintenanc Maintenance Interval
Every 24 000 Ser vice Hours or 3 Years Cooling System Coolant (DEAC) - Change .......... 61
You're Reading a Preview Unlock full access with a free trial.
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Cooling System Coolant Sample (Level 2) Obtain ..................................................... Maintenance Interval Schedule Cooling System Supplemental Coolant Add (SCA) - Test/Add .................................. (Standby) Crankcase Blowby - Measure/Record ....... Crankshaft Vibration Damper - Inspect ...... SMCS Code: 1000; 4450; 7500 Cylinder Pressure - Measure/Record ........ Engine - Clean .......................................... Ensure that all safety information, warnings, Engine Air Cleaner Element - Replace ...... and instructions are read and understood before Engine Crankcase Breather - Clean .......... any operation or any maintenance procedures Engine Oil Sample - Obtain ....................... are performed. The user is responsible for Engine Performance - Test ........................ the performance of maintenance, including all Engine Protective Devices - Check ........... adjustments, the use of proper lubricants, fluids, Engine Speed/Timing Sensor - Clean/Inspe filters, and the installation of new components Engine Valve Lash - Inspect/Adjust ........... due to normal wear and aging. The performance Engine Valve Rotators - Inspect ................ of this product may be diminished if proper Gas Pressure Regulator - Check ............... maintenance intervals and procedures are not Hoses and Clamps - Inspect/Replace ....... followed. Components may experience accelerated Ignition System Spark Plugs - Check/Adju wear if proper maintenance intervals and procedures Replace ............................................... are not followed. Ignition System Timing - Check/Adjust ...... Inlet Air System - Inspect ........................... Use whichever of the following that occurs fi rst in Radiator - Clean ........................................ order to determine the maintenance intervals: fuel Speed Sensor - Clean/Inspect ............... consumption, service hours, and calendar time . Starting Motor - Inspect ............................. Products that operate in severe operating conditions - Inspect ............................... may require more frequent maintenance. You're Reading aTurbocharger Preview Water Pump - Inspect ................................ allfull access with a free trial. Before each consecutive interval is performed, Unlock Every 3 Years maintenance from the previous intervals must be performed. Batteries - Replace ................................... Download With Free Trial Cooling System Coolant (DEAC) - Change Every Week Exhaust Bypass - Inspect .......................... Exhaust Piping - Inspect ............................ Air Tank Moisture and Sediment - Drain ............... 57 Governor - Inspect .................................... Automatic Start/Stop - Inspect .............................. 57 Hoses and Clamps - Replace .................... Battery Charger - Check ....................................... 58 Sign up to vote on this titleResistance - T Ignition System Transformer Battery Electrolyte Level - Check .......................... 59 Water Control Panel - Inspect ......................................... 60 Useful Not useful - Replace ... Temperature Regulator Engine Air Cleaner Service Indicator - Inspect ..... 70 Engine Air Precleaner - Clean .............................. 71 Engine Oil Level - Check ...................................... 72 i02752313
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Maintenanc Actuator Control Linkage
i01600724
Actuator Control Linkage Lubricate
1. Open the drain valve that is on the botto air tank. Allow the moisture and sedimen 2. Close the drain valve.
SMCS Code: 1265-086
Alternator - Inspect SMCS Code: 1405-040
Inspect the alternator for the following cond
• Proper connections • Clean ports for cooling air flow • Proper charging of the battery
Illustration 40
g00709892
Observe the ammeter during engine opera order to ensure proper battery performance proper performance of the electrical system
Grease fittings
Make repairs, if necessary. See the Service Apply grease to the grease fittings. Use a hand for service procedures. Consult your Cater grease gun and lubricate the grease fittings with for assistance. You're Reading adealer Preview MPGM.
Check the Linkage
Unlock full access with a free trial.
Automatic Start/Stop - Ins
Download With Free Trial Check the linkage for proper operation. Adjust (Generator Set) the linkage, if necessary. Refer to the engine’s Specifications. SMCS Code: 4462 i00351324
Air Tank Moisture and Sediment - Drain
operate The generator set must be ready to Sign up to vote on this title load at any time. After performing maintena Not useful Useful set,inspect the generator the position of th switches. Ensure the following conditions: The starting system is enabled.
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58 Maintenance Section Batteries - Replace
S
i01041029
Batteries - Replace
Battery Charger - Check
SMCS Code: 1401-510
SMCS Code: 1401-535
Checking Before Start-Up Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can result in severe personal in jury or death. Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced. 1. Turn the key start switch to the OFF position. Remove the key and all electrical loads. 2. Turn OFF the battery charger. Disconnect the charger.
Check the battery charger for proper opera the batteries are properly charged, the nee ammeter will register near “0” (zero).
The battery charger must not produce exce current during start-up. Alternatively, the must be automatically disconnected for If the engine has an alternator, the charger be automatically disconnected during startduring engine operation.
Charging the Battery
Never disconnect any charging unit circ circuit cable from the battery when t You're Reading atery Preview 3. The NEGATIVE “-” cable connects the NEGATIVE ing unit is operated. A spark can cause “-” battery terminal to the ground plane. Disconnect sion from the flammable vapor mixture full access with a free trial. the cable from the NEGATIVE “-” batteryUnlock terminal. gen and oxygen that is released fro trolyte through the battery outlets. Inju 4. The POSITIVE “+” cable connects the POSITIVE sonnel can be the result. Download With Free Trial “+” battery terminal to the starting motor. Disconnect the cable from the POSITIVE “+” Perform the following procedure to charge battery terminal. battery: Note: Always recycle a battery. Never discard a 1. Ensure that is turned OFF. battery. Return used batteries to an appropriate Sign up to the votecharger on this title recycling facility. useful Useful Not 2. Adjust the voltage of the charger in orde the voltage of the battery. 5. Remove the used battery.
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Maintenanc Battery Electrolyte Lev
Perform one of the following procedures if the battery shows symptoms of overcharging:
• Reduce the rate of charging by a signi ficant
amount. Complete the charging at the reduced rate.
All lead-acid batteries contain sulfuric a can burn the skin and clothing. Always shield and protective clothing when wor near batteries.
• Turn OFF the charger. Table 15 descr ibes the effects of overcharging on different types of batteries. Table 15
Effects of Overcharging Batteries Type of Battery
Effect
Caterpillar General Service All of the battery cells have Batteries a low level of electrolyte. Caterpillar Premium High Output Batteries
1. Remove the filler caps. Maintain the ele level to the “FULL” mark on the battery.
If the addition of water is necessary, use water. If distilled water is not available u water that is low in minerals. Do not use softened water.
2. Check the condition of the electrolyte w 245-5829 Coolant Battery Tester Refra 3. Keep the batteries clean.
Clean the battery case with one of the fo cleaning solutions:
• A mixture of 0.1 kg (0.2 lb) of baking s When the plates of the 1 L (1 qt) of clean water battery are inspected You're Reading a Preview through the fi ller holes, the plates may appear to be mixture of 0.1 L (0.11 qt) of ammon • Atrial. Unlock full warped. This is caused by access with a free(1 qt) of clean water an excessive temperature. The battery may not pass Download a load test. Caterpillar Maintenance Free Batteries
The battery may not accept a charging current. The battery may not pass a load test.
Checking After Stopping
rinse the battery case with cle With FreeThoroughly Trial
Use a fine grade of sandpaper to clean terminals and the cable clamps. Clean t until the surfaces are bright or shiny. DO remove material excessively. Excessive up tocan votecause on this title of Sign material the clamps to not Coat the clamps the terminals with Not useful Useful and Silicone Lubricant, petroleum jelly or MP
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60 Maintenance Section Carburetor Air/Fuel Ratio - Check/Adjust
S
• Pulleys
3. Move the pulley in order to adjust the be
• Bearings
4. Tighten the adjusting nut to the proper to
If the belts are too tight, unnecessary stress is placed on the components. This reduces the service life of the components.
5. Tighten the mounting bolt to the proper t
Adjusting the Alternator Belt
For the proper torque speci fications, refer Service Manual, “Speci fications” module.
Replacement
For applications that require multiple drive replace the drive belts in matched sets. Re one drive belt of a matched set will cause t drive belt to carry more load because the o belts are stretched. The additional load on drive belt could cause the new drive belt to
Carburetor Air/Fuel Ratio Check/Adjust SMCS Code: 1266-535; 1266
You're Reading a Preview
An engine failure may occur if the air/fuel appropriate for the fuel and for the ope Unlock full access withnot a free trial. conditions. The service life of the turbochar valves, and of the other components may be Illustration 41
Download g01092641 With Free Trial
Typical alternator (1) Mounting bolt (2) Adjusting nuts (3) Mounting bolt
1. Remove the drive belt guard. 2. Loosen mounting bolt (1), adjusting nuts (2) and mounting bolt (3).
Ensure that the carburetor is adjusted prop that the air/fuel ratio is correct.
For information on adjusting the carburetor the Service “Systems Sign upManual, to vote on this title Operation/T and Adjusting”, or refer to the Special Instr NotStart-Up useful Procedure” Useful and Initial “Installation
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Maintenanc Cooling System Coolant (DEAC)
Record the Data and Review the Data If equipped, check the gauges and check the indicators fr equently during normal operation. Record the data in a log. Compare the new data to the data that was previously recorded. Comparing the new data to the recorded data will establish the normal gauge readings for the engine. A gauge reading that is abnormal may indicate a problem with operation or with the gauge. i02057429
Cooling System Coolant (DEAC) - Change SMCS Code: 1350-044 Clean the cooling system before the recommended maintenance interval if the following conditions exist:
Illustration 43
Drain plugs on the oil cooler, water pumps, and elbow
• The engine overheats frequently. • Foaming is observed.
3. Open the cooling system drain valve. Re drain plugs. You're Reading a Preview
coolant • Oil has entered the cooling system and the Unlock full access with a free trial.
NOTICE Dispose of used engine coolant properly o Various methods have been proposed to rec Trial Drain the Cooling System Download With Free coolant for reuse in engine cooling system distillation procedure is the only method acc 1. Stop the engine and allow the engine to cool. Caterpillar to reclaim the used coolant. Ensure that the engine will not start when the cooling system is drained. For information regarding the disposal and Sign up to vote on this title recycling of used coolant, consult your Cate Not useful orUseful dealer consult Caterpillar Dealer Service is contaminated.
Outside Illinois: 1-800-542-TOOL
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62 Maintenance Section Cooling System Coolant (DEAC) - Change
S
NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
NOTICE Fill the cooling system no faster than 19 L per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L (4 US gal) of the cooling system capacity. Install the cooling system fi ller cap.
3. Fill the cooling system with a mixture of water and Caterpillar Fast Acting Coolin Cleaner. Add 0.5 L (1 pint) of cleaner p 3.8 to 7.6 L (1 to 2 US gal) of the cooling capacity. Install the cooling system filler
4. Start the engine. Operate the engine for a minimum of 30 minutes with a coolant temperature of at least 82 °C (180 °F).
4. Start the engine. Operate the engine fo minimum of 90 minutes with a coolant te 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 fi ller cap. Open the cooling system drain valve. Remove the drain plugs.
5. Stop the engine and allow the engine to Loosen the cooling system filler cap slo order to relieve any pressure. Remove th system fi ller cap. Open the cooling syste valve. Remove the drain plugs. Allow th to drain.
NOTICE NOTICE Improper or incomplete rinsing of the cooling system Improper or incomplete rinsing of the coolin can result in damage to copper and other metal comcan result in damage to copper and other m ponents. You're Reading aponents. Preview To avoid damage to the cooling system, make Unlocksure full access with a free trial. To avoid damage to the cooling system, m to completely flush the cooling system with clear wato completely flush the cooling system with ter. Continue to flush the system until all signs of the ter. Continue to flush the system until all si cleaning agent are gone. Download With Free Trial cleaning agent are gone. 6. Allow the water to drain. Flush the cooling system with clean water until the water that drains is clean. Close the cooling system drain valve. Clean the drain plugs and install the plugs.
Cleaning a Cooling System that has Heavy Deposits or Plugging
6. Flush the cooling system with clean wat the water that drains is clean. Close the system drain valve. Clean Sign up to vote on this titlethe drain plug install the plugs. Useful Not useful
Fill the Cooling System
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Maintenanc Cooling System Coolant Sample (Level 1
3. Check the coolant level. Maintain the coolant to the proper level on the sight gauge (if equipped). If a sight gauge is not equipped, maintain the coolant within 13 mm (0.5 inch) below the bottom of the filler pipe.
• Keep the unused sampling bottles stored
4. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets of the cooling system filler cap are damaged, discard the old cooling system fi ller cap and install a new cooling system filler cap. If the gaskets of the cooling system filler cap are not damaged, use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system fi ller cap. The correct pressure is stamped on the face of the cooling system fi ller cap. If the cooling system filler cap does not maintain the correct pressure, install a new cooling system fi ller cap.
• Complete the information on the label fo
5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.
Note: Level 1 results may indicate a nee Level 2 Analysis.
i02064894
bags.
• Keep the lids on empty sampling bottles are ready to collect the sample.
sampling bottle before you begin to take samples.
• Obtain coolant samples directly from the
sample port. You should not obtain the sa from any other location.
• In order to avoid contamination, immedia
the sample in the tube that is provided fo
Submit the sample for Level 1 analysis.
For additional information about coolant see the Special Publication, SEBU6400, “C Gas Engine Lubricant, Fuel and Coolant Recommendations” or consult your Caterpil
Cooling System Coolant Sample (Level 1) - ObtainYou're Reading a Preview
Unlock full access with a free trial. SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Cooling System Coolant
NOTICE Download With Free Trial Sample (Level 2) - Obtain Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. SMCS Code: 1350-008; 1395-008; 1395-5 Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorNOTICE Sign up to vote on this title rect interpretation that could lead to concerns by both Always use a designated pump for oil sam Useful separ Not useful ate designated pump for coolan dealers and customers. use a Using the same pump for both types of sam contaminate the samples that are being dr For conventional heavy-duty coolant/antifreeze, te may cause a false analysis and
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64 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add
i02017557
Cooling System Supplemental Coolant Additive (SCA) Test/Add SMCS Code: 1352-045; 1395-081
S
6. Repeat 5 until the solution changes colo to light gray, green, or blue. Record the n drops of “NITRITE TEST SOLUTION A” required to cause the color change. 7. Use Table 16 to interpret the results. Table 16
Cooling system coolant additive contains alkali. To help prevent personal injury, avoid contact with the skin and eyes. Do not drink cooling system coolant additive.
Number of Drops
Concentration of SCA
Mainte Requir
Less than 25
Less than the recommended concentration of SCA
Add Retest coolan
25 to 30
The recommended concentration of SCA
None
More than 30
More than the recommended concentration of SCA
Remov coolan Replac water o Retest coolan
Note: Caterpillar recommends an S·O·S coolant analysis (Level 1).
Test the Concentration of the SCA Coolant/Antifreeze and SCA NOTICE You're Reading a Preview suppleDo not exceed the recommended six percent Add the mental coolant additive concentration. Unlock full access with a free trial.
SCA, If Necessary
Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. Follow the instructions Download With Free Trial Pressurized System: Hot coolant can ca that are provided in the kit. ous burns. To open the cooling system stop the engine and wait until the coolin Water and SCA components are cool. Loosen the coolin pressure cap slowly in order torelieve Sign up to vote on this title NOTICE sure. Do not exceed the recommended eight percent sup Useful Not useful plemental coolant additive concentration. 1. Remove the cooling system fi ller cap slo
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Maintenanc Crankcase Blowby - Measu
NOTICE Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine’s heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger, overheating, and/or accelerated wear of the water pump seal. Do not exceed the recommended amount of supplemental coolant additive concentration. 3. Add the proper amount of SCA. The concentration of the SCA depends on the type of coolant that is used. To determine the proper amount, see this Operation and Maintenance Manual, “Re fill Capacities and Recommendations” topic.
Note: A problem with the piston rings caus oil to deteriorate rapidly. Information regard condition of the piston rings can be obtaine the measurement of the blowby and the re oil analysis.
The blowby of a worn engine may exceed th of a new engine by two times or more.
A sudden incr ease in blowby could indicate piston ring. The following conditions are ot potential sources of blowby:
• Worn valve guides • A turbocharger seal that leaks A rebuilt engine can have a high blowby following factors:
• The piston rings are not seated properly
• Worn parts such as valve guides were no
4. Clean the cooling system filler cap. Install the cooling system filler cap.
Excessive blowby may indicate the need fo overhaul. By keeping a record of the result You're Reading agradual Preview increase in the amount of the blow amount has become excess noted until the i01333307
Unlock full access with a free trial.
Crankcase Blowby Measure/Record SMCS Code: 1317
To measure the blowby, use the 8T-2700 FlowTrial Indicator. Refer to Special Instruction Download With Free SEHS8712, “Using the 8T-2700 Blowby/Ai Indicator Group”. The instruction is provide tool.
Note: For a new G3400 Engine, the typical range for crankcase blowby is approximately 22 to 37 L/Bkw-hr (0.6 to 1.0 cu ft/Bhp-hr). Measure the crankcase blowby of new engines. Record the data. Continue to periodically measure
Keep a record of the results. Sign up to vote on this title For more information, the Service Man useful Useful Notsee “Systems Operation/Testing and Adjusting” assistance, consult your Caterpillar dealer
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66 Maintenance Section Cylinder Pressure - Measure/Record
S
Visconic Damper
• Fully open the throttle plate.
The visconic damper has a weight that is located inside a fluid filled case. The weight moves in the case in order to limit torsional vibration.
• Minimize the cranking time. This will ena
Inspect the damper for evidence of fluid leaks. If a fluid leak is found, determine the type of fluid. The fluid in the damper is silicone. Silicone has the following characteristics: transparent, viscous, smooth, and adhesive.
A loss of cylinder pressure or a change of p in one or more cylinders may indicate the fo conditions. These conditions may indica with lubrication:
If the fl uid leak is oil, inspect the crankshaft seals for leaks. If a leak is observed, replace the crankshaft seals. Inspect the damper and repair or replace the damper for any of the following reasons:
maximum consistent cranking speed for t Also, the battery power will be conserved
• Excessive deposits • Guttering of valves • A broken valve • A piston ring that sticks
• The damper is dented, cracked, or leaking.
• A broken piston ring
• The paint on the damper is discolored from heat.
• Worn piston r ings
• The engine has had a failure because of a broken
• Worn cylinder liners
crankshaft.
If the cylinder pressure has risen by one or
You're Reading acompression Preview ratios, the engine needs a top • Analysis of the oil has revealed that the front main bearing is badly worn.
overhaul in order to remove deposits. Failu remove the deposits will increase the chan detonation. Severe guttering of the valves w
Unlock full access with a free trial.
• There is a large amount of gear train wear that is not caused by a lack of oil. Download With Free Trial Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement. i01519864
Cylinder Pressure Measure/Record
To measure the cylinder pressure, use the Cylinder Pressure Gauge Gp. Follow the pr in the Special Instruction, NEHS0798 that i with the gauge group. Record the pressure each cylinder. Use the Operation and Main Sign up to vote on this title Manual, “Valve Data Sheet” (Reference Ma Section). Useful Not useful
Illustration 44 is a graph of typical cylinder p for engines with different compression ratio
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Maintenanc Driven Equipme
Driven Equipment Inspect/Replace/Lubricat SMCS Code: 3279-040
Observe the driven equipment during opera for the following items:
• Unusual noise and vibration • Loose connections • Damaged parts
Perform any maintenance that is recomme by the OEM of the driven equipment. Refe literature of the OEM of the driven equipme following service instructions.
• Inspection
• Lubricating grease and lubricating oil req Specifications for adjustment You're Reading a•Preview Illustration 44
components g00760309 Unlock full access with•a Replacement of free trial.
(Y) Cylinder pressure in kPa (psi) (X) Compression ratio (1) Normal range for cylinder pressure
• Requirements for ventilation Download With Free Trial i00449093
Driven Equipment - Check SMCS Code: 3279-535 To minimize bearing problems and vibration of the engine crankshaft and the driven equipment, the
Engine - Clean SMCS Code: 1000-070 Sign up to vote on this title
Useful
Not useful
Personal in jury or death can result from
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68 Maintenance Section Engine Air Cleaner Element - Replace
S
• Operating conditions (dust, dirt and debr NOTICE Accumulated gr e ase and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid spills whenever a signi ficant quantity accumulates on the engine.
require more frequent service of the air c element.
• The air cleaner element may be cleaned
six times if the element is properly clean inspected.
Steam cleaning the engine will remove accumulated oil and grease. A clean engine provides the following benefits:
• The air cleaner element should be replac
• Easy detection of fl uid leaks
Replace the dirty paper elements with clea elements. Before installation, thoroughly ins element for tears and/or holes in the filter Inspect the gasket or the seal of the eleme damage. Maintain a supply of suitable elem replacement purposes.
• Maximum heat transfer characteristics • Ease of maintenance Note: For more information on cleaning and drying electric generators, refer to Special Instruction, SEHS9124, “Cleaning and Drying of Electric Set Generators”.
one time per year. This replacement sho performed regardless of the number of cl
i01749609
Engine Air Cleaner Element You're- Reading a Preview Replace
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SMCS Code: 1051-510; 1054-510
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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 airborne debris from entering the air inlet.
Illustration 45 Fasteners for the air cleaner cover
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Maintenanc Engine Air Cleaner Element
4. Clean the inside of the cover and the body with a clean, dry cloth. 5. Remove the tape for the air inlet. Install a new element or a clean element. 6. Install the cover. 7. If necessary, reset the air cleaner service indicator.
Cleaning the Primary Air Cleaner Elements The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected. When the element is cleaned, check the filter material for rips or tears. Replace the element at least one time per year regardless of the number of cleanings. Use clean elements while dirty elements are being cleaned.
Note: When the elements are cleaned, alw with the clean side (inside) in order to forc particles toward the dirty side (outside).
Aim the hose so that the air fl ows inside the along the length of the fi lter in order to help damage to the paper pleats. Do not aim the of air directly at the primary air cleaner elem could be forced into the pleats.
Note: Refer to “Inspecting the Primary Air C Elements”.
Vacuum Cleaning
Vacuum cleaning is a good method for clea elements which require daily cleaning beca dry, dusty environment. Cleaning with press is recommended prior to vacuum cleaning. cleaning will not remove deposits of carbon
Note: Refer to “Inspecting the Primary Air C Elements”.
NOTICE Inspecting the or Do not clean the air cleaner elements by bumping You're Reading aElements Preview tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. DamUnlock full access with a free trial. aged elements will allow dirt to pass through. Engine damage could result.
Primary Air Clean
Download With Free Trial Visually inspect the elements before cleaning. Inspect the elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged elements. Air cleaner elements can be cleaned with pressurized air and with a vacuum.
Pressurized Air
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70 Maintenance Section Engine Air Cleaner Service Indicator - Inspect
Illustration 49
g00281694
Do not use paint, a waterproof cover, or plastic as a protective covering for storage. Restricted air fl ow may result. To protect against dirt and damage, wrap the elements in Volatile Corrosion Inhibited (VCI) paper.
78494036 QUASAR 1F
S
Illustration 50 Service indicator
Some engines may be equipped with a diff service indicator.
Observe the service indicator. Clean the air element or replace the element when the fo conditions occur:
Place the element into a cardboard box for storage. For identification, mark the outside of the container and mark the element. Include the following • The yellow diaphragm enters the red zon You're Reading a Preview information: • The red piston locks in the visible positio Unlock full access with a free trial. • Date of cleaning • The air restriction reaches 3.7 kPa • Number of cleanings (15 inches of H2O).
Download With Free Trial
Store the container in a dry location. For more detailed information on cleaning the primary air cleaner element, refer to Special Publication, SEBF8062, “Procedure to Inspect and Clean Air Filters”. i01505252
Inspect the service indicator daily for cracks loose fi ttings. If any of these conditions are repair the service indicator or replace the s indicator. Sign up to vote on this title
UsefulService the Not useful Test Indicator Service indicators are important instrum
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Maintenanc Engine Air Preclean
Remove wing nut (1) and cover (2). Check accumulation of dirt and debris in body (3). body, if necessary. After cleaning the precleaner, install cover wing nut (1).
Note: When the engine is operated in dus applications, more frequent cleaning is requ
Illustration 51
g00351792
Engine Crankcase Breath Clean SMCS Code: 1317-070
Porous filter
A porous filter is part of a fitting that is used for mounting of the service indicator. Inspect the filter for cleanliness. Clean the filter, if necessary. Use compressed air or a clean, non flammable solvent. The service indicator may need to be replaced frequently in environments that are severely dusty. Replace the service indicator annually regardless You're Reading a Preview of the operating conditions. Replace the service indicator when the engine is overhauled, and Unlock full access with a free trial. whenever major engine components are replaced. Note: When a new service indicator is installed, Download With Free Trial excessive force may crack the top of the service Illustration 53 indicator. Tighten the service indicator to a torque (1) Hose clamp of 2 N·m (18 lb in). (2) Breather assembly (3) Retaining clamp
Engine Air Precleaner - Clean
Sign up to vote on this title 1. Loosen hose clamp (1). Slide the hose useful Useful Not(2). breather assembly
SMCS Code: 1055-070
2. Loosen retaining clamp (3). Remove bre
i01397717
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72 Maintenance Section Engine Oil Level - Check
S
i02070400
Engine Oil Level - Check SMCS Code: 1348-535-FLV The most accurate check of the oil level is performed when the engine is stopped. Perform this maintenance on a surface that is as level as possible. Note: For engines with positive crankcase ventilation, remove the oil fi ller cap. Allow the crankcase pressure to stabilize before checking the engine oil level.
The oil level should be between “ADD (5) and “FULL” mark (6).
NOTICE Engine damage can occur if the crankcas above the “FULL” mark on the oil level ga stick).
An overfull crankcase can enable the cra dip into the oil. This will reduce the power veloped and also force air bubbles into the bubbles (foam) can cause the following pro duction of the oil’s ability to lubricate, redu pressure, inadequate cooling of the pistons ing out of the crankcase breathers, and exc consumption.
Excessive oil consumption will enable dep on the pistons and in the combustion cham posits in the combustion chamber lead to problems: guttering of the valves, packing under the piston rings, and wear of the cylin
If the oil level is above the “FULL” mark on th gauge, drain some of the oil immediately.
You're Reading a Preview Illustration 54 (1) Oil level gauge (dipstick) (2) Oil filler cap
2. If necessary, remove oil filler cap (2) an oil. For the correct oil to use, see this Op and Maintenance Manual, “Refill Capac topic (Maintenance Download With FreeRecommendations” Trial Do not fi ll the crankcase above “FULL” m Clean the oil fi ller cap. Install the oil fi
g00781190 Unlock full access with a free trial.
3. Record the amount of oil that is added. th next oil sample and analysis, include Sign up to vote on this title amount of oil that has been added since previous oil change. usefulwill help to pro Useful Not This most accurate oil analysis.
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Maintenanc Engine Oil and Filter
Before taking the sample, complete the Label, PEEP5031 for identification of the sample. To help obtain the most accurate analysis, provide the following inf ormation:
Engine Oil and Filter - Ch SMCS Code: 1318-510
• Engine model • Service hours on the engine • The oil’s hour s of use • The amount of oil that has been added since the
Hot oil and hot components can cause injury. Do not allow hot oil or hot compo contact the skin.
last oil change
To ensure that the sample is representative of the oil in the crankcase, obtain a warm, well mixed oil sample. To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean.
NOTICE Ensure that the engine is stopped before p this procedure. Attach a DO NOT OPERA starting controls.
Do not drain the oil when the engine is cold. cools, suspended waste particles settle on t of the oil pan. The waste particles are not r when the cold oil is drained. Drain the crank the oil warm, immediately after the engine i This method of draining allows the waste p that are suspended in the oil to be drained.
Caterpillar recommends using the sampling valve in order to obtain oil samples. The quality and the consistency of the samples is better when the sampling valve is used. The location of the sampling You're Reading a Preview valve allows oil that is flowing under pressure to be Failure to follow this recommended proced obtained during normal engine operation. the waste particles to be recirculated Unlock full access withcause a free trial. the engine lubrication system with the new The 8T-9190 Fluid Sampling Bottle Group is The recommended for use with the sampling valve. Download With Free Trial 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 extracting oil samples that is used for extracting coolant samples. A small residue of either type sample may remain in
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74 Maintenance Section Engine Oil and Filter - Change
S
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fl uids according to local regulations and mandates. 2. Drain the oil. a. If the engine has an oil drain valve, open the valve in order to drain the oil. After the oil has drained, close the valve.
Illustration 57 Typical fi lter mounting base and filter gasket
3. Clean the sealing surface of the filter m base. Ensure that all of the old oil filter g removed.
NOTICE Caterpillar oil filters are built to Cater b. If the engine does not have a drain valve, fications. Use of an oil filter not recomm remove an oil drain plug. Allow the oil to drain. You're Reading aCaterpillar Preview could result in severe engine d the engine bearings, crankshaft, etc., as a Replace the Oil Filter the larger waste particles from un filtered o Unlock full access with a free trial. the engine lubricating system. Only use 1. Remove the oil filter with a 1U-8760 Chain recommended by Caterpillar. Wrench. Download With Free Trial 2. Cut the oil filter open with a 4C-5084 Oil Filter Cutter. Break apart the pleats and inspect the oil filter for metal debris. An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure. Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in
4. Apply clean engine oil to the new oil fi
NOTICE insta Do not fill the oil fi lters with oil before Sign up tonot vote this title This oil would beon fi ltered and could be co ed. Contaminated can cause accelerate useful Useful oilNot engine components.
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Maintenanc Engine Performa
Fill the Engine Crankcase NOTICE Engine damage can occur if the crankcase is filled above the “FULL” mark on the oil level gauge (dipstick). An overfull crankcase can cause the crankshaft to dip into the oil. This will reduce the power that is developed and also force air bubbles into the oil. These bubbles (foam) can cause the following problems: reduction 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. Deposits in the combustion chamber lead to the following problems: guttering of the valves, packing of carbon under the piston rings, and wear of the cylinder liner. If the oil level is above the “FULL” mark on the oil level gauge, drain some of the oil immediately.
Engine Performance - Tes SMCS Code: 1000-081
Operate the engine for a minimum of two h minimum load of 60 percent.
• Monitor the operation of the generator se
• Observe the gauges. Ensure that the gau in the normal r anges.
• Record the data. Maintain a record of the the engine per formance.
Engine Protective Device Check SMCS Code: 7400-535
Alarms and shutoffs must function properly 1. Remove the oil filler cap. Fill the crankcase with You're Reading aprovide Preview timely warning to the operator. Shu the proper amount of oil. Refer to the Operation to prevent damage to the engine. It is impo and Maintenance Manual, “Re fill Capacities & Unlock full access withtoa free trial. determine if the engine protective device Recommendations” topic (Maintenance Section). in good working order during normal opera Malfunctions must be simulated in order to Download With Free Trial NOTICE engine protective devices. To prevent crankshaft damage or bearing damage, crank the engine with the fuel supply line closed. This A calibration check of the engine protective will ensure that all of the oil fi lters are fi lled with oil bewill ensure that the alarms and shutoffs act fore the engine is started. Do not crank the engine for at the setpoints. Ensure that the engine pro more than 30 seconds. Allow the starting motor to cool devices properly. Signare upfunctioning to vote on this title for two minutes before cranking again. Useful Not useful NOTICE During testing, abnormal operating conditio 2. Close the fuel supply line. Crank the engine until simulated. normal oil pressure shows on the oil pressure
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76 Maintenance Section Engine Speed/Timing Sensor - Clean/Inspect
S
i02799088
Engine Speed/Timing Sensor Clean/Inspect SMCS Code: 1905-040; 1905-070; 1907-040; 1907-070
NOTICE Only qualified service personnel should pe maintenance. Refer to the Service Man Caterpillar dealer for the complete valve la ment procedur e.
Operation of Caterpillar engines with impro adjustments can reduce engine ef ficiency duced ef ficiency could result in excessive f and/or shortened engine component life.
Ensure that the engine can not be star this maintenance is being performed. To vent possible injury, do not use the start to turn the flywheel.
Hot engine components can cause bur additional time for the engine to cool be suring/adjusting valve lash clearance.
Ensure that the engine is stopped before m
You're Reading athe Preview valve lash. To obtain an accurate meas
allow the valves to cool before this mainten
Unlock full access withperformed. a free trial. Illustration 58
g01398834
Refer to the engine’s Speci fication manual Download With Free Trial lash settings, or the engine’s Sys 1. Remove the sensor from the cover. Check the the valve condition of the end of the magnet. Check for Operation/Testing and Adjusting manual fo signs of wear and contaminants. settings and the procedure. 2. Clean the metal shavings and other debris from the face of the magnet. 3. Install the sensor and adjust the sensor according to the engine’s Speci fications.
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Engine useful UsefulValve NotRotators SMCS Code: 1109-040
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Maintenanc Exhaust Bypass
3. Start the engine. Operate the engine for 5 minutes. Stop the engine. 4. Remove the valve covers. Observe the position of the marks that are on the valve rotators.
Exhaust Piping - Inspect SMCS Code: 1061-040
If a valve fails to rotate, consult your Caterpillar dealer. i01505507
Exhaust Bypass - Inspect SMCS Code: 1057-040 For instructions on removal and installation, see the Service Manual, “Disassembly and Assembly”.
Hot engine components can cause burns. Before performing maintenanc engine, allow the engine and the compo cool.
Inspect the components of the exhaust sys Repair the components or replace the comp any of the following conditions occur:
• Damage
1. Remove the exhaust bypass valve.
• Cracks • Leaks The exhaust bypass valve cover is under spring compression. To prevent personal injury, use caution when removing the cover.
• Loose connections
You're Reading aConsult Preview your Caterpillar dealer for assist
2. Disassemble the valve.
Unlock full access with a free trial.
Water Cooled Exhaust Manif
The water Download With Free Trial cooled exhaust manifolds do not
maintenance unless excessive deposits bu the exhaust passages. Buildup of deposits an increase in back pressure that will caus following conditions: Sign up to vote on this title Increased fuel consumption • Useful Not useful • Reduced boost pressure
If excessive deposits build up in the exhau
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78 Maintenance Section Gas Pressure Regulator - Check
S
A fuel fi lter dif ferential pressure gauge indicates the difference in fuel pressure between the inlet side and the outlet side of the fuel fi lter. The differential pressure incr eases as the fuel filter becomes plugged. Operate the engine at the rated speed and at the normal operating temperature. Check the fuel fi lter differential pressure. Service of the fuel fi lter depends on the pressure of the fuel system:
• For low pressure gas fuel systems, service the
fuel fi lter when the fuel fi lter differential pressure reaches 1.7 kPa (0.25 psi).
Use a water manometer for measuring the differential. Obtain the measurement when engine is operating at high idle rpm. After a is applied, the fuel pressure will usually dec by approximately 0.1 to 0.25 kPa (0.50 to 1 of H2O). If the performance of the gas pres regulator is erratic, the gas pressure regula require service.
Natural Gas
Set the pressure of the fuel supply to a max 1 to 1.2 kPa (4 to 4.5 inches of H 2O) HIGH the ambient air pressure.
• For high pressure gas fuel systems, service the
fuel fi lter when the fuel fi lter differential pressure reaches 34 kPa (5 psi).
For instructions, see Special Instruction, SEHS9298, “Installation and Maintenance of Gaseous Fuel Filters”. Consult your Caterpillar dealer for assistance. i01348680
Governor - Inspect SMCS Code: 1264-040 Inspect the governor for oil leaks.
For service information, see the literature t provided by the OEM of the governor.
Gas Pressure Regulator You're Reading a Preview Check Unlock full access with a free trial.
Hoses and Clamps Download With Free Trial Inspect/Replace Check the fuel pressure before the gas pressure SMCS Code: 1270-535
regulator and after the gas pressure regulator. Table 17 lists the fuel pressure that is required for the gas pressure regulator. Table 17
Requirements for Fuel Pressure To the Gas Pressure Regulator Fuel System
Pressure
SMCS Code: 7554-040; 7554-510 Inspect all hoses for leaks that are caused following Sign conditions: up to vote on this title
• Cracking
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Maintenanc Hoses and Clamps
• Exposed wire that is used for reinforcement • Outer covering that is ballooning locally
Note: Refer to the Specifications, SENR31 “Torque Specifications” in order to locate th torques.
• Flexible part of the hose that is kinked or crushed
8. Refill the cooling system.
• Armoring that is embedded in the outer covering
9. Clean the cooling system filler cap. Insp cooling system filler cap’s gaskets. Rep the cooling system filler cap if the gaske damaged. Install the cooling system fi
A constant torque hose clamp can be used in place of any standar d hose clamp. Ensure that the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen. This can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps. Each installation application can be different. The differences depend on the following factors:
10. Start the engine. Inspect the cooling sy leaks.
Hoses and Clamps - Repl SMCS Code: 1380-510
Note: For instructions on draining the cooli and filling the cooling system, see this Ope and Maintenance Manual, “Cooling System • Type of fitting material (DEAC) - Change” topic or see the Operati Maintenance Manual, “Cooling System Co the hose • Anticipated expansion and contraction of You're - Change” topic (Maintenance Sectio Reading a(ELC) Preview
• Type of hose
the • Anticipated expansion and contraction ofUnlock the cooling system. full access with1.a Drain free trial. fittings
Replace the Hoses and the
2. Remove the used hoses and clamps. Di Download With Freeitems. Trial Clamps
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pres-
3. Install new hoses and clamps. For the correct torque to use on the hose clam see the Specifications, SENR3130, “Tor topic. Speci cations”, Signfiup to vote“Hose on thisClamps” title
Useful Not useful the system. 4. Fill cooling
5. Start the engine. Inspect the hose conne
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80 Maintenance Section Ignition System Spark Plugs - Check/Adjust/Replace
i01342582
Ignition System Spark Plugs Check/Adjust /Replace SMCS Code: 1555-535
S
Removing the Spark Plug NOTICE Do not pull on the wires. Damage to the wi may result.
1. Disconnect wiring harness (1) from trans assembly (2). Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers.
2. Remove transformer assembly (2).
3. Ensure that the area around spark plug clean. Use a 2P-5481 Deep Well Socke extension in order to remove spark plug
Cleaning the Spark Plug
Clean the spark plug with a nonmetallic br Inspect the spark plug for the following con corrosion, pitting, and wear. If the spark plu good condition, the spark plug may be inst Maintenance of the spark plugs is required in order the spark plug is not in good condition, inst to achieve the following bene fits: spark plug. Check the spark plug gap before the spark plug. The spark plug gap depend • Normal fuel consumption You're Reading acompression Preview ratio of the engine.
• Normal level of emissions • Maximum ser vice life of the spark plugs
Unlock full access with•a free Settrial. spark plug gap to 0.28 ± 0.05 mm
(0.011 ± 0.002 inch) for the compression 11.3:1.
Download With Free Trial • Set spark plug gap to 0.46 ± 0.05 mm
The service life of the spark plugs is affected by fouling due to deposits from the oil and by peak voltage. Maintenance of the ignition system is also affected by voltage. Higher voltage is required by higher inlet manifold air pressure and a higher compression ratio. Higher voltage reduces the service life of components such as spark plugs, wires, and transformers.
(0.018 ± 0.002 inch) for the compression 8.5:1.
Sign up to the vote on this title Plug Installing Spark
Useful Not useful 1. Install the spark plug.
2. Tighten spark plug (3) to 30 ± 4 N·m (22
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Maintenanc Ignition System Transformer Resista
The optimum ignition timing for a gas engine varies according to several factors:
• Loose connections Inspect the following components:
• Compression r atio of the engine
• Piping between the air cleaner and the
• Inlet air temperature
• Turbocharger
• 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.
• Piping between the turbocharger and th aftercooler
• Aftercooler • Connection of the aftercooler to the air
• Connection of the air plenum to the cylind i00682407
Ignition System Transformer Resistance - Test SMCS Code: 1550-081
Ensure that all of the connections are secur that the components are in good condition.
Make repairs, if necessary. For information removal and installation of the components the Service Manual, “Disassembly and Ass module. Consult your Caterpillar dealer fo assistance.
The transformers produce a voltage increase. For good operation, the connections must be clean and You're Reading a Preview secure. Inspect the transformers for the following conditions. If any of the conditions are found, correct Unlock full access with a free trial. the condition:
Instrument Panel - Inspec
• Corrosion • Dirty insulator • Loose connections • Moisture • Open circuits • Short circuits
Download With Free Trial SMCS Code: 7451-040
Inspect the instrument panel for good cond Check the condition of all of the gauges. If is broken, r epair the gauge or replace the g immediately. Sign up to vote on this title
Notfollowing useful parameter Useful the Frequently monitor normal operation:
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82 Maintenance Section Jacket Water Heater - Check
S
i01042517
Jacket Water Heater - Check SMCS Code: 1383-535
• The service hours of the engine • The wear metal analysis of the lube oil
• An increase in the levels of noise and vib
S/N: 6ZM1-Up
An increase of wear metals in the lube oil in that the bearings and the surfaces that wea need to be serviced. An increase in the lev noise and vibr ation indicates that rotating p require service.
S/N: 8LW1-Up S/N: BAZ1-Up Jacket water heaters help to improve startability in ambient temperatures that are below 21 °C (70 °F). All installations that require automatic starting should have jacket water heaters. Check the operation of the jacket water heater. For an ambient temperature of 0 °C (32 °F), the heater should maintain the jacket water temperature at approximately 32 °C (90 °F). i02064986
Overhaul (Major)
Note: It is possible for oil analysis to indica decrease of wear metals in the lube oil. The liners may be worn so that polishing of the occurs. Also, the increased use of lube oil w the wear metals.
Monitor the engine as the engine accumula service hours. Consult your Caterpillar dea scheduling a major overhaul.
Note: The driven equipment may also requ when the engine is overhauled. Refer to the that is provided by the OEM of the driven eq
You're Reading a Preview
SMCS Code: 7595-020-MJ
Major Overhaul Information
Scheduling a Major
OverhaulUnlock full access with a free trial.
A major overhaul includes all of the work for top end overhauls. A major overhaul inc The need for a major overhaul is determined by Download With Free Trial parts and labor. Additional parts additional several factors. labor are required in order to completely re engine. In some cases, the engine is reloca • An increase of oil consumption disassembly.
• An increase of crankcase blowby • A decrease and variation of cylinder compression The following changes in the three conditions normally require a scheduled overhaul:
For the major of the bearings Sign up tooverhaul, vote on thisalltitle seals, gaskets, and components that wear Not useful Useful The parts disassembled. are cleaned and t are inspected. If necessary, the parts are re The crankshaft is measured for wear. The c
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Maintenanc Overha
Inspect – Inspect the components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”. The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures. New parts are not required if the existing parts can still be used, reconditioned, or repaired. If the components are not in the reusability guidelines, refer to the Service Manual, “Specifications” module. Rebuild – The component can be reconditioned in order to comply with reusability guidelines. Replace – The service life of the part is exhausted. The part may fail before the next maintenance interval. The part must be replaced with a part that meets functional specifications. The replacement part may be a new part, a CAT remanufactured part, a rebuilt part, or a used part. Some worn components may be exchanged with your Caterpillar dealer. Consult your Caterpillar dealer about repair options for your engine.
Replacing of Components
• Main bearings • Piston rings
• Rod ends for the control linkage of the ac • Spark plugs • Spark plug wires • Transformers • Valve rotator s • Water temperature regulators • Wiring harnesses Rebuilding of Components
Rebuild the following components during th overhaul. If the components cannot be reb replace the components.
• Carburetor You're Reading a Preview • Cylinder packs
Unlock full access with a free trial.
Note: The cylinder head may be rebuilt, when possible.
• Exhaust bypass
regulator Download With Free Trial • Gas
Replace the following components during the major overhaul.
• Inlet air piping
• Alternator
• Oil pump
• Alternator and fan drive belts • Camshaft bearings Connecting rod bearings
Sign up to vote on this title • Starting motor Useful Not useful Turbocharger • Water pumps
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84 Maintenance Section Overhaul (Top End)
S
• Gears of the gear train • Gear train bushings
Unexpected problems may be found during end overhaul. Plan to correct these problem necessary.
• Governor
• Buildup in the cylinders from excessive consumption
• Inlet air piping
• Buildup in the cylinders from contaminati
• Oil cooler
fuel
• Oil pump
• Plugging of the aftercooler from coolant poorly maintained
• Pistons
• Plugging of the aftercooler from contam
• Transformers
the inlet air
i02064994
Overhaul (Top End) SMCS Code: 7595-020-TE
Scheduling a Top End Overhaul
• Degradation of the oil cooler from hydrog in the fuel
Inspect the following components accordin the instructions that are in Caterpillar reusa publications. Refer to Guidelines for Reusa Parts and Salvage Operations, SEBF8029, of Publications on Reusability or Salvage o Parts”.
Top end overhauls are scheduled according to You're Reading aYour Preview the recession of the exhaust valve stems. This Caterpillar dealer can provide these s measurement provides an accurate indication of the and components. Your Caterpillar dealer ca Unlock fulltoaccess with a free trial. rate of valve wear. This measurement can be used that the components are operating within t predict when a cylinder head requires replacement. appropriate speci fications. For more information, refer to this Operation and Download With Free Trial Maintenance Manual, “Valve Stem Projection If you elect to perform an overhaul without Measure/Record” topic. services of a Caterpillar dealer, be aware o following recommendations. Note: The generator or the driven equipment may also require service when the engine overhaul is The following definitions explain the termin Sign up to vote on this title performed. the services that are performed during an o Useful Not useful Inspect – Inspect the components accord Top End Overhaul Information the instr uctions that are in Caterpillar reusa publications. Refer to Guidelines for Reusa A end overhaul involves servicing the cylinder
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Maintenanc Overhaul
Replace – The service life of the part is exhausted. The part may fail before the next maintenance interval. The part must be replaced with a part that meets functional speci fications. The replacement part may be a new part, a CAT remanufactured part, a rebuilt part, or a used part. Some worn components may be exchanged with your Caterpillar dealer. Consult your Caterpillar dealer about repair options for your engine.
Inspecting of Components
Clean the following components. Pressure components. Replace the components, if
• Aftercooler core (if equipped) • Oil cooler core
Replacing of Components
Note: It is dif ficult to clean the aftercooler c maintenance is not performed.
Note: The cylinder head may be rebuilt, when possible.
Note: This procedure may be used for clea the aftercooler core and the oil cooler core.
Replace the f ollowing components during a top end overhaul.
1. Remove the cor e. For the procedure, re Service Manual, “Disassembly and Asse module.
• Alternator and fan drive belts
2. Turn the core upside-down in order to re debris.
• Cylinder heads and gaskets
NOTICE Do not use a high concentration of caustic clean the core. A high concentration of ca the control linkage of the actuator Rod ends for • attack the internal metals of the core a You're Reading acan Preview leakage. Only use the recommended conce • Spark plugs Unlock full access withcleaner. a free trial. • Spark plug wires
• Hoses and clamps
• Water temperature regulator Rebuilding of Components
Rebuild the following components during a top end overhaul:
• Carburetor • Gas regulator
NOTICE Do not use a high pressure spray for cleanin of the core. A high pressure spray can da surface of the fins and reduce the flow of a the core. Sign up to vote on this title 3. Back flush the core with cleaner. Useful Not useful Caterpillar recommends the use of Hydr liquid cleaner. Use a two to five percen
Download With Free Trial
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86 Maintenance Section Overhaul Considerations
Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.
S
Test the resistance of the transformers acc the Service Manual, “Speci fications” modul your Caterpillar dealer for assistance.
Overhaul Considerations SMCS Code: 7595-043
Overhaul Information 6. Dry the core with compressed air. Direct the air in the reverse direction of the normal fl ow. Note: The test pressure for the oil cooler is 790 kPa (115 psi). The maximum differential pressure of water for the aftercooler is 44 kPa (6 psi). The maximum differential pressure of air for the aftercooler is 5.1 kPa (0.74 psi). 7. Inspect the core in order to ensure cleanliness. Pressure test the core. Many shops that service radiators are equipped to perform pressure tests. If necessary, repair the core.
An overhaul is replacing the major worn of the engine. An overhaul is a maintenanc that is planned. The engine is rebuilt with c rebuilt parts or new parts that replace the w
An overhaul also includes the following mai
• Inspection of all the parts that are visible the disassembly
• Replacement of the seals and gaskets th removed
You're Reading a•Preview Cleaning of the internal passages of the 8. Install the core. For the procedure, refer to the and the engine block Service Manual, “Disassembly and Assembly” Unlock full access with a free trial. module. Most owners will save money by overhaulin engine at the intervals that are recommend For more information on cleaning the cores,Download consult With Free Trial this Operation and Maintenance Manual. It your Caterpillar dealer. practical to wait until the engine exhibits sy of excessive wear or failure. It is not less c Exhaust Bypass wait. A planned overhaul before failure may best value for the following reasons: Inspect the condition of the exhaust bypass (if Sign up to vote on this title equipped). Recondition the component, if necessary. unplanned downtime • Costly Refer to this Operation and Maintenance Manual, useful can be avoid Useful Not “Exhaust Bypass - Inspect” topic (Maintenance • Many original parts can be reused accord Section). guidelines for reusable parts.
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Maintenanc Overhaul Cons
• Use of recommended lubricants
Overhaul Progr ams
• Use of recommended coolants
• Operating conditions
An economical way to obtain most of the that are needed for overhauls is to use Cat remanufactured parts. Caterpillar remanuf parts are available at a fraction of the cost parts. These parts have been rebuilt by Ca and certified for use. The following compon examples of the remanufactured parts:
• Operation within acceptable limits
• Alternators
• Engine load
• Connecting r ods
• Engine speed
• Crankshafts
Note: To avoid oil problems, engines that are turbocharged and aftercooled must be operated at a minimum of 60 percent of rated load.
• Cylinder heads
Generally, engines that are operated at a reduced load and/or speed achieve more service life before an overhaul. However, this is for engines that are properly adjusted, operated and maintained.
• Starting motors
• Use of recommended fuels • Proper installation
Overhaul Inspection
• Oil Pumps
• Turbochargers
• Water pumps You're Reading aConsult Preview your Caterpillar dealer for details a
list of the remanufactured parts that are Refer to the Service Manual for the disassembly Unlockand full access with a free trial. assembly procedures that are necessary in order Your Caterpillar dealer may be offering a va to perform the required maintenance on the items overhaul that are listed. Consult your Caterpillar dealer for Download With Free Trialoptions. assistance. A Flat Rate Overhaul guarantees the maxim that you will pay for an overhaul. Flat rate p To determine the reusability publications that are preventive maintenance programs or majo needed to inspect the engine, refer to Guidelines for options are available from many servicing d Reusable Parts and Salvage Operations, SEBF8029, Sign up to vote on this title for all Caterpillar Engines. Consult your Ca “Index of Publications on Reusability or Salvage of dealer order to schedule a before failure Not useful inUseful Used Parts”. The Guidelines For Reusable Parts and Salvage Operations is part of an established Caterpillar
Overhaul Recommendation
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88 Maintenance Section Power Take-Off Clutch - Check/Adjust/Lubricate
S
i01506009
Power Take-Off Clutch Check/Adjust /Lubricate
Radiator - Clean SMCS Code: 1353-070
SMCS Code: 3055-036; 3055-086
Note: Adjust the frequency of cleaning acc the effects of the operating environment.
NOTICE New power take-offs should have the clutch adjustment checked before being placed into service. The clutch adjustment should be checked again after the first ten hours of operation. New clutch plates have a “wear in” period, and the clutch may require several adjustments until the new plates are “worn in”.
Inspect the radiator for these items: damag corrosion, dirt, grease, insects, leaves, oil, debris. Clean the radiator, if necessary.
Personal injury can result from air press
Personal injury can result without follow er procedure. When using pressure air tective face shield and protective clothin
The maximum air pressure for cleanin must be reduced to 205 kPa (30 psi) wh nozzle is deadheaded.
You're Reading aPressurized Preview air is the preferred method for
loose debris. Direct the air in the opposite d
Unlock full access withofa free the trial. fan’s air fl ow. Hold the nozzle approx Illustration 61 (1) Instruction plate (2) Serial number plate
6 mm (0.25 inch) away from the fi ns. Slowly air nozzle in a direction that is parallel with Download With Free Trial This will remove debris that is between the g00781502
Check the clutch adjustment regularly after “wear in”. Heavy-duty applications which have engagements that are frequent and relatively long periods of clutch slippage require more frequent adjustment than light-duty applications. The operating torque should be measured in order to determine if a clutch adjustment is required
Pressurized water may also be used for cle The maximum water pressure for cleanin must be less than 275 kPa (40 psi). Use pre up toto vote on this titleClean the cor waterSign in order soften mud. both sides. Useful Not useful
Use a degreaser and steam for removal of grease. Clean both sides of the core. Wash
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Maintenanc Speed Sensor - Clea
i01511915
Speed Sensor - Clean/Inspect SMCS Code: 1907-040; 1907-070
• Longer service life for the generator set • Minimum of expensive repairs
Your Caterpillar dealer can help you to esta effective Preventive Maintenance Program generator set. Consult your Caterpillar dea details.
Maintenance and Operation Procedures
The high voltage that is produced by an generator set can cause severe injury Before performing any maintenance ensure that the generator will not start. Illustration 62
g00784740
Place the engine control switch in the “O tion. Attach “DO NOT OPERATE” tags to ing controls. Disconnect the batteries o 1. Remove the speed sensor from the flywheel the starting system. Lock out all switch housing. Check the condition of the end of automatic transfer switches that are as the magnet. Check for signs of wear and the generator. You're Reading awith Preview contaminants. Speed sensors
Unlock full access withThe a free trial. 2. Clean the metal shavings and other debris from recommended maintenance for the en the face of the magnet. listed in this Operation and Maintenance M “Maintenance Interval Schedule (Standby G Download With Free Trial 3. Install the speed sensor and adjust the speed Set Engines)” (Maintenance Section). sensor according to the engine’s Speci fications module. For the recommended generator maintena the Operation and Maintenance Manual fo generator and the control panel. i01038735 Sign up to vote on this title
Standby Generator Set Maintenance Recommendations
NotRepair useful Maintenance and Useful
The maintenance that is recommended for Week can be performed by an authorized o
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90 Maintenance Section Starting Motor - Inspect
S
Operation
Electric Starting Motor
To ensure proper operation, the generator set must be exercised regularly. For instructions on operating the generator set, see the Operation and Maintenance Manual for the generator set control panel.
Note: Problems with the electric starting m be caused by the following conditions: malf the solenoid and malfunction of the electric system.
For these operation procedures, follow the instructions that are provided in this Operation and Maintenance Manual, “Operation Section”: starting the engine, engine operation, and stopping the engine.
Inspect the electrical system for the follow conditions:
• Loose connections • Corrosion
Record Keeping
• Wires that are worn or frayed
Maintain a record in order to document these items: gauge readings, maintenance that is performed, problems, and repairs.
Space Heaters
• Cleanliness Make repairs, if necessary.
Air Starting Motor
Moisture causes damage to generators and other electrical equipment. Make every effort to keep the generator set as dry as possible.
Generators can operate without problems in humidReading aPersonal You're Preview injury or death can result from erly checking for a leak. environments. However, problems can occur when on access with a free trial. the generator is inactive. Moisture can condense Unlock full Always use a board or cardboard when the windings. This can result in poor performance. for a leak. Escaping air or fluid under Also, damage to the windings can occur. evenTrial a pin-hole size leak, can penetrate Download With Free sue causing serious injury, and possible Use space heaters in order to help keep the windings dry. When the generator is not active, ensure that the space heaters are operating. When the generator is operating, turn OFF the space heaters. i01113939
Starting Motor - Inspect
If fluid is injected into your skin, it must b immediately by a doctor familiar with th injury. Sign up to vote on this title
Useful Not useful Inspect all of the components in the air circ the starting motor. Inspect all of the air line connections for leaks.
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Maintenanc Turbocharge
i01012850
Turbocharger - Inspect SMCS Code: 1052-040 Periodic inspection and cleaning is recommended for the turbocharger. Fouling of the turbine wheels can contribute to loss of engine power and overall loss of engine ef ficiency. If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to the turbocharger compressor wheel could allow parts from the compressor wheel to enter an engine cylinder. This can cause additional damage to the pistons, the valves, and the cylinder head. NOTICE Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems. Loss of engine lubricant can result in serious engine damage.
1. Remove the exhaust outlet piping and r the air inlet piping from the turbocharger inspect the piping for the presence of oil
2. Turn the compressor wheel and the turb by hand. The assembly should turn free the compressor wheel and the turbine w contact with the turbocharger housing. T should not be any visible signs of contac the turbine wheel or compressor wheel turbocharger housing. If there is any ind contact between the rotating turbine whe compressor wheel and the turbocharger the turbocharger should be reconditione
3. Check the compressor wheel for cleanli If only the blade side of the wheel is dirt and/or moisture is passing through the a system. If oil is found only on the back s wheel, there is a possibility of a failed tur oil seal.
The presence of oil may be the result of engine operation at low idle. The presen may also be the result of a restriction of t the inlet air (plugged air fi lters), which ca You're Reading a Preview turbocharger to slobber. Minor leakage of a turbocharger housing under extended low idle operation should not causeUnlock problems full access with a free trial. Note: Deposits can accumulate on the turb as long as a turbocharger bearing failure has not ocThe turbine wheel will become unbalanced curred. deposits Download With Free Trial fl ake off. The turbocharger cartrid be replaced when this occurs. However, re When a turbocharger bearing failure is accompanied deposits from the housing. This will preven by a significant engine performance loss (exhaust 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 replaced. Sign up to vote on this title of 25 mm (1/16 inch) thickness are foun the in contact with the housin Useful is Not useful turbine An inspection of the turbocharger can minimize turbocharger must be disassembled and unscheduled downtime. Also, the chance for potential The deposits can be very dif ficult to rem damage to other engine parts is reduced.
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92 Maintenance Section Valve Stem Projection - Measure/Record
S
i01360109
Valve Stem Projection Measure/Record SMCS Code: 1105-082 Valve Recession – The valves and the valve seats are worn over time. This causes the valves to recede into the cylinder head. This condition is called “valve recession”. The exhaust valves and valve seats show the greatest wear due to high operating temperatures. The top end overhaul is normally scheduled according to the exhaust valve recession. It is dif ficult to obtain an accurate measurement of valve recession inside the cylinder head. Use the following method in order to determine the valve recession: 1. Remove the valve cover. For instructions, see the Service Manual, “Disassembly and Assembly” module.
You're Reading a Preview
2. Move the rocker arm from the top of the valve stem. Unlock full access with a free trial. 3. Use a depth micrometer. Obtain the measurement from the tip of the valve stem to the cylinder head. With Free Trial Download Obtain this measurement for each exhaust valve. Make sever al copies of this Operation and Maintenance Manual, “Valve Data Sheet” (Reference Materials Section). Record the measurements on the sheets.
•
The projection of the exhaust valve stems should be measured after completion of the initial start-up tests and the engine commissioning. This
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Maintenanc Walk-Around
You're Reading a Preview Illustration 63 (A) Schedule (B) Schedule (C) Schedule
Unlock full access with a free trial. (Y) Valve recession in millimeters (inches) (X) Hours of operation Download With inch)Free Trial (1) 0.254 mm (0.0100
To determine intervals, use the point on the graph in Illustration 63 that is closest to the measurement for each cylinder. For example, suppose that the measurement that was obtained at the initial oil change shows a valve recession of approximately 0.152 mm (0.0060 inch). According to Schedule (C), the next interval for
(2) 0.218 mm (0.0086 inch) (3) 0.152 mm (0.0060 inch)
Consult your Caterpillar dealer for assistan
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Walk-Around useful Useful NotInspection SMCS Code: 1000-040
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94 Maintenance Section Walk-Around Inspection
S
• Inspect the exhaust system for leaks. If a NOTICE For any type of leak, clean up the fluid. If leaking is observed, fi nd the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted. NOTICE Accumulated grease and/or oil on an engine or deck is a fi re hazard. Remove this debris with steam cleaning or high pressure water.
found, make repairs.
Walk-Around Inspection (Exercise Inspection of Standby Generator Set Engines) SMCS Code: 1000-040
• Ensure that cooling lines are properly clamped.
Check for leaks. Check the condition of all pipes.
• Inspect the water pumps for coolant leaks. Note: The water pump seal is lubricated by coolant in the cooling system. It is normal for a small amount of leakage to occur when the engine cools and the parts contract.
NEVER use a gas detector.
flame
to check for gas lea
An open fl ame can ignite mixtures of air This will cause explosion and/or fire wh result in severe personal injury or death
1. Perform the procedures that are describ Excessive coolant leakage may indicate the need this Operation and Maintenance Manua You're Reading a Preview to replace the water pump seal. For instructions Starting Engine” topic (Operation Sectio on removal and installation of water pumps and/or Unlock and full access with a free trial. seals, refer to the Service Manual, “Disassembly 2. Start the engine according to the instruc Assembly” module for the engine or consult your this Operation and Maintenance Manua Caterpillar dealer. Starting” topic (Operation Section).
Download With Free Trial
• Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters and the valve covers.
NEVER use a flame to check for gas leaks. Use a gas detector.
NOTICE For any type of leak (coolant, lube, or fuel fluid. If leaking is observed, find the source the leak. leaking SignIfup to voteisonsuspected, this title check the more often than recommended until the lea Not usefulof a leak is pro Useful suspicion or fi xed, or until the unwarranted.
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Maintenanc Water Pump
• Inspect the exhaust system for leaks. • If the enclosure has louvers, inspect the louvers
Water Temperature Regul Replace
• Observe the gauges. Ensure the correct
SMCS Code: 1355-510
• Record the data for the performance of the
Replace the water temperature regulators b the water temperature regulators fail. This recommended preventive maintenance pra Replacing the water temperature regulators the chances for unscheduled downtime.
4. After exercising the generator set, stop the engine according to this Operation and Maintenance Manual, “Engine Stopping” topic (Operation Section).
A water temperature regulator that fails partially opened position can cause overhe overcooling of the engine.
5. Perform the procedures that are described in this Operation and Maintenance Manual, “After Stopping Engine” topic (Operation Section).
A water temperature regulator that fails in position can cause excessive overheating. overheating could result in cracking of the c head or a seizure of the pistons.
for proper operation.
readings for the engine rpm. Record the engine oil pressure and the jacket water temperature. generator. See the Operation and Maintenance Manual for the generator and the control panel.
6. Ensure that the control switches are in the correct position for automatic starting of the generator set.
A water temperature regulator that fails position will cause the engine operating tem to be too low during partial load operation. operating temperatures during parti You're Reading aengine Preview i02624237 could cause an excessive carbon buildup in Water Pump - Inspect Unlock full access withcylinders. a free trial. This excessive carbon buildup co in an accelerated wear of the piston rings a of the cylinder liner. Also, a low temperatur SMCS Code: 1361-040 allowTrial moisture to condense in the oil. This Download With Free damaging acids. A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head, a piston seizure or other potential NOTICE damage to the engine. Failure to replace the water temperature on a regularly basis could cau Sign up to scheduled vote on this title Visually inspect the water pump for leaks. If leaking engine damage. Useful Not useful of the water pump seals is observed, replace all of the water pump seals. Refer to two articles in the Never operate the engine without the water Disassembly and Assembly Manual, “Water Pump ture regulators installed.
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96 Reference Information Section Customer Service
S
Reference Information Section
Latin America, Mexico, Carribean Caterpillar Americas Co. 701 Waterford Way, Suite 200 Miami, FL 33126-4670 USA Phone: 305-476-6800 Fax: 305-476-6801
Customer Service i02097871
Customer Assistance SMCS Code: 1000; 4450
USA and Canada When a problem arises concerning the operation of an engine or concerning the service of an engine, the problem will normally be managed by the dealer in your area. Your satisfaction is a primary concern to Caterpillar and to Caterpillar dealers. If you have a problem that has not been handled to your complete satisfaction, follow these steps:
Europe, Africa, and Middle East Caterpillar Overseas S.A. 76 Route de Frontenex P.O. Box 6000 CH-1211 Geneva 6 Switzerland Phone: 22-849-4444 Fax: 22-849-4544 Far East Caterpillar Asia Pte. Ltd. 7 Tractor Road Jurong, Singapore 627968 Republic of Singapore Phone: 65-662-8333 Fax: 65-662-8302 China
You're Reading a Preview Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens Unlock full access with a free trial. dealership. 33 Hysan Avenue Causeway Bay 2. If your problem cannot be resolved at the dealer G.P.O. Download Trial Box 3069 level without additional assistance, use the phone With Free Hong Kong number that is listed below to talk with a Field Phone: 852-2848-0333 Service Coordinator: Fax: 852-2848-0440 1-800-447-4986 The normal hours are from 8:00 to 4:30 Monday through Friday Central Standard Time. 3. If your needs have not been met still, submit the
Japan Sign Caterpillar up to vote on this title Ltd. Shin Mitsubishi SBS Tower Not useful Useful 10-1, Yoga 4-Chome Setagaya-Ku, Tokyo 158-8530 Japan
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Reference Informatio Custo
i01028392
Ordering Replacement Parts SMCS Code: 4450; 7567
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature 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.
You're Reading a Preview When you order parts, please specify the following information:
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• Part number • Part name
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• 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
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98 Reference Information Section Reference Materials
S
Reference Materials i02408969
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:
• Demonstration of compliance with the required
maintenance practices and maintenance intervals
• Determination of operating costs • Establishment of maintenance schedules for other engines that are operated in the same environment
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 Reading a Preview maintenance program that is well managed.You're Accurate maintenance records can help your Caterpillar dealer full access with a free trial. to fi ne tune the recommended maintenanceUnlock intervals in order to meet the speci fic operating situation. This should result in a lower engine operating cost.
Download With Free Trial
Keep records for the following items: 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
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Reference Informatio Reference
i02209903
Maintenance Log SMCS Code: 1000; 4450 Table 18
Engine Model
Customer Identifier
Serial Number
Arrangement Number
Service Hours
Service Item
Date
Auth
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100 Reference Information Section Reference Materials
S
i01340010
Valve Data Sheet SMCS Code: 1000 Table 19
Engine Model Cylinder 1
Cylinder Pressure
Serial Number
Service Hours
Valve Location
Current Measure
Stem Baseline
Authorization Rotator Baseline
Pushrod Side Inlet Manifold
2
Pushrod Side Inlet Manifold
3
Pushrod Side Inlet Manifold
4
Pushrod Side Inlet Manifold
5
Pushrod Side Inlet Manifold
6
7
Pushrod Side
You're Reading a Preview
Inlet Manifold
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Pushrod Side Inlet Manifold
8
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Pushrod Side Inlet Manifold
9
Pushrod Side Inlet Manifold
10
Pushrod Side Inlet Manifold
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Reference Informatio Reference
• Special Publication, PEGJ0035, “Grease Selection Guide”
• Special Publication, SEBU6400, “Caterp
Gas Engine Lubricant, Fuel, and Coolan Recommendations”
• Data Sheet, PEHJ0088, “Cat Multipurpose Grease” • Data Sheet, PEHP0002, “Cat Advanced 3Moly Grease”
Miscellaneous
• Systems Operation, KENR5186, “G3408
• Data Sheet, NEHP6015, “Cat High Speed Ball Bearing Grease”
• Special Publication, SEBU6400, “Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations”
• Special Publication, PECP9067, “One Safe Source”
G3412C” Engines Air/Fuel Ratio Control Feedback)
• Troubleshooting, RENR5916, “Air/Fuel Control”
• Service Manual, RENR1340, “G3408C E
• Specifications, SENR3130, “Torque Spec
• Special Instruction, SMHS7001, “Assem
Fuels
Drive Pulley Assemblies”
• Data Sheet, LEKQ9360, “Internal Combustion
• Special Instruction, SEHS9124, “Cleanin
• Data Sheet, LEKQ2364, “US Stationary Engine
• Special Instruction, SEHS7332, “Do Not
Engine Fuel Gases”
Regulations/Spark Ignited Emissions”
Drying of Electric Set Generators” Tag”
You're Reading a Preview • Data Sheet, LEKQ5404, “Fuels Speci fications • Special Instruction, SEHS7633, “Battery Changes”
Unlock full access with a Procedure” free trial.
• Application and Installation Guide, LEKQ7256, • Special Instruction, SEHS7654, “Alignm Download With Free Trial Instructions” “Fuels, Fuel Systems” General • Application and Installation Guide, LEKQ7260,
• Special Instruction, SEHS8712, “Using t
• Special Publication, SEBU6400, “Caterpillar
“Storage Instruction, • Special Sign up to vote on SEHS9031, this title
“Low Energy Fuels”
Gas Engine Lubricant, Fuel, and Coolant Recommendations”
8T-2700 Blowby/Air flow Indicator Group” Procedure for Caterpillar Products” Useful Not useful
• Special Instruction, SEHS9298, “Install
Coolants
Maintenance of Gaseous Fuel Filters”
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102 Reference Information Section Reference Materials
S
Engine Manufacturers Association Two North LaSalle Street, Suite 2200 Chicago, Illinois, USA 60602 E-mail:
[email protected] (312) 827-8700 Facsimile: (312) 827-8737 The “Society of Automotive Engineers (SAE) Specifications” can be found in your SAE handbook. This publication can also be obtained from the following locations: local technological society, local library, and local college. If necessary, consult SAE at the following address: SAE International 400 Commonwealth Drive Warrendale, PA, USA 15096-0001 Telephone: (724) 776-4841
Warranty Information SMCS Code: 1000
Engine Protection Plans
Extended Warr anties and Service Contracts
A wide variety of protection plans are avail Caterpillar Engines. Consult your Caterpilla for detailed information on the speci fic prog coverages that are available.
Consult your Caterpillar dealer for informat plan that is tailored in order to fi t your requi
The “American Petroleum Institute Publication No. 1509” can be obtained from the following locations: local technological society, local library, and local college. If necessary, consult API at the following address: American Petroleum Institute 1220 L St. N.W. Washington, DC, USA 20005 Telephone: (202) 682-8000
You're Reading a Preview Unlock full access with a free trial.
The International Organization for Standardization Download With Free Trial (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, Sign up to vote on this title certification, and related activities. Consult the member of ISO in your country. Useful Not useful International Organization for Standardization (ISO)
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Index A Actuator Control Control Linkage - Lubricate..................... 57 Check the Linkage ........................ .................................... ..................... ......... 57 After Starting Engine ...... ............. ............ ............ .. 46 Equipment ...................... ........................ .. 46 Engaging the Driven Driven Equipment After Stopping Engine........... ............. ............. ....... 49 Air Tank Moisture and Sediment - Drain.............. Drain .............. .. 57 .................................... ...................... .......... 34 Alarms and Shutoffs Shutoffs ........................ Alternator - Inspect ............ ............ ............ ............ 57 Automatic Start/Stop - Inspect (Generator Set)..... Set) ..... 57 B Batteries Batteries - Replace........................... Replace....................................... ..................... ......... 58 Battery Charger - Check....................... Check................................... ................. ..... 58 Checking After Stopping Stopping ....................... .................................. ............. .. 59 Checking Checking Before Start-Up........................... Start-Up.................................. ....... 58 Battery Electrolyte Electrolyte Level - Check .................. .......................... ........ 59 .................................... ......... 15, 42 Before Starting Starting Engine ........................... Air Inlet System.............. System. ............. ............. ............ ........... 42 Cooling Cooling System....................... System................................... ........................ ............... ... 42 ............................................. .............. 42 Driven Equipment Equipment ................................. Electrical Electrical System ............................ ....................................... ................... ........ 42 Fuel System.............................. System.......................................... ....................... ............. .. 43 .......................................... ............. .. 43 Lubrication System System ............................... Starting System............ System........................ ........................ ........................ .............. .. 43 Walk-Around Walk-Around Inspection.................... Inspection.............................. ................. ....... 42 eplace.............. ........................ ................. ..... 59 Belts - Inspect/Adjust/R Inspect/Adjust/Replace.. Adjusting the Alternator Belt ................. ... .............. ............. 60 Adjusting the Fan Drive D rive Belt .................. .... .............. ............ 60 Inspection.... Inspection................ ........................ ........................ ........................ ................... ....... 59 Replacement........... Replacement....................... ........................ ........................ ................... ....... 60 Burn Prevention.............. Prevention.......................... ........................ ........................ ............... ... 12 Batteries................. Batteries............................. ........................ ........................ .................... ........ 13 Coolant........... Coolant....................... ........................ ........................ ........................ ................ .... 12 Oils............. 13
Cooling System Coolant Sample (Level 2) Obtain ........................ .................................... ........................ .................. ...... Cooling System System Supplemental Coolant Add (SCA) - Test/Add...................... est/Add.................................. ............ Add the SCA, If Necessary ............ ......... Test the Concentration Concentration of the SCA.......... Crankcase Crankcase Blowby - Measure/Recor Measure/Record d ........ Crankshaft Crankshaft Vibration Damper - Inspect ...... ............ Visconic Damper.................... Damper................................ Crushing Crushing Prevention and Cutting Preventio Customer Customer Assistance..... Assistance................ ....................... .................. ...... Outside of the USA USA and of Canada......... USA and Canada............................. Canada.................................... ....... Customer Customer Service........................... Service...................................... ........... Measure/Record rd ......... Cylinder Pressure Pressure - Measure/Reco D
Driven Equipment - Check.............. Check.......................... ............ Inspect/Replace/Lubric Lubric Driven Equipment Equipment - Inspect/Replace/ E
Electrical Electrical System............................ System....................................... ........... ........................... Grounding Practices Practices ........................... Emergency Emergency Stopping Stopping ........................ .................................. .......... Emergency Emergency Stop Button.......................... Button.......................... Engine - Clean...................... Clean.................................. ..................... ......... Engine Air Cleaner Element - Replace....... Cleaning the Primary Air Cleaner Elemen ........ Cleaner Elements Servicing the Air Air Cleaner Sign up to vote on this title Engine Air Cleaner Service Indicator - Insp Useful Not useful .................... the Indicator................ Test Service Indicator.... ........ Engine Air Precleaner Precleaner - Clean.................... Engine Crankcase Crankcase Breather - Clean........... Engine Oil and Filter Filter - Change
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104 Index Section
Exhaust Piping Piping - Inspect................... Inspect............................... ..................... ......... 77 Water Water Cooled Exhaust Manifolds............... Manifolds....................... ........ 77
78494036 QUASAR 1F
S
L Lifting and Storage ..................... ................................. ............
F M ....................... ............... ... 31 Features and Controls................. Controls............................ Fire Prevention and Explosion Prevention ............ ............ 13 Fire Extinguisher..................... Extinguisher................................. ........................ ............... ... 14 .................................. .............. .. 14 Lines, Tubes and an d Hoses ...................... Foreword Foreword ........................ ..................................... ......................... ........................ ................ .... 5 California California Proposition 65 Warning Warning ....................... ....................... 4 ormation............................... ........................ ............ 4 Literature Inf ormation................... Maintenance Maintenance ...................... .................................. ....................... ...................... ........... 4 Maintenance Maintenance Intervals................... Intervals................................ ....................... .......... 4 Operation Operation ...................... .................................. .......................... .......................... .............. 4 Overhaul Overhaul ...................... .................................. ....................... ....................... ................. ..... 5 Safety..................... Safety................................. ........................ ........................ ...................... .......... 4 Fuel System Fuel Filter F ilter Differential Pressure Check............ Check........................ ........................ ........................ ........................ ................... ....... 77 G Check......................... .............. .. 78 Gas Pressure Regulator Reg ulator - Check............. Pressure Pressure of the Fuel Supply To To the Carburetor.. 78 Gauges and Indicators Indicators ........................... ....................................... ............... ... 28 on ........................ .................................. .......... 10 General Hazard Informati Information Asbestos Information ........... ............. ............ ...... 11 Containing Containing Fluid Spillage Spillage ...................... .................................. .............. .. 11 ................................ ........ 12 Dispose of Waste Properly P roperly ........................ Fluid Penetration............... Penetration........................... ........................ ...................... .......... 11 Pressurized Pressurized Air and Water ........................ .................................. .......... 11 Governor Governor - Inspect..................... Inspect................................. ........................ ................ .... 78
H Hoses and Clamps - Inspect/Replac Inspect/Replace e ................... ................... 78 Replace the Hoses and the Clamps .................. 79 Hoses and Clamps - Replace....... 79
Maintenance Maintenance Interval Schedule Schedule (Standard Maintenance Maintenance Interval Schedule (Standby).. .................................... ............ Maintenance Log Log ........................ Maintenance Maintenance Records.......... Records...................... ....................... ........... Maintenance Maintenance Section............................ Section.................................. ...... .................... ....... Manual Stop Procedure.......... Procedure....................... Model View Illustrations.............. Illustrations.......................... ............ Model Views and Specifications................. ............ Mounting and Dismounting........ Dismounting....................
O
Operation Operation Section.................... Section................................ .................. ....... Ordering Replacement Replacement Parts...................... Overhaul Overhaul (Major)............ (Major)........................ ......................... ............. Major Overhaul Information .................... .................... Overhaul.................. ...... Scheduling Scheduling a Major Major Overhaul............ Overhaul Overhaul (Top (Top End) ........................ ................................... ............ Scheduling Scheduling a Top End Overhaul Overhaul ............. Information ............ Top End Overhaul Information Overhaul Overhaul Considerations............... Considerations........................... ............ Overhaul Overhaul Information Information .............................. .............................. P
Performance Performance Parameters Parameters ........................... ........................... Air/Fuel Ratio ............ ............ ............ ...... Sign up to vote on this title .................. ...... Fuel Consumption................. Consumption............................. Throttle Throttl e Angle and Exhaust Exhaus t Bypass Useful Not useful (Wastegate)........ (Wastegate).................... ........................ ...................... .......... Plate Locations and and Film Locations............ Engine Identi fication.
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Reference Reference Information.................. Information.............................. ........................ .............. 25 Reference Reference Information Section ...................... .............................. ........ 96 Reference Reference Material ...................... .................................. ........................ ............ 100 erence Material....................... Material.......................... ... 101 Additional Ref erence Coolants................. Coolants............................ ....................... ........................ ................... ....... 101 Fuels ....................... ................................... ........................ ........................ ................. ..... 101 Lubricants Lubricants ........................ .................................... ........................ .................... ........ 100 Miscellaneous Miscellaneous ..................... ................................. ....................... ................. ...... 101 Reference Reference Materials Materials ....................... ................................... ....................... ........... 98 ........................ ...................... .......... 50 Refill Capacities................... Capacities............................... Refill Capacities and Recommendations........... Recommendations............... .... 50 Cooling Cooling System....................... System................................... ........................ ............... ... 51 Fuel............................... Fuel........................................... ........................ ........................ .............. 50 Lubrication Lubrication System ............................. ......................................... ............... ... 50
Water Pump - Inspect................. Inspect............................. ............ Water Water Temperature emperature Regulator - Replace Replace
S Safety Messages Messages ....................... ................................... ........................ .................. ...... 6 Type Type 1 ........................ .................................... ........................ ........................ .................. ...... 7 Type Type 2 ........................ .................................... ........................ ........................ .................. ...... 8 Safety Section ........................... ....................................... ........................ .................. ...... 6 Sensors Sensors and Electrical Components .................... ...................... 33 Specifications .................................. .............................................. ...................... .......... 22 ect.................. ....................... ............. .. 89 Speed Sensor - Clean/Insp Cle an/Inspect...... Standby Generator Set Maintenance Recommendation Recommendations................ s............................ ........................ ................... ....... 89 n Procedures Procedures ........... ........... 89 Maintenance and Operatio O peration Starting Starting Motor - Inspect Inspect ...................... ................................. ................... ........ 90 Air Starting Motor ............ ............. ............ .......... 90 Motor............................. ....................... ........... 90 Electric Starting Motor................. Removal and Installation of the Starting Motor.. 90 Starting Starting the Engine ....................... .................................. ....................... .............. .. 44 Automatic Starting............ Starting........................ ....................... ...................... ........... 45 Manual Starting................... Starting............................... ........................ ................... ....... 45 Operation of the Generator Set Control Panel... 45 ................................... ............... ... 44 Purging Unburned Gas G as ....................... Starting Starting with Jump Start Cables ..................... ............................ ....... 46 T
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Operation and Maintenance Manual G3408 and G3412 Engines - 2007 July
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Operation and Maintenance Manual G3408 and G3412 Engines - 2007 July
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Product and Dealer Information
Note: For product identification plate locations, see t he section “Product Identi fication Information” in the 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:
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