SEBU8099 Maint PDF

SEBU8099-01
March 2006
Operation and
Maintenance
Manual
G3500 A3 Engines
A3J1-Up (Engine)
A3K1-Up (Engine)
WPM1-Up (Engine)
A3N1-Up (Engine)
WPN1-Up (Engine)
WPP1-Up (Engine)
DLR1-Up (Engine)
WPR1-Up (Engine)
A3S1-Up (Engine)
GNS1-Up (Engine)
WPS1-Up (Engine)
A3T1-Up (Engine)
WPT1-Up (Engine)
A3W1-Up (Engine)
WPW1-Up (Engine)
A3X1-Up (Engine)
A3Y1-Up (Engine)
i01658146
Important Safety Information

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

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

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SEBU8099-01 3
Table of Contents
Table of Contents Reference Materials .............................................. 91
Index Section
Foreword ................................................................. 4
Index ..................................................................... 97
Safety Section
Safety Messages .................................................... 6
General Hazard Information ................................... 9
Burn Prevention ..................................................... 11
Fire Prevention and Explosion Prevention ............ 12
Crushing Prevention and Cutting Prevention ........ 13
Mounting and Dismounting ................................... 14
Ignition Systems ................................................... 14
Before Starting Engine .......................................... 14
Engine Starting ..................................................... 14
Engine Stopping ................................................... 15
Electrical System .................................................. 15
Product Information Section

General Information .............................................. 16
Model Views and Specifications ........................... 18
Product Identification Information ........................ 22
Operation Section
Lifting and Storage ................................................ 24
Features and Controls .......................................... 26
Engine Starting ..................................................... 33
Engine Operation .................................................. 38
Engine Stopping ................................................... 39
Maintenance Section
Refill Capacities .................................................... 41
Maintenance Recommendations .......................... 44
Maintenance Interval Schedule (Standard) .......... 45
Reference Information Section

Customer Service ................................................. 89
4 SEBU8099-01
Foreword
Foreword Use service hours to determine intervals. Calendar

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

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

California Proposition 65 Warning
Photographs and illustrations guide the operator Battery posts, terminals and related accessories
through procedures of inspecting, starting, operating contain lead and lead compounds. Wash hands after
and stopping the engine. This section also includes a handling.
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
SEBU8099-01 5
Foreword
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
programs. If you experience a major engine failure,
there are also numerous after failure overhaul options
available from your Caterpillar dealer. Consult with
your dealer for information regarding these options.
6 SEBU8099-01
Safety Section
Safety Messages
Safety Section
i02469648
Safety Messages
SMCS Code: 1000; 7405
g01232290
Illustration 1
There may be several specific safety messages Replace any safety message that is damaged or
on your engine. The approximate location and a missing. If a safety message is attached to a part
description of the safety messages are reviewed in of the engine that is replaced, install a new safety
this section. Please become familiar with all of the message on the replacement part. Your Caterpillar
safety messages. dealer can provide new safety messages.
Ensure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and Do not operate or work on this engine unless you
soap for cleaning the safety messages. Do not have read and understand the instructions and
use solvents, gasoline, or other harsh chemicals. warnings in the Operation and Maintenance Man-
Solvents, gasoline, or harsh chemicals could loosen ual. Failure to follow the instructions or heed the
the adhesive that secures the safety messages. The warnings could result in injury or death. Contact
safety messages that are loosened could drop off any Caterpillar dealer for replacement manuals.
of the engine. Proper care is your responsibility.
SEBU8099-01 7
Safety Section
Safety Messages
The safety messages that may be attached on the Read the Manual Before Operating
engine are illustrated and described below.
(2)
Coupling (1)
g00306265
Illustration 3
g00305692
Illustration 2 The safety message for reading the manual before
operating the unit is located on the outside of the
The safety message for the coupling is located on door of the control panel.
the sides of the flywheel housing.
Do not operate or work on this engine or genera-

If engine runs and coupling is not properly re- tor set unless you have read and understand the
strained, personal injury or property damage may instructions and warnings in the Operation and
result. Maintenance Manuals.
Before starting engine, do one of the following: Failure to follow the warnings and instructions
could result in injury or death. Contact any
1. Align and couple the equipment. Caterpillar dealer for replacement manuals. Prop-
er care is your responsibility.
2. Remove the loose parts.
3. Center and restrain the loose parts.

8 SEBU8099-01
Safety Section
Safety Messages
Open Vandal Door (3) Hot Pressurized Fluid (4)

The safety message for keeping the vandal door
open during operation is located on the outside of the
door of the control panel.
g00305896
g01061488
Illustration 4
Always operate this unit with the vandal door
open. Operating the unit with the vandal door The safety message for hot pressurized fluid is
closed restricts access to the emergency stop located on the cover of the oil filter.
button and could result in injury or death.
Filter contains hot pressurized fluid when engine

is running. Follow instructions on control valve to
avoid injury if rapid air movement exists to blow
fluid. Stop engine to avoid fire.
SEBU8099-01 9
Safety Section
General Hazard Information
Flash Fire (5) Do not allow unauthorized personnel on the engine,

or around the engine when the engine is being
serviced.
Engine exhaust contains products of combustion

which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
Cautiously remove the following parts. To help

prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps
g01061123
Illustration 5 • Grease fittings
The safety messages for flash fire are located on the • Pressure taps
crankcase covers.
• Breathers
• Drain plugs
Flash fire may result in personal injury, if
crankcase covers are removed within fifteen Use caution when cover plates are removed.
minutes after emergency shut down. Do not Gradually loosen, but do not remove the last two
restart engine until cause for shutdown has been bolts or nuts that are located at opposite ends of
corrected. the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
i02327617

SMCS Code: 1000; 4450; 7405
g00702020
Illustration 7
• Wear a hard hat, protective glasses, and other

protective equipment, as required.
Illustration 6
g00104545 • When work is performed around an engine that is
operating, wear protective devices for ears in order
Attach a “Do Not Operate” warning tag or a similar to help prevent damage to hearing.
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is • Do not wear loose clothing or jewelry that can snag
repaired. These warning tags (Special Instruction, on controls or on other parts of the engine.
SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine and to • Ensure that all protective guards and all covers are
each operator control station. When it is appropriate, secured in place on the engine.
disconnect the starting controls.
• Never put maintenance fluids into glass containers.
Glass containers can break.
10 SEBU8099-01
Safety Section
• Use all cleaning solutions with care. Containing Fluid Spillage

• Report all necessary repairs. Care must be taken in order to ensure that fluids
are contained during performance of inspection,
Unless other instructions are provided, perform maintenance, testing, adjusting and repair of the
the maintenance under the following conditions: engine. Prepare to collect the fluid with suitable
containers before opening any compartment or
• The engine is stopped. Ensure that the engine disassembling any component that contains fluids.
cannot be started.
Refer to Special Publication, NENG2500, “Dealer
• Disconnect the batteries when maintenance Service Tool Catalog” for the following items:
is performed or when the electrical system is
serviced. Disconnect the battery ground leads. • Tools that are suitable for collecting fluids and
Tape the leads in order to help prevent sparks. equipment that is suitable for collecting fluids
• Do not attempt any repairs that are not understood. • Tools that are suitable for containing fluids and
Use the proper tools. Replace any equipment that equipment that is suitable for containing fluids
is damaged or repair the equipment.
Obey all local regulations for the disposal of liquids.
Pressurized Air and Water
Asbestos Information
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.
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). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration Illustration 9

g00702022
Caterpillar equipment and replacement parts that are

shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be

generated when you handle components that contain
asbestos fibers. 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
Illustration 8
g00687600 asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
Always use a board or cardboard when you check handling is not hazardous unless airborne dust that
for a leak. Leaking fluid that is under pressure can contains asbestos is generated.
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can If dust that may contain asbestos is present, there
cause severe injury. If fluid is injected into your skin, are several guidelines that should be followed:
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury. • Never use compressed air for cleaning.
SEBU8099-01 11
Safety Section
Burn Prevention
• Avoid brushing materials that contain asbestos. i02088921
• Avoid grinding materials that contain asbestos. Burn Prevention

• Use a wet method in order to clean up asbestos SMCS Code: 1000; 4450; 7405
materials.
Do not touch any part of an operating engine.
• A vacuum cleaner that is equipped with a high Allow the engine to cool before any maintenance
efficiency particulate air filter (HEPA) can also be is performed on the engine. Relieve all pressure in
used. the appropriate system before any lines, fittings or
related items are disconnected.
• Use exhaust ventilation on permanent machining
jobs. Coolant
• Wear an approved respirator if there is no other When the engine is at operating temperature, the
way to control the dust. engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
• Comply with applicable rules and regulations to the engine contain hot coolant. Any contact with
for the work place. In the United States, use hot coolant or with steam can cause severe burns.
Occupational Safety and Health Administration Allow cooling system components to cool before the
(OSHA) requirements. These OSHA requirements cooling system is drained.
can be found in “29 CFR 1910.1001”.
Check the coolant level after the engine has stopped
• Obey environmental regulations for the disposal and the engine has been allowed to cool. Ensure
of asbestos. that the filler cap is cool before removing the filler
cap. The filler cap must be cool enough to touch with
• Stay away from areas that might have asbestos a bare hand. Remove the filler cap slowly in order
particles in the air. to relieve pressure.
Dispose of Waste Properly Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot components
to contact the skin.
If the application has a makeup tank, remove the cap

for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.
Batteries
g00706404
Illustration 10
The liquid in a battery is an electrolyte. Electrolyte is
Improperly disposing of waste can threaten the an acid that can cause personal injury. Do not allow
environment. Potentially harmful fluids should be electrolyte to contact the skin or the eyes.
disposed of according to local regulations.
Do not smoke while checking the battery electrolyte
Always use leakproof containers when you drain levels. Batteries give off flammable fumes which can
fluids. Do not pour waste onto the ground, down a explode.
drain, or into any source of water.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
12 SEBU8099-01
Safety Section
Fire Prevention and Explosion Prevention
i02377302 Store fuels and lubricants in properly marked

containers away from unauthorized persons. Store
Fire Prevention and Explosion oily rags and any flammable materials in protective
Prevention containers. Do not smoke in areas that are used for
storing flammable materials.
SMCS Code: 1000; 4450; 7405
Do not operate the equipment near any flame.
Exhaust shields (if equipped) protect hot exhaust

components from oil spray or fuel spray in case of
a break in a line, in a hose, or in a seal. Exhaust
shields must be installed correctly.
Do not weld on lines or on tanks that contain

flammable fluids. Do not flame cut lines or tanks
that contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior
to welding or flame cutting.
Wiring must be kept in good condition. All electrical

wires must be properly routed and securely attached.
Illustration 11
g00704000 Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
equipment. Clean all electrical connections and
tighten all electrical connections.
Gaseous fuel is present. Personal Injury or Death
Eliminate all wiring that is unattached or unnecessary.
can result from an open flame or spark igniting
Do not use any wires or cables that are smaller than
the gaseous fuel causing an explosion and/or fire. the recommended gauge. Do not bypass any fuses
Always use a gas detector to determine the pres-
and/or circuit breakers.
ence of gaseous fuel when maintaining and ser-
vicing. Contact you local gas provider immediate- Arcing or sparking could cause a fire. Secure
ly for assistance in the event of a leak.
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
All fuels, most lubricants, and some coolant mixtures or sparking.
are flammable.
Inspect all lines and hoses for wear or for
Flammable fluids that are leaking or spilled onto hot deterioration. The hoses must be properly routed.
surfaces or onto electrical components can cause The lines and the hoses must have adequate support
a fire. Fire may cause personal injury and property and secure clamps. Tighten all connections to the
damage. recommended torque. Leaks can cause fires.
A flash fire may result if the covers for the engine Oil filters and fuel filters must be properly installed.
crankcase are removed within fifteen minutes after The filter housings must be tightened to the proper
an emergency shutdown. torque.
Determine whether the engine will be operated in an

environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result. If
the application involves the presence of combustible
gases, consult your Caterpillar dealer for additional
information about suitable protection devices.
Remove all flammable materials such as fuel, oil,

and debris from the equipment. Do not allow any
flammable materials to accumulate on the equipment.
SEBU8099-01 13
Safety Section
Crushing Prevention and Cutting Prevention
Repair any lines that are loose or damaged. Leaks

can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions

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.
g00704135
Illustration 12
• Outer covers have embedded armoring.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do • End fittings are displaced.
not smoke in battery charging areas.
Make sure that all clamps, guards, and heat shields
Never check the battery charge by placing a metal are installed correctly. During equipment operation,
object across the terminal posts. Use a voltmeter or this will help to prevent vibration, rubbing against
a hydrometer. other parts, and excessive heat.
Improper jumper cable connections can cause i01359666

an explosion that can result in injury. Refer to
the Operation Section of this manual for specific Crushing Prevention and
instructions.
Cutting Prevention
Do not charge a frozen battery. This may cause an
explosion. SMCS Code: 1000; 4450; 7405
The batteries must be kept clean. The covers Support the component properly when work beneath
(if equipped) must be kept on the cells. Use the the component is performed.
recommended cables, connections, and battery box
covers when the engine is operated. Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Fire Extinguisher
Stay clear of all rotating parts and of all moving
Make sure that a fire extinguisher is available. Be parts. Leave the guards in place until maintenance
familiar with the operation of the fire extinguisher. is performed. After the maintenance is performed,
Inspect the fire extinguisher and service the fire reinstall the guards.
extinguisher regularly. Obey the recommendations
on the instruction plate. Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
Lines, Tubes and Hoses
When objects are struck, wear protective glasses in
Do not bend high pressure lines. Do not strike high order to avoid injury to the eyes.
pressure lines. Do not install any lines that are bent
or damaged. Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
14 SEBU8099-01
Safety Section
Mounting and Dismounting
i01372247 Overspeed shutdown should occur automatically.

If automatic shutdown does not occur, press the
Mounting and Dismounting emergency stop button in order to cut the fuel and/or
air to the engine.
SMCS Code: 1000; 4450; 7405
Inspect the engine for potential hazards.
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean Before starting the engine, ensure that no one is on,
and keep these items in good repair. underneath, or close to the engine. Ensure that the
area is free of personnel.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not If equipped, ensure that the lighting system for the
climb on the engine, and do not jump off the engine. engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact All protective guards and all protective covers must
with the steps and handholds. Use two feet and one be installed if the engine must be started in order
hand or use one foot and two hands. Do not use any to perform service procedures. To help prevent an
controls as handholds. accident that is caused by parts in rotation, work
around the parts carefully.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work Do not bypass the automatic shutoff circuits. Do not
platform. Secure the climbing equipment so that the disable the automatic shutoff circuits. The circuits are
equipment will not move. provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
Do not carry tools or supplies when you mount the engine damage.
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies. See the Service Manual for repairs and for
adjustments.
i00702251
Ignition Systems i02136012
Engine Starting
SMCS Code: 1550
SMCS Code: 1000
Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and If a warning tag is attached to the engine start switch
wiring. or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
Do not attempt to remove the valve covers when the the warning tag before the engine is started.
engine is operating. The transformers are grounded
to the valve covers. Personal injury or death may All protective guards and all protective covers must
result and the ignition system will be damaged if the be installed if the engine must be started in order
valve covers are removed during engine operation. to perform service procedures. To help prevent an
The engine will not operate without the valve covers. accident that is caused by parts in rotation, work
around the parts carefully.
i01805780
If there is a possibility that unburned gas remains in
Before Starting Engine the exhaust system, refer to the purge procedure in
this Operation and Maintenance Manual, “Engine
SMCS Code: 1000 Starting” topic in the Operation Section.
NOTICE Start the engine from the operator’s compartment or

For initial start-up of a new or rebuilt engine, and for from the engine start switch.
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
SEBU8099-01 15
Safety Section
Engine Stopping
Always start the engine according to the procedure Grounding Practices

that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation Proper grounding is necessary for optimum engine
Section. Knowing the correct procedure will help to performance and reliability. Improper grounding will
prevent major damage to the engine components. result in uncontrolled electrical circuit paths and in
Knowing the procedure will also help to prevent unreliable electrical circuit paths.
personal injury.
Uncontrolled electrical circuit paths can result in
To ensure that the jacket water heater (if equipped) damage to main bearings, to crankshaft journal
and/or the lube oil heater (if equipped) is working surfaces, and to aluminum components. Uncontrolled
properly, check the water temperature and the oil electrical circuit paths can also cause electrical
temperature during heater operation. activity that may degrade the engine electronics and
communications.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the For the starting motor, do not attach the battery
engine and operate the engine in a well ventilated negative terminal to the engine block.
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside. Use a ground strap to ground the case of all control
panels to the engine block.
i00659907
Ground the engine block with a ground strap that is
Engine Stopping furnished by the customer. Connect this ground strap
to the ground plane.
SMCS Code: 1000
Use a separate ground strap to ground the battery
To avoid overheating of the engine and accelerated negative terminal for the control system to the ground
wear of the engine components, stop the engine plane.
according to the instructions in this Operation and
Maintenance Manual, “Engine Stopping” topic Rubber couplings may connect the steel piping of
(Operation Section). the cooling system and the radiator. This causes the
piping and the radiator to be electrically isolated.
Use the Emergency Stop Button (if equipped) ONLY Ensure that the piping and the radiator is continuously
in an emergency situation. Do not use the Emergency grounded to the engine. Use ground straps that
Stop Button for normal engine stopping. After an bypass the rubber couplings.
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been Ensure that all grounds are secure and free of
corrected. corrosion.
On the initial start-up of a new engine or an engine

that has been serviced, make provisions to stop
the engine if an overspeed occurs. This may be
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
i00887114
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery

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

loose or frayed. Tighten all loose electrical wires
before the engine is operated. Repair all frayed
electrical wires before the engine is started.
16 SEBU8099-01
General Information
Product Information 4. Disconnect the connectors from the CRT

diagnostic module. Move the harness to a position
Section that will not allow the harness to accidentally move
back and make contact with any of the CRT pins.
General Information
i02164135
Welding on Engines with

Electronic Controls
SMCS Code: 1000
NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
Proper welding procedures are necessary in order

to avoid damage to the engine’s ECM, sensors,
and associated components. When possible,
remove the component from the unit and then
weld the component. If removal of the component
is not possible, the following procedure must be
followed when you weld on a unit that is equipped
with a Caterpillar Electronic Engine. The following
procedure is considered to be the safest procedure to g01075639
Illustration 13
weld on a component. This procedure should provide
a minimum risk of damage to electronic components. Use the example above. The current flow from the welder to
the ground clamp of the welder will not cause damage to any
associated components.
NOTICE (1) Engine
Do not ground the welder to electrical components (2) Welding rod
such as the ECM or sensors. Improper grounding can (3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
cause damage to the drive train bearings, hydraulic (5) Disconnected battery cables
components, electrical components, and other com- (6) Battery
ponents. (7) Electrical/Electronic component
(8) Maximum distance between the component that is being
Clamp the ground cable from the welder to the com- welded and any electrical/electronic component
(9) The component that is being welded
ponent that will be welded. Place the clamp as close (10) Current path of the welder
as possible to the weld. This will help reduce the pos- (11) Ground clamp for the welder
sibility of damage.
5. Connect the welding ground cable directly to the
1. Stop the engine. Turn the switched power to the part that will be welded. Place the ground cable as
OFF position. close as possible to the weld in order to reduce the
possibility of welding current damage to bearings,
2. Disconnect the negative battery cable from the hydraulic components, electrical components, and
battery. If a battery disconnect switch is provided, ground straps.
open the switch.
Note: If electrical/electronic components are used
3. Disconnect the J1/P1 and J2/P2 connectors from as a ground for the welder, or electrical/electronic
the ECM. Move the harness to a position that will components are located between the welder ground
not allow the harness to accidentally move back and the weld, current flow from the welder could
and make contact with any of the ECM pins. severely damage the component.
SEBU8099-01 17
General Information
6. Protect the wiring harness from welding debris

and spatter.
7. Use standard welding practices to weld the

materials.
18 SEBU8099-01
Model Views and Specifications
Model Views and

Specifications
i02469649
Model View Illustrations

SMCS Code: 1000; 4450
The illustrations show various typical features of

G3500 A3 Engines. The illustrations do not show all
of the options that are available.
g01231713
Illustration 14
(1) Exhaust bypass (7) Air starting motor (13) Exhaust
(2) Lifting eye (8) Oil level gauge (dipstick) (14) Engine control module (ECM)
(3) Aftercooler (9) Pyrometer (15) Auxiliary water pump
(4) Crankcase breather (10) Jacket water pump (16) Engine interface box
(5) Oil filter (11) Oil screen
(6) Oil filler (12) Oil drain
SEBU8099-01 19
i02151232
Specifications
SMCS Code: 1000
General Engine Specifications
g00845207
Illustration 16
(1 through 12) Cylinder numbers
(A) Inlet valves
(B) Exhaust valves
(C) Flywheel
Table 2
g00845204 G3512 Engine Specifications

Illustration 15
(1 through 8) Cylinder numbers Rated rpm 1000 to 1800
(A) Inlet valves
Cylinders and arrangement 65 degree Vee 12
(B) Exhaust valves
(C) Flywheel Bore 170 mm (6.7 inch)
Table 1 Stroke 190 mm (7.5 inch)
G3508 Engine Specifications Displacement 51.8 L (3158 cubic inch)
Rated rpm 1000 to 1800 Compression ratio 7.5:1
Cylinders and arrangement 65 degree Vee 8 8:1
Bore 170 mm (6.7 inch) 11:1
Stroke 190 mm (7.5 inch) 12.5:1
Displacement 34.5 L (2105 cubic inch) Aspiration Naturally aspirated
Compression ratio 7.5:1 Turbocharged aftercooled
Separate circuit
8:1 aftercooling
11:1 Rotation (flywheel end) Counterclockwise rotation
12.5:1 is standard.
Aspiration Naturally aspirated Clockwise rotation is

optional.
Turbocharged aftercooled
Separate circuit Inlet valve lash 0.51 mm (0.020 inch)
aftercooling Exhaust valve lash 1.27 mm (0.050 inch)
Rotation (flywheel end) Counterclockwise rotation
is standard.
Clockwise rotation is
optional.
Inlet valve lash 0.51 mm (0.020 inch)
Exhaust valve lash 1.27 mm (0.050 inch)
20 SEBU8099-01
g00845212
Illustration 17
(1 through 16) Cylinder numbers
(A) Inlet valves
(B) Exhaust valves
(C) Flywheel
Table 3
G3516 Engine Specifications
Rated rpm 1000 to 1800
Cylinders and arrangement 65 degree Vee 16
Bore 170 mm (6.7 inch)
Stroke 190 mm (7.5 inch)
Displacement 69 L (4210 cubic inch)
Compression ratio 7.5:1
8:1
11:1
12.5:1
Aspiration Naturally aspirated
Turbocharged aftercooled
Separate circuit
aftercooling
Rotation (flywheel end) Counterclockwise rotation
is standard.
Clockwise rotation is
optional.
Inlet valve lash 0.51 mm (0.020 inch)
Exhaust valve lash 1.27 mm (0.050 inch)
SEBU8099-01 21
Crankshaft Positions for Valve

Lash Setting
Table 4
Crankshaft Positions For Valve Lash Setting

Standard Counterclockwise Rotation
Stroke For The Number
Engine 1 Piston At Top Center Inlet Valves Exhaust Valves
Position(1)
Compression Stroke 1-2-6-8 1-2-3-7
G3508 Exhaust Stroke 3-4-5-7 4-5-6-8
Firing Order 1-2-7-3-4-5-6-8
Compression Stroke 1-3-6-7-10-12 1-4-5-6-9-12
G3512 Exhaust Stroke 2-4-5-8-9-11 2-3-7-8-10-11
Firing Order 1-12-9-4-5-8-11-2-3-10-7-6
Compression Stroke 1-2-5-7-8-12-13-14 1-2-3-4-5-6-8-9
G3516 Exhaust Stroke 3-4-6-9-10-11-15-16 7-10-11-12-13-14-15-16
Firing Order 1-2-5-6-3-4-9-10-15-16-11-12-13-14-7-8
Crankshaft Positions For Valve Lash Setting
Optional Clockwise Rotation
Compression Stroke 1-3-4-8 1-2-7-8
G3508 Exhaust Stroke 2-5-6-7 3-4-5-6
Firing Order 1-8-7-2-6-5-4-3
Compression Stroke 1-3-4-6-7-12 1-4-5-8-9-12
G3512 Exhaust Stroke 2-5-8-9-10-11 2-3-6-7-10-11
Firing Order 1-4-9-8-5-2-11-10-3-6-7-12
Compression Stroke 1-2-5-6-7-8-13-14 1-2-3-4-5-6-9-10
G3516 Exhaust Stroke 3-4-9-10-11-12-15-16 7-8-11-12-13-14-15-16
Firing Order 1-6-5-4-3-10-9-16-15-12-11-14-13-8-7-2
(1) For the complete procedure, refer to the Service Manual, “Systems Operations Testing and Adjusting”.
22 SEBU8099-01
Product Identification Information
Product Identification
Information
i01627115
Plate Locations and Film

Locations
SMCS Code: 1000; 4450
Engine Identification
Caterpillar engines are identified with serial numbers, Illustration 19
g00123229
with performance specification numbers, and with
arrangement numbers. In some of the cases, The following information is stamped on the Serial
modification numbers are used. These numbers Number Plate: engine serial number, model, and
are shown on the Serial Number Plate and the arrangement number.
Information Plate that are mounted on the engine.
Caterpillar dealers need these numbers in order to Information Plate

determine the components that were included with
the engine. This permits accurate identification of
replacement part numbers.
Serial Number Plate
g00842967
Illustration 20
(1) Location of the Information Plate
The Information Plate is on the left side top surface of

the cylinder block in front of the front cylinder head.
g00842942
Illustration 18
(1) Location of the Serial Number Plate
The Serial Number Plate is on the left side of the

cylinder block near the rear of the engine.
g00361974
Illustration 21
SEBU8099-01 23
Product Identification Information
The following information is stamped on the Table 5

Information Plate: compression ratio, aftercooler Reference Numbers
temperature, power (kilowatts and horsepower), full
load rpm, and other information. Engine Model
Serial Number
i02135788 Arrangement Number
Reference Information Packaging Arrangement
SMCS Code: 1000; 4450 Turbocharger

Fuel Filter Element
Identification of the items in Table 5 may be needed
in order to obtain parts and service. Some of the Lubrication Oil Filter
Element
numbers are on the engine Serial Number Plate
and/or Information Plate. Locate the information Auxiliary Oil Filter Element
for your engine. Record the information on the
Air Cleaner Element
appropriate space in Table 5. Make a copy of this
list for a record. Retain the information for future Fan Drive Belt
reference.
Alternator Belt
The top level part numbers in the Parts Manual for Capacity of the Lubrication
the engine are listed with the engine arrangement System
number.
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 Performance Specification
that are not included in the engine arrangement. Number
The performance specification can be used by Low Idle rpm

your Caterpillar dealer with the Technical Marketing High Idle rpm
Information system. Before the engine leaves the
factory, the engine performance is tested. Detailed Full Load rpm
performance data is recorded. The performance Power Rating
specification number can be used for obtaining the
data.
24 SEBU8099-01
Operation Section
Lifting and Storage
Operation Section Engine Lifting with a Generator

NOTICE
Lifting and Storage Do not use the engine lifting eyes to remove the en-
gine and generator together.
i01536259 A lifting plate is provided with the package generator

set. Instructions for lifting the package generator set
Product Lifting are stamped on the lifting plate.
SMCS Code: 7000; 7002
Consult your Caterpillar dealer for information
regarding proper fixtures and lifting devices.
Lifting packaged generator sets will not be level if you

lift the unit with a single point lift. A counterweight can
be added between the package frame rails whenever
the application requires frequent relocation of the
unit. For complete information about adding the
counterweight, consult your Caterpillar dealer.
The single point lifting eye is secured from the

factory before the enclosure is shipped. The correct
orientation of the single point lifting eye will allow you
to look through the eye when you stand at the side of
the enclosure. The lifting eye may stretch when the
Illustration 22
g00103219 package is lifted. This may cause the locking nuts
to loosen. This could cause the lifting eye to swivel.
Ensure that the lifting eye is correctly oriented on the
NOTICE packaged generator set. Ensure that the lifting eye
Never bend the eyebolts and the brackets. Only load is tightened to the correct torque before you lift the
the eyebolts and the brackets under tension. Remem- packaged generator set.
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
When it is necessary to remove a component at an

angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use

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

obtain proper balance and safety.
To remove the engine ONLY, use the lifting eyes that

are on the engine.
Lifting eyes are designed and installed for the specific

engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.
SEBU8099-01 25
Operation Section
Lifting and Storage
i02057737
Product Storage
SMCS Code: 7002
If the engine will not be started for several weeks, the

lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface, which will increase engine wear which
can reduce engine service life.
To help prevent excessive engine wear, use the

following guidelines:
• Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).
• If freezing temperatures are expected, check the

cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
If an engine is out of operation and if use of the engine

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

preparing the engine for extended storage periods.
For more detailed information on engine storage, see

Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”.
Generator Storage
For information on generator storage, see the
literature that is provided by the OEM of the
generator. Consult your Caterpillar dealer for
assistance.
26 SEBU8099-01
Operation Section
Features and Controls
Features and Controls Gas Pressure Regulator
The gas pressure regulator maintains a pressure

i02506879 differential between the air and the fuel that is
supplied to the carburetor. Set the pressure of the fuel
Performance Parameters supply to a maximum of 1.5 kPa (6 inch of H2O) more
than the pressure of the air supply. The gas pressure
SMCS Code: 1000 regulator will maintain the pressure differential in
response to changes in the air pressure. If high idle
Note: For information on the following topics, see is important, lower the differential pressure to 1 kPa
the Service Manual, “Systems Operation/Testing and (4 inch of H2O). The higher differential pressures will
Adjusting” or see Special Instruction, REHS2558, give better engine response to load changes.
“Installation and Initial Start-Up Procedure for G3500
A3 Engines”. A water manometer is used to measure the pressure
differential. This measurement is taken when the
• Adjusting the carburetor engine is operating at high idle rpm. When a load is
applied, the fuel pressure will usually decrease by
• Adjusting the control linkage for the carburetor approximately 0.25 to 0.5 kPa (1 to 2 inch of H2O).
If the performance of the gas pressure regulator
• Adjusting the exhaust bypass is erratic, the gas pressure regulator may require
service.
Consult your Caterpillar dealer for assistance.
Temperature of the Fuel Supply
Air/Fuel Ratio
Changes in the temperature of the fuel supply affects
The correct air/fuel ratio is very important for the the air/fuel ratio. Warmer fuel is less dense than cold
following considerations: fuel. This results in a leaner mixture that causes a
noticeable reduction of power. The recommended
• Margin of detonation temperature differential of the air and the fuel is
2.8 °C (5 °F).
• Control of emissions
The maximum fuel temperature depends on the
• Achieving optimum service life for the engine temperature regulator of the aftercooler:
If the air/fuel ratio is not appropriate for the fuel and • For engines with a 32 °C (90 °F) aftercooler, the
the operating conditions, a failure of the engine may maximum temperature of the air/fuel mixture is
occur. The service life of the turbocharger, the valves, 38 °C (100 °F).
and other components may be reduced.
• For engines with a 54 °C (130 °F) aftercooler, the
Fuel Supply Pressure maximum temperature of the air/fuel mixture is
60 °C (140 °F).
Fluctuations of the fuel pressure can change the
air/fuel ratio. For high pressure gas fuel systems, For more information, see Application and Installation
the maximum fluctuation that is allowed in the fuel Guide, LEKQ7260, “Low BTU Engines”. Consult your
pressure is 3.4 kPa (0.50 psi). For low pressure gas Caterpillar dealer for assistance.
fuel systems, the maximum fluctuation that is allowed
in the fuel pressure is 1.7 kPa (0.25 psi). Ensure Temperature of the Air Supply
a stable fuel pressure to the engine by installing
a second gas pressure regulator prior to the gas Changes in the temperature of the air supply affects
pressure regulator on the engine. the air/fuel ratio. In addition to seasonal changes,
the air temperature changes overnight. Control of the
temperature in the engine room will help to maintain
the air/fuel ratio.
To optimize the inlet air temperature, use ducting and

a heat exchanger. This will help to avoid exposure
to hot air from a generator. For more information,
see Application and Installation Guide, LEKQ7250,
“Air Intake”. Consult your Caterpillar dealer for
assistance.
SEBU8099-01 27
Operation Section
Carburetor • Throttle actuator

Engines That Use Bio-Gas • Input switches
The carburetor that is used on some applications For more information regarding the Air/Fuel
tends to supply a rich air/fuel mixture during partial Ratio Control, see the Service Manual, “Systems
load operation. The rich air/fuel mixture and rapid Operation/Testing and Adjusting”.
loading can cause detonation. This depends on the
following factors:
Angle of the Throttle Plate
• Temperature of the inlet air and fuel The angle of the throttle plate is adjusted for full load
operation. The angle is adjusted by changing the
• Btu of the fuel setting of the exhaust bypass valve.
• Air/fuel setting • Adjust the angle of the throttle plate between 60
and 75 degrees.
• Carburetor jet
The following factors affect the angle of the throttle:
• Ignition timing
• LHV of the fuel
• Deposits in the combustion chamber
To reduce the risk of detonation during loading, adjust • Setting of the air/fuel ratio (inlet manifold air
pressure)
the ramp time so that the load is applied over five
to ten minutes.
• Setting of the exhaust bypass (wastegate)
If detonation still occurs, or if startability is inhibited,
the air/fuel ratio for partial load operation can be • Altitude
made leaner. Install 7E-1569 Washers behind each
Ensure that the angle of the throttle plate is properly
gas valve of the carburetor. Use a maximum of three
set. This will maintain the margin for detonation. This
washers per valve. After the washers are installed, will also enable the engine to accept load changes
adjust the setting for the oxygen at full load.
without lugging.
Optional Air/Fuel Ratio Control Setting of the Exhaust Bypass

The engine may be equipped with an air/fuel ratio (Wastegate)
control system. The system provides the following
capabilities: The engines are equipped with exhaust bypass
valves that are adjustable. This enables the throttle
• Control of exhaust emissions position to be correctly set for the application.
Adjustments must be made for the following
• Adjustment for changes in the fuel BTU variables:
• Engine speed governing • Altitude

The system consists of the following components: • Setting of the air/fuel ratio
• Electronic Control Module (ECM) • Methane number of the fuel
• Oxygen sensor The exhaust bypass is adjusted in order to achieve
the proper angle of the throttle plate when the engine
• Oxygen buffer is operating under a rated load.
• Speed sensor Oil Consumption

• Inlet manifold pressure sensor High loads will cause the engine to consume more oil.
• Inlet manifold temperature sensor
• Fuel valve
28 SEBU8099-01
Operation Section
The rate of oil consumption is called the Brake • Governing of the engine rpm
Specific Oil Consumption (BSOC). The unit of
measure is grams per brake kilowatt hour (pounds • Control of ignition
per brake horsepower hour). The BSOC depends on
the following factors: engine model, aspiration, and • Control of the air/fuel ratio
operating load.
• Start/stop control
Table 6 lists the normal mid-life BSOC for G3500
Engines under the following conditions: • Monitoring of engine operation
• Load factor of 100 percent Governing of the Engine RPM
• Maintenance is performed according to this The ECM maintains the desired engine speed
Operation and Maintenance Manual, “Maintenance through electrical control of the throttle. The throttle
Interval Schedule” (Maintenance Section). regulates the throttle plate.
Table 6
For more information on the desired speed input,
BSOC for G3500 Engines see the Systems Operation/Testing and Adjusting
manual.
Naturally Aspirated Engine 0.913 g/bkw h
(0.0015 lb/bhp h)
Control of Ignition
Turbocharged Aftercooled Engine 0.426 g/bkw h
(0.0007 lb/bhp h)
Each cylinder has an ignition transformer that is
located under the valve cover. To initiate combustion
in each cylinder, the ECM sends a pulse to
i02472611
the primary coil of the ignition transformer. The
Sensors and Electrical transformer increases the voltage which creates a
spark across the spark plug electrode.
Components
The transformers are grounded through the valve
SMCS Code: 1900; 7400 cover. Use caution when a valve cover is removed.
Note: This section contains some general information Always disconnect the ignition harness from the
about the engine electronic system and sensors. transformer when a valve cover is removed.
For more information, refer to the engine’s Systems
Operation/Testing and Adjusting manual. An ignition harness connects each transformer to the
ECM. The harness is routed inside the engine.
Electronic System
Control of Air and Fuel
The Caterpillar Electronic System is a complete
electronic control system for gas engines. The The ECM determines the desired volume for the flow
following benefits are the most significant advantages rates of the air and fuel. The ECM sends information
of the electronic system: on the desired flow of air and fuel to the fuel metering
valve. The ECM fine tunes the signal to the fuel
• Air/Fuel ratio control metering valve in order to achieve the desired
emissions. The process is repeated continuously
• Extensive system diagnostics during engine operation.
• Elimination of parts that are prone to mechanical Start/Stop Control

wear
The ECM contains the logic and the outputs
• Precise control of engine operation for controlling the starting and stopping of the
engine. The logic for starting and stopping can be
• Engine protection programmed by the customer.
• Timing control of individual cylinders The engine uses an energize-to-run system. The
gas shutoff valve must remain energized in order to
Most of the functions of the electronic system are supply fuel to the engine. If power is removed from
provided by the Electronic Control Module (ECM). the gas shutoff valve, the fuel is shut off.
Five primary functions are supported by the ECM:
SEBU8099-01 29
Operation Section
Monitoring Engine Operation Detonation

Sensors are used in order to monitor engine
operation. Wiring harnesses connect the sensors
to the ECM. The ECM uses information from the
sensors in order to monitor the engine. The ECM also
uses information from the sensors in order to control
the engine. The information is also used to generate
event codes, and diagnostic codes.
Note: The codes can be read with Caterpillar

Electronic Technician (ET). The codes can also be
read on the Advisor monitor display, if equipped.
Event – An event is a result of abnormal engine

operation. If abnormal engine operation is detected, g01255077
the ECM generates an event code. The ECM can Illustration 23
generate an alarm or a shutdown for abnormal engine Detonation sensor
operation. These conditions are some examples of
events: high inlet air temperature, low oil pressure, The detonation sensors monitor the engine for
and engine overspeed. detonation. One sensor is mounted in the center of
each cylinder bank. The sensor produces a voltage
Diagnostic – A diagnostic code is a result of a signal that is proportional to the engine detonation.
problem with the operating system or with the This information is processed by the engine control
monitoring system. The ECM uses sensors and module in order to determine detonation levels. To
internal circuitry to monitor the system components. eliminate detonation, the engine control module
If a problem develops in a component or a wiring retards the engine timing, if necessary. If excessive
harness, the control system will sense the problem. detonation continues, the engine control module will
The control system will notify the operator by creating shut down the engine.
a diagnostic code. Some examples of conditions
that activate diagnostics are a short in a circuit for a Engine Oil Pressure
sensor, an open circuit, or a noisy signal.
Note: For detailed information on event codes

and diagnostic codes, refer to the engine’s
Troubleshooting manual.
Sensors
Sensors provide information to the engine interface
box and the engine control module. The information
enables the module to control the engine as
efficiently as possible over a wide range of operating
conditions. The information is used for monitoring
engine operation via gauges and indicators on the
engine interface box. g01255244
Illustration 24
The sensors also enable the activation of alarms and (1) Oil pressure sensor for unfiltered oil
shutoffs in response to abnormal operation. (2) Oil pressure sensor for filtered oil
(3) Oil filter housing
Air Inlet Temperature There are two engine oil pressure sensors. The
sensors are located on the top of the oil filter housing.
A probe for monitoring the air inlet temperature is One of the sensors measures the unfiltered oil
located in the air inlet manifold. No adjustment can pressure. The other sensor measures the filtered oil
be made to the temperature range. Excessive inlet pressure. Low oil pressure will cause a shutdown.
air temperature can activate an alarm or a shutdown. High differential oil pressure will also cause a
shutdown.
30 SEBU8099-01
Operation Section
Engine Speed/Timing Sensor Water Temperature
g00309907 g01255442
Illustration 25 Illustration 27
Engine speed/timing sensor Water temperature sensor
The engine speed/timing sensor provides accurate The water temperature sensor is located in the
information about the speed of the crankshaft and the water temperature regulator housing. To monitor
position of the crankshaft. A ring that is mounted on the coolant temperature, the element must be in
the camshaft provides the information that is detected contact with the coolant. If overheating occurs due to
by the sensor. The engine control module uses the low coolant level or no coolant, the sensor will not
information in order to determine ignition timing. This function properly. The sensor can be wired into an
sensor is also used to detect an overspeed condition. alarm system or an indicator in order to indicate high
water temperature. After an overheated engine is
Manifold Air Pressure allowed to cool, the contactor is automatically reset.
g01255807
Illustration 26
Manifold air pressure sensor
The manifold air pressure sensor is located in the

inlet elbow for the number two cylinder. The sensor
monitors the absolute manifold air pressure. This is
the atmospheric pressure plus the gauge pressure.
The information is used by the engine control module
to determine the engine load. The output of the
sensor can be read with the Digital Diagnostic Tool.
SEBU8099-01 31
Operation Section
i02507475 Advisor Monitor Display

Control Panel
SMCS Code: 7451
Engine Monitoring System
g01199161
Illustration 29
(1) “Engine failure”
(2) “Left/Up”
(3) “Active Alarm”
(4) “Right/Down”
(5) “Engine on”
(6) “Previous”
(7) Spare
(8) “Home”
(9) Spare
(10) “OK/Select”
Advisor monitors the engine operations, diagnostic

events, service intervals, and modes of operation.
Illustration 28
g01255452 Advisor is used to change customer preferences and
(1) Advisor monitor display
operation parameters. This allows additional means
(2) “MANUAL PRELUBE” switch and “PRELUBE ACTIVE” for the operator to increase engine efficiency.
indicator
(3) “EMERGENCY STOP” button If an action alarm, alert indicator, or warning occurs,
(4) Service tool connector the message will override any screen that was
(5) Engine control switch
(6) “DESIRED SPEED” dial displayed on the CAT Advisor graphic display
module.
“Engine Failure” (1) – This button will illuminate in

the event of an engine failure.
“Left/Up” (2) – This button is used for the following

purposes: navigating backward through the screens,
navigating upward through the screens, entering data
information, and a decrease in a setting value.
“Active Alarm” (3) – This button will illuminate

when an alarm is active.
“Right/Down” (4) – This button is used for the

following purposes: navigating forward through the
screens, navigating downward through the screens,
entering data information, and an increase in a
setting value.
“Engine On” (5) – This button will illuminate when

the engine is running.
“Previous” (6) – This button is used to return to the

previous screen.
Spare (7) – This is a spare button.

32 SEBU8099-01
Operation Section
“Home” (8) – This button will return you to the main • “OFF/RESET”
menu.
• “AUTO”
Spare (9) – This is a spare button.
• “START”
“OK/Select” (10) – This button is used to make
selections on the screen. Also, use this button to • “COOLDOWN/STOP”
confirm an password entry or use the button to save
an operator profile. “OFF/RESET” – When the engine control switch is
turned to this position, the indicators on the status
Prelube Switch control module are reset and the engine shuts down
immediately. The power to the engine control module
Activation of the manual prelube switch will cause the and the status control module is shut off. This method
prelube pump to operate until the switch for prelube is not recommended for normal stopping.
oil pressure closes. When the output is activated,
the “PRELUBE ON” indicator on the optional control “AUTO” – When the engine control switch is in
panel is illuminated. this position, the system is configured for remote
operation. When the remote start/stop initiate contact
closes, the engine will start. When the remote
“EMERGENCY STOP” button start/stop initiate contact opens, the engine will
shut down. If the cooling cycle is programmed, the
Use of the emergency stop will shut off the fuel. The
engine will operate for the cooldown period before
air shutoffs will also be activated. the engine stops.
NOTICE “START” – When the engine control switch is turned
Do not start the engine until the problem necessitating to this position, the engine will start. The engine
the emergency stop has been located and corrected. will continue to operate when the switch is in this
position. However, if a setpoint for a shutdown is
It may be necessary to reset the emergency stop exceeded, the engine will shut down.
button before the engine can be restarted. If the
emergency stop button is used, both of the air “COOLDOWN/STOP” – This is the preferred
shutoffs must be reset before the engine can be method for normal stopping. When the engine
restarted. The power for the ECM must be cycled control switch is turned to this position, the engine
before the engine can be restarted. will continue to operate until a programmable
cooling cycle has elapsed. The cooling cycle can be
programmed for a 0 to 30 minute period. The default
Service Tool Connector setting is five minutes.
This allows the connection of a diagnostic tool.
“DESIRED SPEED” Dial
Engine Control Switch Use this dial to set the engine at the desired rpm.
g01255453
Illustration 30
Engine control switch in the “OFF/RESET” position
The engine control switch is a rotary switch that has

four positions:
SEBU8099-01 33
Operation Section
Engine Starting
Engine Starting • Ensure that all clamps and connections are secure.
• Inspect the air cleaner service indicator (if
i02507769 equipped). Service the air cleaner filter element
when the yellow diaphragm enters the red zone, or
Before Starting Engine the red piston locks in the visible position.
SMCS Code: 1000; 1400; 1450

Cooling System
Note: Certain procedures are required before an
engine is started for the first time. See Special • Inspect the cooling system for leaks or loose
Instruction, REHS2558, “Installation and Initial connections. Inspect the condition of all the hoses
Start-Up Procedure for G3500 A3 Engines”. and pipes for the cooling system. Ensure that the
connections are properly clamped.
Perform the required daily maintenance and other
periodic maintenance before starting the engine. This • Inspect the water pumps for evidence of leaks.
can prevent major repairs at a later date. See this
Operation and Maintenance Manual, “Maintenance • Check the coolant level. Add coolant, if necessary.
Interval Schedule” (Maintenance Section). For information on the proper coolant to use, see
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” (Maintenance
Walk-Around Inspection Section).
NOTICE Driven Equipment

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

damaged guards or replace missing guards.
Inspect the wiring for the following conditions:
• Ensure that the areas around the rotating parts are
clear. • Loose connections
Air Inlet System • Wiring that is worn or frayed

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

burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on NEVER use a flame to check for gas leaks. Use a
purging unburned gas in the “Starting the Engine” gas detector.
section.
An open flame can ignite mixtures of air and fuel.
This will cause explosion and/or fire which could
• Ensure that the air inlet piping and the air filters result in severe personal injury or death.
are in place.
34 SEBU8099-01
Operation Section
Engine Starting
• Check the fuel lines for leaks with a gas detector. Air Starting Motor
• Inspect the fuel lines for loose fittings and leaks. • Drain moisture and sediment from the air tank and
Ensure that the fuel lines are properly clamped. from any other air piping.
• Ensure that the fuel is supplied to the engine at the • Check the oil level in the lubricator. Keep the
correct pressure for the engine. lubricator at least half full. Add oil, if necessary.
For temperatures above 0 °C (32 °F), use a
nondetergent 10W oil. For temperatures below
Lubrication System 0 °C (32 °F), use air tool oil.
• Check the air pressure for starting. The air starting

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

• Disconnect any battery chargers that are not
protected against the high current drain that is
created when the electric starting motor engages.
Inspect the wiring, the electrical cables, and the

battery for the following conditions:
g00760044
Illustration 31
Oil level gauge (dipstick) • Loose connections
(1) “ADD” mark
(2) “FULL” mark • Wires that are worn or frayed
• Corrosion
NOTICE
Excessive engine oil will increase oil consumption and
result in excessive deposits in the combustion cham- i02508805
ber. Do not overfill the engine with oil.
Cold Weather Starting
• Check the engine crankcase oil level. Maintain the SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
oil level between the “ADD” and “FULL” marks on
the “ENGINE STOPPED WITH OIL COLD” side of Note: Oil pan immersion heaters are not
the oil level gauge. For information on the proper recommended for heating the lube oil. To ensure the
oil to use, see this Operation and Maintenance compatibility of the components, only use equipment
Manual, “Refill Capacities and Recommendations” that is recommended by Caterpillar.
A jacket water heater is recommended for starting
• Check for leaks at the following components: in temperatures as low as 0 °C (32 °F). The jacket
crankshaft seals, crankcase, oil filters, oil gallery water heater can maintain the water temperature at
plugs, sensors, and valve covers. approximately 32 °C (90 °F). The heated water will
help to keep the oil in the engine block warm enough
• Inspect the tubes, tee pieces, and clamps on the to flow when the engine is started. A jacket water
crankcase breathers. heater is required for starting when the temperature
is less than 16 °C (60 °F).
Starting System For air starting motors, a larger volume of starting
Note: If the engine is equipped with a system for air and/or a higher air pressure may be necessary in
external support, prepare the system before starting order to start the engine at colder temperatures.
the engine. Ensure that all of the systems for engine
support are enabled. Perform all prestart checks for For electric starting, extra battery capacity may be
the control system. necessary.
Consult your Caterpillar dealer for more information

on the starting aids that are available for cold weather
starting.
SEBU8099-01 35
Operation Section
Engine Starting
i02508810 • The GSOV is commanded to close and the GSOV

does not close.
Starting the Engine
• Unsuccessful successive attempts to start the
SMCS Code: 1000; 1450 engine
Unburned gas may remain in the air inlet and exhaust

system after several unsuccessful attempts to start
Engine exhaust contains products of combustion the engine. The unburned gas may increase to a
which may be harmful to your health. Always start concentration that may ignite during a successive
and operate the engine in a well ventilated area attempt to start the engine.
and, if in an enclosed area, vent the exhaust to the
outside. Perform the following procedure in order to purge
the unburned gas:
NOTICE 1. Connect Cat ET to the engine.

For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make 2. Verify that the value of the “Engine Purge Cycle”
provision to shut the engine off should an overspeed parameter is equal to ten seconds less than the
occur. This may be accomplished by shutting off the value of the “Crank Cycle” parameter.
fuel supply and/or the ignition to the engine.
3. Set the engine control to the START mode. The
engine will crank for the “Engine Purge Cycle”
time. Then, the gas shutoff valve will be energized
and the ignition will be enabled. The engine will
Unburned gas in the air inlet and exhaust system start.
may ignite when the engine is started. Personal
injury and/or property damage may result. 4. Continue with your previous procedure.
Before starting an engine that may contain un- Operation of the Generator Set
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on Control Panel
purging unburned gas in the “Starting the Engine”
section. For information on operation for a specific generator
set control panel, refer to the Operation and
Maintenance Manual for the generator and the
Note: Using the “EMERGENCY STOP” button will control panel.
shut off both the fuel and the ignition.
Do not start the engine or move any of the controls Automatic Starting
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or to
the controls.
When the engine is in the AUTOMATIC mode, the
Ensure that no one will be endangered before the
engine can start at any moment. To avoid personal
engine is started and when the engine is started. injury, always remain clear of the the engine when
the engine is in the AUTOMATIC mode.
Perform the procedures that are described in this
Operation and Maintenance Manual, “Before Starting
Engine” (Operation Section). If the engine control switch is in the “AUTO” position,
the engine will automatically start when the remote
start/stop initiate contact closes. The engine will
Purging Unburned Gas accelerate to rated rpm when the oil pressure is
sufficient.
The following events cause unburned gas to remain
in the air inlet and in the exhaust manifold:
Manual Starting
• Emergency stop
1. Ensure that fuel is supplied to the engine. Ensure
• Engine overspeed that no gas is leaking.
2. Ensure that the driven equipment is unloaded.

36 SEBU8099-01
Operation Section
Engine Starting
a. For generator set engines, ensure that the i02509489

main circuit breaker is open.
Starting with Jump Start
b. For industrial engines, unload the compressor
or pump. Disengage the clutch (if equipped).
Cables
Place the transmission and/or other SMCS Code: 1000; 1401; 1402; 1900
attachments for the power take-off in
NEUTRAL.
Note: Before starting an industrial engine, move the

governor control lever to the position for 1/2 of rated Improper jump start cable connections can cause
rpm. an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could

NOTICE cause vapors to explode. Do not allow jump start
Do not engage the starting motor when flywheel is cable ends to contact each other or the engine.
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release If the installation is not equipped with a backup
the starter switch or button and wait two minutes to battery system, it may be necessary to start the
allow the starting motor to cool before attempting to engine from an external electrical source.
start the engine again.
For information on troubleshooting the charging
system, refer to Special Instruction, REHS0354,
3. Turn the engine control switch to the “Start” “Charging System Troubleshooting”.
position in order to start the engine.
Many batteries which are considered unusable are
4. Allow the engine to idle for three to five minutes. still rechargeable. After jump starting, the alternator
The engine speed should stabilize at low idle rpm. may not be able to fully recharge batteries that
Check all of the pressure gauges. Inspect the are severely discharged. The batteries must be
engine for leaks and listen for unusual noises. charged to the proper voltage with a battery charger.
When all systems are normal, the rpm may be For information on testing and charging, refer to
increased. the Special Instruction, SEHS7633, “Battery Test
Procedure”.
Starting Failure
NOTICE
If the engine fails to start after cranking for 30 Using a battery source with the same voltage as the
seconds, stop cranking. Perform the following electric starting motor. Use ONLY equal voltage for
procedure: jump starting. The use of higher voltage will damage
the electrical system.
1. Turn the engine control switch to the “OFF/RESET”
position. Do not reverse the battery cables. The alternator can
be damaged. Attach ground cable last and remove
2. Allow the starting motor to cool for two minutes. first.
3. Perform the “Purge Unburned Gas” procedure. When using an external electrical source to start the
engine, turn the generator set control switch to the
4. Allow the starting motor to cool for two minutes. “OFF” position. Turn all electrical accessories OFF be-
Turn the gas supply ON. Repeat the starting fore attaching the jump start cables.
procedure.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
gine being started.
1. Turn the start switch on the engine to the

OFF/RESET position. Turn off all accessories.
SEBU8099-01 37
Operation Section
Engine Starting
2. Connect one positive end of the jump start cable i02509497

to the positive cable terminal of the discharged
battery. Connect the other positive end of the jump After Starting Engine
start cable to the positive cable terminal of the
electrical source. SMCS Code: 1000
3. Connect one negative end of the jump start cable For new installations and engines that are recently
to the negative cable terminal of the electrical rebuilt, carefully monitor the engine in order to detect
source. Connect the other negative end of the any unusual engine performance.
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent It may be necessary to apply some load in order to
potential sparks from igniting combustible gases attain normal operating temperatures. The operator
that are produced by some batteries. can ramp the load manually. For automatic loading,
programmable logic control can be used.
4. Charge the batteries. The engine will not continue
to run after starting if the batteries have not been Engaging the Driven Equipment
charged.
Generator Set Engines
5. Start the engine.
1. Increase the engine speed to rated rpm.
6. Immediately after the engine is started, disconnect
the jump start cables in reverse order. 2. Ensure that the outlet temperature of the jacket
water reaches 77 °C (170 °F). Ensure that the
Refer to the Electrical Schematic for your engine.
gauges are in the normal ranges for the engine
Consult your Caterpillar dealer for more information. rpm.
3. Apply the load.
Industrial Engines
1. Increase the engine rpm. Ensure that the gauges
are in the normal ranges for the engine rpm.
2. Engage the driven equipment with no load on the

driven equipment.
The engine can be loaded up to 50 percent of full

load before the outlet temperature of the jacket
water reaches 77 °C (170 °F). The temperature is
usually achieved in two to four minutes. After this
temperature is reached, begin to ramp the engine
to full load.
3. Ramp to full load after the outlet temperature of

the jacket water reaches 77 °C (170 °F). Five
minutes may be required.
38 SEBU8099-01
Operation Section
Engine Operation
Engine Operation For example, an engine is operating at 20 percent

of the rated torque. The engine may be operated at
this load factor for a maximum of one-half hour. After
i02097665 the one-half hour, operate this engine for at least two
hours at a load factor of more than 70 percent.
Engine Operation
To keep engine maintenance at a minimum, follow
SMCS Code: 1000 the guidelines that are listed in Table 7.
Proper operation and maintenance are key factors in Table 7

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

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

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

Extended operation at low idle or at a reduced load
will cause increased oil consumption and carbon
buildup in the cylinders. Carbon buildup results in
the following effects:
• Power loss
• Poor performance
• Accelerated wear of components
Caterpillar Engines can be operated at very light
loads (torques) for limited times with no harmful
effects. Table 7 lists the limits for hours of operation
at various torques.
After the time limit for reduced load operation has

expired, operate the engine for a minimum of two
hours at a torque that is more than 70 percent.
SEBU8099-01 39
Operation Section
Engine Stopping
Engine Stopping Emergency Stop Button
i02508845
Emergency Stopping
SMCS Code: 1000; 7418
NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.
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.
Pressing the Emergency Stop Button may cause

unburned gas to remain in the air inlet and in the
exhaust manifold.
g01255876
Illustration 32
Unburned gas in the air inlet and exhaust system (1) Emergency stop button on the engine monitoring system
may ignite when the engine is started. Personal
injury and/or property damage may result. Emergency stop button (1) is in the OUT position
for normal engine operation. Push the button for
Before starting an engine that may contain un- emergency stopping. This shuts off both the fuel
burned gas, purge the unburned gas from the air and the ignition. The engine will not start when the
inlet and exhaust system. Refer to the topic on button is locked. To reset the button, turn the button
purging unburned gas in the “Starting the Engine” clockwise. The spring-loaded button will return to the
section. OUT position.
NOTICE
Do not use this method to stop the engine unless
an emergency has occurred. Continuous emergency
shutdowns can cause damage to some engine com-
ponents. This will leave unburned fuels in the combus-
tion chambers and in the exhaust system. If an emer-
gency shutdown occurs, purge the system by cranking
the engine for 5 to 10 seconds with the ignition shutoff.
The control panel must also be reset before the

engine will start. To reset the control panel, turn
engine control switch (2) to the “OFF/RESET”
position.
40 SEBU8099-01
Operation Section
Engine Stopping
i02508903 c. If the engine control switch is in the “AUTO”

position, open the remote start/stop initiate
Manual Stop Procedure contact. If the cooldown feature is utilized, the
engine will operate for a programmed period of
SMCS Code: 1000; 7418 time before the engine stops. Otherwise, the
engine will immediately shut off.
NOTICE
Stopping the engine immediately after the engine has The engine will coast to a stop. Ensure that any
been operating under a load can result in overheating system that provides external support to the engine
and accelerated wear of the engine components. is secured after the engine is stopped.
Allow the engine to gradually cool before stopping the

i02508920
engine.
After Stopping Engine
Note: Remove the load at a rate that will avoid
detonation. SMCS Code: 1000
1. Disengage the driven equipment. • Check the engine crankcase oil level. Maintain
the oil level between the “ADD” and “FULL” marks
a. For generator set engines, open the main on the “ENGINE STOPPED” side of the oil level
circuit breaker. gauge.
b. For industrial engines, unload the compressor • If necessary, perform minor adjustments. Repair
or pump. Disengage the clutch (if equipped). any leaks and tighten loose bolts.
Place the transmission and/or other
attachments for the power take-off in • Note the service hour reading. Perform the
NEUTRAL. maintenance that is scheduled in this Operation
and Maintenance Manual, “Maintenance Interval
Note: Extended idling can cause excessive oil Schedule” (Maintenance Section).
consumption and related problems. See this
Operation and Maintenance Manual, “Engine NOTICE
Operation” topic (Operation Section). Only use antifreeze/coolant mixtures recommended in
the Refill Capacities and Recommendations section of
2. Reduce the engine rpm to low idle. this manual. Failure to do so can cause engine dam-
age.
Note: If the cooldown feature is not utilized, operate
the engine at low idle rpm for a cooldown period
before stopping the engine. If the engine has been • Allow the engine to cool. Check the coolant level.
operated at a low load, operate the engine at low idle
for approximately 30 seconds before stopping the • If freezing temperatures are expected, check the
engine. If the engine has been operated at a high coolant for protection against freezing. The cooling
load, operate the engine at low idle for one minute system must be protected against freezing to the
before stopping the engine. lowest expected outside temperature. Add the
proper coolant/water mixture, if necessary.
3. Use one of the following methods in order to stop
the engine: • Perform all required periodic maintenance on all
driven equipment. Refer to the instructions that are
a. Turn the engine control switch to the provided by the OEM of the driven equipment.
“COOLDOWN/STOP” position. If the cooldown
feature is utilized, the engine will operate for a
programmed period of time before the engine
stops. Otherwise, the engine will immediately
shut off.
b. Turn the engine control switch to the

“OFF/RESET” position. The engine will
immediately shut off.
SEBU8099-01 41
Maintenance Section
Refill Capacities
Maintenance Section Table 9

Lubrication System
Approximate Refill Capacities
Refill Capacities Engine Liters US Gallons

G3508 231 61
i02508971 G3512 338 89
Refill Capacities and G3516 423 112
Recommendations
Auxiliary Oil Filters
SMCS Code: 1348; 1395; 7560
Table 10
Lubrication System Approximate Capacities for Auxiliary Oil Filters

Capacity
Auxiliary Oil Filter Capacity With
Lubricant Recommendations System Elements
Without
Elements(1)
Due to significant variations in the quality and in 117-9550 Oil Filter 132 L 176 L
the performance of commercially available oils, Assembly(2) (35 US gal) (46.5 US gal)
Caterpillar makes the following recommendations:
1118-8419 Oil 132 L 176 L
Filter Assembly(3) (35 US gal) (46.5 US gal)
• Cat NGEO (Natural Gas Engine Oil)
119-2104 Oil Filter 178 L 244 L
• Cat NGEO EL350 (Natural Gas Engine Oil) Assembly(4) (47 US gal) (64 US gal)
(1) Auxiliary oil filter systems increase the oil capacity in order
The proper SAE viscosity grade of oil is determined to increase the service life of the oil. Caterpillar recommends
by the minimum ambient temperature during operation without the auxiliary oil filter elements.
cold engine start-up, and the maximum ambient (2) This assembly contains 14 elements. This assembly is for use
temperature during engine operation. To determine with G3508 Engines.
(3) This assembly contains 14 elements. This assembly is for use
the oil viscosity that is required for starting a cold
with G3512 Engines.
soaked engine, refer to the minimum temperature in (4) This assembly contains 21 elements. This assembly is for use
Table 8. To select the oil viscosity for operation at with G3516 Engines.
the highest anticipated ambient temperature, refer
to the maximum temperature in the Table. Use the
highest oil viscosity that is available in order to meet Fuel
the required temperature during start-up.
Fuel Recommendations
Table 8
Engine Oil Viscosity Caterpillar gas engines will operate successfully on
a broad range of gaseous fuels. Pipeline natural
Cat NGEO Ambient Temperature gas has been used for many years. Commercial
Grade of fuel gases are mixtures of gases. These fuels
Viscosity Minimum Maximum
consist primarily of hydrocarbons (combinations of
SAE 30(1) 0 °C (32 °F) 40 °C (104 °F) hydrogen and carbon) and some inert gases. The
compositions of these gas mixtures have extreme
SAE 40(1) 5 °C (41 °F) 50 °C (122 °F) variations. Fuels such as wellhead gas, bio-gas,
(1) Cat NGEO is available in these grades only. Multigrade oils are and manufactured gas need to be reviewed for
NOT recommended for use in Caterpillar Gas Engines. If other acceptability. Analyze the fuel in order to determine
grades of viscosity are selected, ensure that the oil meets the
requirements for Caterpillar Gas Engines.
the following characteristics:
For further information about oils, see Special • Composition

Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”. • Contaminants
• Heat value
Lubricant Capacities
• Methane number
The capacity of the engine crankcase includes the
capacity of the oil filters that are installed at the • Specific gravity
factory.
42 SEBU8099-01
Maintenance Section
Refill Capacities
Field gas can have varying characteristics of Table 11

combustion. Field gas can contain numerous Caterpillar Minimum Acceptable Water Requirements
harmful impurities. The impurities can alter the BTU
content. The impurities can also alter the methane Property Maximum Limit ASTM Test
number. The impurities include everything from 40 mg/L “D512”,
water up to complex hydrocarbons that can lead to Chloride (Cl)
(2.4 grains per US gal) “D4327”
detonation and severe engine damage. To minimize
these effects, Caterpillar recommends the following 100 mg/L
Sulfate (SO4) “D516”
guidelines: (5.9 grains per US gal)
170 mg/L
1. Evaluate the fuel with the Caterpillar Methane Total Hardness “D1126”
(10 grains per US gal)
Number Program, LEKQ6378. Methane values
below 30 are not recommended for use in a 340 mg/L
Total Solids “D1888”
Caterpillar engine. Fuels with a methane number (20 grains per US gal)
that is below 30 must first be processed in order to Acidity pH of 5.5 to 9.0 “D1293”
remove harmful impurities in the fuel and raising
the methane number into the acceptable range.
NOTICE
2. If necessary, use an engine that is configured Use of water that does not meet the recommendations
for a fuel that has a high energy. Consult the for the cooling system will damage the cooling system.
appropriate manual for the engine in order to
determine the recommended engine timing. Do not use these types of water in the cooling system:
sea water, softened water that has been conditioned
3. Reduce the oil change interval according to the with salt, hard water, and tap water.
results of the oil analysis.
Only use water that meets the recommendations for
For further information on fuels, see Special the cooling system.
Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”. If you are not sure about the properties of your water,
consult one of the following sources for a water
Cooling System analysis:
Coolant Recommendations • Caterpillar dealer
During shipping and storage, the engine must be • Local water utility company
protected from damage that can be caused by
freezing of the cooling system. If the engine is • Agricultural agent
shipped to a site with freezing temperatures and/or
if the engine is stored in a location with freezing • Independent laboratory
temperatures, the cooling system must contain
antifreeze that will withstand the lowest ambient Glycol
temperature. Frequently check the concentration
of glycol in the coolant/antifreeze. Make sure that NOTICE
the concentration is adequate in order to prevent Do not use Extended Life Coolant (ELC) with
freezing. Otherwise, the cooling system must be Caterpillar Gas Engines.
completely drained.
ELC was not formulated for use in Caterpillar Gas En-
Coolant/antifreeze is normally composed of three gines.
elements: water, glycol, and additives. Each element
must meet specific guidelines. Use only the coolant/antifreeze that is recommended.
Water
Preferred – Cat NGEC (Natural Gas Engine
Deionized water or distilled water is Coolant)
recommended for use in engine cooling systems.
If distilled water or deionized water is not available, Alternatively, use Cat DEAC (Diesel Engine
use water with the properties that are listed in Table Antifreeze/Coolant) or a commercial heavy-duty
11. coolant/antifreeze that meets “ASTM D6210” or
“ASTM D4985” specifications.
SEBU8099-01 43
Maintenance Section
Refill Capacities
Note: A 50/50 concentration of Cat NGEC or of

NOTICE Cat DEAC does not require a treatment with
Do not use a commercial coolant/antifreeze that only an SCA at the initial fill. Commercial heavy-duty
meets the ASTM “D3306” specification. This type of coolant/antifreeze that meets “ASTM D6210”
coolant/antifreeze is made for light duty automotive or “ASTM D4985” specifications may require a
applications. treatment with an SCA at the initial fill. Read the label
or the instructions that are provided by the OEM of
Use only the coolant/antifreeze that is recommended. the product.
To ensure that the correct amount of SCA is in the

Acceptable – In applications that do not require cooling system, the concentration of SCA must be
protection from boiling or from freezing, a mixture of tested on a scheduled basis. Obtain an S·O·S coolant
Cat SCA and water that meets the properties that are analysis (Level 1) or use a test kit to check the
listed in Table 11 is acceptable. concentration of the SCA according to this Operation
and Maintenance Manual, “Maintenance Interval
Note: The preferred coolant/antifreeze and the Schedule”.
acceptable mixture of SCA and water require
different concentrations of SCA. Refer to the Special For further information on coolant, see Special
Publication, SEBU6400, “Caterpillar Gas Engine Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”, Lubricant, Fuel, and Coolant Recommendations”.
“Supplemental Coolant Additive (SCA)” topic.
Table 12 is a list of the coolant/antifreeze that is

Coolant Capacities
recommended for Caterpillar Gas Engines. The
To properly maintain the cooling system, the Total
service life of the coolant/antifreeze that is used in
Cooling System capacity must be determined. The
Caterpillar Gas Engines is also listed. To achieve
Total Cooling System capacity will vary between
this service life, the coolants must be properly
individual installations. The Total Cooling System
maintained. The maintenance program includes
capacity equals the capacity of the Jacket Water
S·O·S coolant analysis.
Circuit plus the Aftercooler Circuit plus the External
Table 12 System capacity. The External System capacity
includes the following components: expansion tank,
Recommended Coolant/Antifreeze and Service heat exchanger, radiator, and piping. Refer to the
Life of the Coolant/Antifreeze specifications that are provided by Caterpillar or by
Coolant/Antifreeze Service Life (1) the OEM of the equipment. Record the Total Cooling
System capacity in the following Table:
Cat NGEC
Three Years Table 13
Cat DEAC
Cooling System
Commercial Heavy-Duty
Approximate Refill Capacities
Coolant/Antifreeze that Two Years
meets “ASTM D6210” System G3508 G3512 G3516
Commercial Heavy-Duty Jacket 114 L 148 L 205 L
Coolant/Antifreeze that One Year Water 30 US gal 39 US gal 53 US gal
meets “ASTM D4985” Circuit
Cat SCA and Water Two Years Aftercooler 13 L 15 L 16.5 L
Circuit 3.5 US gal 4 US gal 4.5 US gal
Commercial SCA and
One Year
Water External
(1) The service life of coolant is also limited by use (service hours).
System
Refer to the specific engine’s Operation and Maintenance Total
Manual, “Maintenance Interval Schedule”.
Cooling
System
Additives
Preferred – Cat Supplemental Coolant Additive

(SCA)
Acceptable – A commercial SCA that provides

1200 mg/L (70 grains per US gal) or 1200 ppm of
nitrites in the final mixture of coolant/antifreeze
44 SEBU8099-01
Maintenance Section
Maintenance Recommendations
Maintenance • knowledgeable visual examination of the

equipment
Recommendations
• the application of electrical tests
i01135057 Never perform a test over the rated potential. These
General Maintenance tests can damage insulation that is contaminated
or insulation that is in marginal condition. For more
Information information, refer to “I.E.E.E. Standard 432-1992” or
consult a Caterpillar dealer.
SMCS Code: 4450; 7000
Note: Read the warnings and read the instructions

Space Heaters
that are contained in the Safety Section of this
The SR4B generator is capable of operating in high
manual. These warnings and instructions must be
humidity conditions without problems. However,
understood before you perform any operation or any
problems can occur when the generator is idle and
maintenance procedures.
the surrounding air is warmer than the generator.
Moisture can form on the windings that will result in
Rotating electric machines are complex structures
poor performance from the windings. Moisture can
that are exposed to the following forms of stress:
also result in damage to the windings. Whenever the
generator is not active, ensure that the space heaters
• mechanical are in operation.
• electrical Whenever the generator is operating, ensure that the
space heaters are disconnected.
• thermal
An external source of either 115 VAC or 230 VAC is
• environmental required to operate the space heaters.
These stresses may be of varying magnitudes. The
insulation systems are very susceptible to damage
that is caused by the stresses that are listed above.
Exposure to these stresses may shorten the effective
life of the insulation system. Therefore, the service
life of an electric machine will largely depend on the
serviceability of the insulation systems. An inspection
program and a testing procedure are recommended.
An inspection program and a testing procedure
will ensure that the equipment is maintained in
satisfactory condition. This will increase field
reliability.
A regular maintenance and inspection program can

provide an evaluation of the present condition of Illustration 33
g00556903
the equipment. A regular maintenance program
Space heater connection to external source (H1), (H2), (H3), and
and a regular inspection program can also reveal (H4) terminals.
future problems. The frequency of this maintenance
program will depend on the following factors: If a 115 VAC source is available, connect both
heaters in parallel across the source. If a 230 VAC
• application source is available, connect both heaters in series
across the source. Refer to Illustration 33.
• environmental conditions
• operator’s experience
• operator’s philosophy
A regular maintenance program is strongly
recommended. This program would involve the
following steps:
• periodic disassembly
SEBU8099-01 45
Maintenance Section
Maintenance Interval Schedule
i02471479 Valve Stem Projection - Measure/Record ............. 84

Maintenance Interval Schedule Every 1000 Service Hours
(Standard) Alternator - Inspect ............................................... 48
Belts - Inspect/Adjust/Replace .............................. 49
SMCS Code: 1000; 4450; 7500
Crankshaft Vibration Damper - Inspect ................. 56
Ensure that all safety information, warnings and Engine Crankcase Breather - Clean ..................... 60
Engine Oil - Change ............................................. 62
instructions are read and understood before any
Engine Oil Filter - Change .................................... 63
operation or any maintenance procedures are
performed. Engine Valve Lash and Bridge - Adjust ................ 68
Gas Pressure Regulator Condensation - Drain .... 69
Hoses and Clamps - Inspect/Replace .................. 70
The user is responsible for the performance of
maintenance, including all adjustments, the use of Ignition System Spark Plugs - Inspect/Adjust/
Replace ............................................................... 71
proper lubricants, fluids, filters, and the replacement
Ignition System Timing - Check/Adjust ................. 74
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and Inlet Air System - Inspect ...................................... 74
Radiator - Clean .................................................... 82
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Every 1000 Service Hours or 6 Weeks
Use mileage, fuel consumption, service hours, or Aftercooler Condensation - Drain ......................... 46
calendar time, WHICHEVER OCCURS FIRST,
in order to determine the maintenance intervals.
Every 2000 Service Hours
Products that operate in severe operating conditions
may require more frequent maintenance. Actuator Control Linkage - Lubricate .................... 46
Cooling System Coolant Sample (Level 2) -
Note: Before each consecutive interval is performed, Obtain ................................................................. 54
all maintenance from the previous interval must be Engine Speed/Timing Sensor - Clean/Inspect ...... 67
performed.
When Required
Air Starting Motor Lubricator Bowl - Clean ........... 46
Engine Air Cleaner Element - Replace ................. 57 Crankcase Blowby - Measure/Record .................. 55
Engine Oil Filter - Change .................................... 63 Cylinder Pressure - Measure/Record ................... 56
Overhaul Considerations ...................................... 80 Engine Mounts - Check ........................................ 61
Throttle Control Valve - Check .............................. 83 Engine Protective Devices - Check ...................... 67
Valve Stem Projection - Measure/Record ............. 84 Exhaust Bypass - Inspect ..................................... 69
Starting Motor - Inspect ........................................ 82
Daily Water Pump - Inspect ........................................... 87
Air Starting Motor Lubricator Oil Level - Check .... 47
Air Tank Moisture and Sediment - Drain ............... 48
Cooling System Coolant Level - Check ................ 52 Turbocharger - Inspect .......................................... 83
Engine Air Cleaner Service Indicator - Inspect ..... 59 Water Temperature Regulator - Replace .............. 87
Engine Oil Level - Check ...................................... 65
Fuel System Fuel Filter Differential Pressure - Between 9000 and 16 000 Service Hours
Check .................................................................. 69
Walk-Around Inspection ........................................ 86 Overhaul (Top End) ............................................... 77
Every 250 Service Hours Every 24 000 Service Hours or 3 Years

Battery Electrolyte Level - Check .......................... 48 Cooling System Coolant (NGEC) - Change .......... 50
Obtain ................................................................. 53 Between 27 000 and 48 000 Service Hours
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 54 Overhaul (In-Frame) ............................................. 75
Engine Oil Sample - Obtain .................................. 66
Between 45 000 and 80 000 Service Hours
Initial 1000 Service Hours
Overhaul (Major) ................................................... 76
Engine Mounts - Check ........................................ 61
Engine Speed/Timing Sensor - Clean/Inspect ...... 67
46 SEBU8099-01
Maintenance Section
Actuator Control Linkage - Lubricate
i02509394 Check the Linkage

Actuator Control Linkage - Check the linkage for proper operation. Adjust
Lubricate the linkage, if necessary. For the adjustment
procedure, refer to the Service Manual, “Systems
SMCS Code: 1265-086 Operation/Testing and Adjusting” module.
i01516337
Aftercooler Condensation -
Drain
SMCS Code: 1063
The aftercooler cools the compressed air/fuel mixture

from the turbocharger. Coolant passes through the
tubes in the aftercooler core. The air/fuel mixture
that is compressed and warmed by the turbocharger
compressor is directed through the aftercooler core.
The air/fuel mixture is cooled in the aftercooler.
Condensation can form in the housing of the

aftercooler. A drain plug is provided for draining the
condensation.
Note: An automatic drain is available for use with

g01256141 32 °C (90 °F) separate circuit aftercoolers. Consult
Illustration 34
your Caterpillar dealer for details.
Throttle linkage
g00786820
Illustration 36
(1) Plug
Remove plug (1). Drain the moisture into a suitable

container. Install the plug.
g01256143 i02344769
Illustration 35
Air/fuel ratio control linkage Air Starting Motor Lubricator
If the fittings have a protective cover, pull the cover Bowl - Clean
out of the way. Apply grease to the grease fittings.
Use a hand grease gun and lubricate the grease SMCS Code: 1451-070
fittings with MPGM.
If the engine is equipped with an air starting motor,
use the following procedure:
SEBU8099-01 47
Maintenance Section
Air Starting Motor Lubricator Oil Level - Check
5. Dry the bowl. Inspect the bowl for cracks. If the

bowl is cracked, replace the damaged bowl with
a new bowl. Inspect the gasket. If the gasket is
Personal injury can result from removing hoses or
damaged, replace the gasket.
fittings in a pressure system.
6. Install the bowl.
Failure to relieve pressure can cause personal in-
jury.
7. Make sure that drain valve (3) is closed.
Do not disconnect or remove hoses or fittings un-
8. For instructions on filling the lubricator, see this
til all pressure in the system has been relieved.
Operation and Maintenance Manual, “Air Starting
Motor Lubricator Oil Level - Check” topic.
1. Ensure that the air supply to the lubricator is OFF.
i02213914
Air Starting Motor Lubricator

Oil Level - Check
SMCS Code: 1451-535
NOTICE
Never allow the lubricator bowl to become empty. The
air starting motor will be damaged by a lack of lubrica-
tion. Ensure that sufficient oil is in the lubricator bowl.
g00745554
Illustration 37
(1) Filler plug
(2) Bowl
(3) Drain valve
2. Slowly loosen filler plug (1) in order to release the

pressure from the lubricator.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- g00745561
Illustration 38
ing any compartment or disassembling any compo-
nent containing fluids. 1. Observe the oil level in sight gauge (3). If the oil
level is less than 1/2, add oil to the lubricator bowl.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Personal injury can result from removing hoses or
Dispose of all fluids according to local regulations and fittings in a pressure system.
mandates.
Failure to relieve pressure can cause personal in-
jury.
3. Place a suitable container under bowl (2) and
open drain valve (3) in order to drain the oil from Do not disconnect or remove hoses or fittings un-
the bowl. til all pressure in the system has been relieved.
4. Remove bowl (2). Clean the bowl with warm water.
2. Ensure that the air supply to the lubricator is OFF.
Slowly loosen filler plug (4) in order to release
pressure from the lubricator bowl.
48 SEBU8099-01
Maintenance Section
Air Tank Moisture and Sediment - Drain
3. Remove filler plug (4). Pour oil into the lubricator 1. Open the drain valve that is on the bottom of the
bowl. Use nondetergent SAE 10W oil for air tank. Allow the moisture and sediment to drain.
temperatures that are greater than 0 °C (32 °F).
Use air tool oil for temperatures that are below 2. Close the drain valve.
0 °C (32 °F).
i02084374
4. Install filler plug (4).
Alternator - Inspect
Adjust the Lubricator
SMCS Code: 1405-040
Note: Adjust the lubricator with a constant rate of air
flow. After the adjustment, the lubricator will release Inspect the alternator for the following conditions:
oil in proportion to variations of the air flow.
• Proper connections
1. Ensure that the fuel supply to the engine is OFF.
• Clean ports for cooling airflow
NOTICE
Do not crank the engine continuously for more than • Proper charging of the battery
30 seconds. Allow the starting motor to cool for two
Observe the ammeter during engine operation in
minutes before cranking the engine again.
order to ensure proper battery performance and/or
proper performance of the electrical system.
2. Operate the air starting motor. Observe the drops
of oil that are released in dome (1). Make repairs, if necessary. See the Service Manual
for service procedures. Consult your Caterpillar
Note: Some lubricators have an adjustment screw dealer for assistance.
rather than a knob.
i02340858
3. If necessary, adjust the lubricator in order
to release from one to three drops of oil per Battery Electrolyte Level -
second. To increase the rate, turn knob (2)
counterclockwise. To decrease the rate, turn the Check
knob clockwise.
SMCS Code: 1401-535-FLV
i00351324 When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
Air Tank Moisture and may not fully recharge. Ensure a full charge in order
Sediment - Drain to help prevent the battery from freezing. If batteries
are properly charged, ammeter reading should be
SMCS Code: 1466-543-M&S very near zero, when the engine is in operation.
Moisture and sediment in the air starting system can

cause the following conditions:
All lead-acid batteries contain sulfuric acid which
• Freezing can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
• Corrosion of internal parts near batteries.
• Malfunction of the air starting system
1. Remove the filler caps. Maintain the electrolyte
level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled

When opening the drain valve, wear protective water. If distilled water is not available use clean
gloves, a protective face shield, protective cloth- water that is low in minerals. Do not use artificially
ing, and protective shoes. Pressurized air could softened water.
cause debris to be blown and result in personal
injury. 2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
SEBU8099-01 49
Maintenance Section
Belts - Inspect/Adjust/Replace
3. Keep the batteries clean. Adjusting the Alternator Belt

Clean the battery case with one of the following
cleaning solutions:
• A mixture of 0.1 kg (0.2 lb) of baking soda and

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

(1 qt) of clean water
Thoroughly rinse the battery case with clean water.
Use a fine grade of sandpaper to clean the

terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
i02509091
g01092641
Illustration 39
Belts - Inspect/Adjust/Replace Typical alternator
(1) Mounting bolt
SMCS Code: 1357-025; 1357-040; 1357-510 (2) Adjusting nuts
(3) Mounting bolt
Inspection
1. Remove the drive belt guard.
Inspect the alternator belt and the fan drive belts for
wear and for cracking. Replace the belts if the belts 2. Loosen mounting bolt (1), adjusting nuts (2) and
are not in good condition. mounting bolt (3).
Check the belt tension according to the information in 3. Turn adjusting nuts (2) in order to increase or
the Service Manual, “Specifications”. decrease the drive belt tension.
Slippage of loose belts can reduce the efficiency 4. Tighten adjusting nuts (2). Tighten mounting bolt
of the driven components. Vibration of loose belts (3). Tighten mounting bolt (1). For the proper
can cause unnecessary wear on the following torque, see the Service Manual, “Specifications”
components: module.
• Belts 5. Reinstall the drive belt guard.
• Pulleys If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation at
• Bearings the rated rpm.
If the belts are too tight, unnecessary stress is placed Adjusting the Fan Drive Belt
on the components. This reduces the service life of
the components. 1. Loosen the mounting bolt for the pulley.
2. Loosen the adjusting nut for the pulley.
3. Move the pulley in order to adjust the belt tension.
4. Tighten the adjusting nut.
5. Tighten the mounting bolt.

50 SEBU8099-01
Maintenance Section
Cooling System Coolant (NGEC) - Change
Replacement
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.
i02209116
Cooling System Coolant

(NGEC) - Change
g00786868
SMCS Code: 1350-044 Illustration 40
Locations of the drain plugs
Clean the cooling system before the recommended (1) Jacket water pump
maintenance interval if the following conditions exist: (2) Cylinder block
(3) Auxiliary water pump
• The engine overheats frequently.
3. Open the cooling system drain valves (if
• Foaming is observed. equipped). If the cooling system is not equipped
with drain valves, remove drain plugs (1), (2), and
• Engine oil has entered the cooling system and the (3). Drain all of the cooling system components:
coolant is contaminated.
• Expansion tank or radiator
NOTICE
Use of commercially available cooling system clean- • Water pumps
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap- • Aftercooler
proved for Caterpillar engines.
• Thermostatic valve
Drain the Cooling System • Engine block
1. Stop the engine and allow the engine to cool. • All coolant lines
Ensure that the engine will not start when the
4. Inspect the cooling system lines that run from the
cooling system is drained.
engine to the expansion tank. Ensure that the
lines maintain a constant upward slope from the
2. Loosen the cooling system filler cap slowly in
engine to the tank.
order to relieve any pressure. Remove the cooling
system filler cap.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the

recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tools:
Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
SEBU8099-01 51
Maintenance Section
Cooling System Coolant (NGEC) - Change
Clean the Cooling System

NOTICE
1. After the cooling system has been drained, flush Improper or incomplete rinsing of the cooling system
the cooling system with clean water in order to can result in damage to copper and other metal com-
remove any debris. ponents.
2. Close the cooling system drain valves (if To avoid damage to the cooling system, make sure
equipped). Clean the drain plugs and install the to completely flush the cooling system with clear wa-
drain plugs. ter. Continue to flush the system until all signs of the
cleaning agent are gone.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) Note: The cleaner has a smell of ammonia. Continue
per minute to avoid air locks. to flush the cooling system until the smell is gone.
7. Allow the water to drain. Flush the cooling system

NOTICE
with clean water until the water that drains is
If the aftercooler circuit has been drained, the vent
clean. Close the cooling system drain valves (if
plug must be opened to allow the aftercooler to fill
equipped). Clean the drain plugs and install the
properly. Failure to do this will cause an air lock re-
drain plugs.
sulting in engine damage.
Cleaning a Cooling System that

has Heavy Deposits or Plugging
Note: For the following procedure to be effective,
there must be an active flow through the cooling
system components.
1. After the cooling system has been drained, flush

the cooling system with clean water in order to
remove any debris.
2. Close the cooling system drain valves (if

equipped). Clean drain plugs and install drain
plugs (1), (2), and (3). See Illustration 40.
g00786870
Illustration 41
Vent plug NOTICE
The vent line of the ebullient cooled engine will be installed by Fill the cooling system no faster than 19 L (5 US gal)
the customer. per minute to avoid air locks.
If a customer has not installed the vent lines, loosen the vent
cap from the tee.
NOTICE
3. Remove vent plug (4) for the aftercooler. If the aftercooler circuit has been drained, the vent
plug must be opened to allow the aftercooler to fill
4. Fill the cooling system with a mixture of clean properly. Failure to do this will cause an air lock re-
water and Caterpillar Fast Acting Cooling System sulting in engine damage.
Cleaner. Add .5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap. Install vent plug (4). 3. Remove vent plug (4) for the aftercooler. See
Illustration 41.
5. Start the engine. Operate the engine for a
minimum of 30 minutes with a coolant temperature 4. Fill the cooling system with a mixture of clean
of at least 82 °C (180 °F). water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 7.5 L
6. Stop the engine and allow the engine to cool. (2 US gal) of the cooling system capacity. Install
Loosen the cooling system filler cap slowly in the cooling system filler cap. Install vent plug (4).
system filler cap. Open the cooling system drain 5. Start the engine. Operate the engine for a
valves (if equipped) or remove drain plugs (1), (2), minimum of 90 minutes with a coolant temperature
and (3). See Illustration 40. of at least 82 °C (180 °F).
52 SEBU8099-01
Maintenance Section
Cooling System Coolant Level - Check
6. Stop the engine and allow the engine to cool. 5. Clean the cooling system filler cap. Inspect the
Loosen the cooling system filler cap slowly in gaskets of the cooling system filler cap. If the
order to relieve any pressure. Remove the cooling gaskets of the cooling system filler cap are
system filler cap. Open the cooling system drain damaged, discard the old cooling system filler cap
valves (if equipped) or remove drain plugs (1), and install a new cooling system filler cap. If the
(2), and (3). See Illustration 40. Allow the water gaskets of the cooling system filler cap are not
to drain. damaged, use a 9S-8140 Pressurizing Pump in
order to pressure test the cooling system filler cap.
NOTICE The correct pressure is stamped on the face of
Improper or incomplete rinsing of the cooling system the cooling system filler cap. If the cooling system
can result in damage to copper and other metal com- filler cap does not maintain the correct pressure,
ponents. install a new cooling system filler cap.
To avoid damage to the cooling system, make sure 6. Start the engine. Inspect the cooling system for
to completely flush the cooling system with clear wa- leaks and for proper operating temperature.
ter. Continue to flush the system until all signs of the
cleaning agent are gone. i02017615
Note: The cleaner has a smell of ammonia. Continue

Cooling System Coolant Level
to flush the cooling system until the smell is gone. - Check
7. Flush the cooling system with clean water until SMCS Code: 1350-535-FLV
the water that drains is clean. Close the cooling
system drain valves (if equipped). Clean the drain
plugs and install the drain plugs.
Climbing equipment may be required to access
Fill the Cooling System this service point. Refer to the Operation and
Maintenance Manual, “Mounting and Dismount-
NOTICE ing” topic for safety information.
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks. NOTICE
Overfilling the overflow tank (if equipped) will result in
Note: For information about the proper coolant to damage to the cooling system.
use, and for the capacity of the cooling system,
see this Operation and Maintenance Manual, “Refill If the cooling system has an overflow tank, maintain
Capacities and Recommendations” (Maintenance the coolant level in the tank below 1/2 full in order to
Section). avoid damage to the cooling system.
1. Remove vent plug (4) for the aftercooler. See

Illustration 41.
2. Fill the cooling system with coolant/antifreeze.

Install vent plug (4). Do not install the cooling
system filler cap.
3. Start the engine. Operate the engine in order to

purge the air from the cavities of the engine block.
Allow the coolant to warm and allow the coolant
level to stabilize. Stop the engine.
4. 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 g00760290
Illustration 42
coolant within 13 mm (.5 inch) below the bottom of Normal position of the coolant in the sight gauge during rated
the filler pipe. operation
SEBU8099-01 53
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
Observe the coolant level in the sight gauge (if For conventional heavy-duty coolant/antifreeze,
equipped). When the engine is running at normal check the concentration of supplemental coolant
operating temperature, the coolant should be in the additive (SCA) regularly. The concentration of SCA
upper half of the sight gauge. If the coolant level is can be checked with an S·O·S coolant analysis
low, add the proper coolant mixture. (Level 1).
Add Coolant Obtain the sample of the coolant as close as possible

to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you
Note: For the proper coolant mixture to use, see
this Operation and Maintenance Manual, “Refill must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
Capacities and Recommendations” topic.
consistent samplings that are evenly spaced.
1. Stop the engine. Allow the engine to cool. Supplies for collecting samples can be obtained from
your Caterpillar dealer.
2. Remove the cooling system filler cap slowly in
order to relieve any pressure. Pour the proper Use the following guidelines for proper sampling of
the coolant:
coolant mixture into the filler pipe.
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
• Keep the unused sampling bottles stored in plastic
bags.
• Keep the lids on empty sampling bottles until you

are ready to collect the sample.
• Complete the information on the label for the

sampling bottle before you begin to take the
samples.
Illustration 43
g00103639 • Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
Filler cap gaskets
from any other location.
3. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the • In order to avoid contamination, immediately place
the sample in the tube that is provided for mailing.
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
Submit the sample for Level 1 analysis.
cap. Install the cooling system filler cap.
Note: Level 1 results may indicate a need for
4. Start the engine. Inspect the cooling system for
Level 2 Analysis.
leaks.
For additional information about coolant analysis,
i02064894 see the Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel and Coolant
Cooling System Coolant Recommendations” or consult your Caterpillar dealer.
Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
54 SEBU8099-01
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
i02168823 Test the Concentration of the SCA

Cooling System Coolant Coolant/Antifreeze and SCA
Sample (Level 2) - Obtain
NOTICE
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 Do not exceed the recommended six percent supple-
mental coolant additive concentration.
NOTICE
Always use a designated pump for oil sampling, and Test the concentration of the SCA with the 8T-5296
use a separate designated pump for coolant sampling. Coolant Conditioner Test Kit. Follow the instructions
Using the same pump for both types of samples may that are provided in the kit.
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both Water and SCA
NOTICE
Do not exceed the recommended eight percent sup-
Obtain the sample of the coolant as close as possible plemental coolant additive concentration.
to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Caterpillar dealer. Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Use the instructions
Refer to this Operation and Maintenance Manual, that follow:
“Cooling System Coolant Sample (Level 1) - Obtain”
(Maintenance Section) for the guidelines for proper 1. Fill the syringe to the “1.0 ml” mark with the
sampling of the coolant. coolant.
Submit the sample for Level 2 analysis. 2. Dispense the 1.0 mL coolant sample from the
syringe into the empty mixing bottle.
For additional information about coolant analysis,
see the Special Publication, SEBU6400, “Caterpillar 3. Add tap water to the mixing bottle in order to bring
Gas Engine Lubricant, Fuel, and Coolant the level up to the “10 ml” mark. Place the cap on
Recommendations” or consult your Caterpillar dealer. the bottle and shake the bottle.
4. Add 2 to 3 drops of the “NITRITE INDICATOR

i02017557
SOLUTION B” to the mixing bottle. Move the bottle
Cooling System Supplemental in a circular motion in order to mix the solution.
Coolant Additive (SCA) - 5. Add 1 drop of “NITRITE TEST SOLUTION A” to

Test/Add the mixing bottle. Move the bottle in a circular
motion in order to mix the solution.
SMCS Code: 1352-045; 1395-081
6. Repeat 5 until the solution changes color from red
to light gray, green, or blue. Record the number of
drops of “NITRITE TEST SOLUTION A” that were
required to cause the color change.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with 7. Use Table 14 to interpret the results.
the skin and eyes. Do not drink cooling system
coolant additive.
Note: Caterpillar recommends an S·O·S coolant

analysis (Level 1).
SEBU8099-01 55
Maintenance Section
Crankcase Blowby - Measure/Record
Table 14 4. Clean the cooling system filler cap. Install the

Number of Concentration Maintenance
cooling system filler cap.
Drops of SCA Required
Less than 25 Less than the Add SCA. i02026805
recommended Retest the
concentration of coolant. Crankcase Blowby -
SCA Measure/Record
25 to 30 The None
recommended SMCS Code: 1317
concentration of
SCA Note: For a G3500 Engine that is rated at 1500
More than 30 More than the Remove the rpm with 1500 service hours, the crankcase
recommended coolant. blowby typically has a range of 259 to 283 L/min
concentration of Replace with (550 to 600 ft3/hr).
SCA water only
Retest the Measure the crankcase blowby of new engines.
coolant. Record the data. Continue to periodically measure
the blowby. Comparing the recorded data to the new
data provides information about the condition of the
Add the SCA, If Necessary engine.
Note: Crankcase blowby is one of the three factors

that help to determine the in-frame overhaul interval.
For more information, see this Operation and
Pressurized System: Hot coolant can cause seri-
Maintenance manual, “Overhaul (In-Frame)” topic
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
After a new engine is used for a short time, the
pressure cap slowly in order to relieve the pres-
blowby can decrease as the piston rings are seated.
sure.
The blowby will gradually increase as the following
components show wear:
1. Remove the cooling system filler cap slowly.
• piston rings
Note: Always dispose of fluids according to local
regulations. • cylinder liners
2. If necessary, drain some coolant in order to allow Note: A problem with the piston rings causes the
space for the addition of the SCA. oil to deteriorate rapidly. Information regarding the
condition of the piston rings can be obtained from
the measurement of the blowby and the results of
NOTICE
oil analysis.
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
The blowby of a worn engine may exceed the blowby
faces of the cooling system, reducing the engine’s
of a new engine by two times or more.
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
A sudden increase in blowby could indicate a broken
high temperature components.
piston ring. The following conditions are other
potential sources of blowby:
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat exchang-
er, overheating, and/or accelerated wear of the water • Worn valve guides
pump seal.
• A turbocharger seal that leaks
Do not exceed the recommended amount of supple-
A rebuilt engine can have a high blowby due to the
mental coolant additive concentration.
following factors:
3. Add the proper amount of SCA. The concentration • The piston rings are not seated properly.
of the SCA depends on the type of coolant that
is used. To determine the proper amount, see • Worn parts such as valve guides were not replaced.
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” topic.
56 SEBU8099-01
Maintenance Section
Crankshaft Vibration Damper - Inspect
Excessive blowby may indicate the need for an Inspect the damper and repair or replace the damper
overhaul. By keeping a record of the results, a for any of the following reasons.
gradual increase in the amount of the blowby will be
noted until the amount has become excessive. • The damper is dented, cracked, or leaking.
To measure the blowby, use the 8T-2700 Blowby/Air • The paint on the damper is discolored from heat.
Flow Indicator. Refer to Special Instruction,
SEHS8712, “Using the 8T-2700 Blowby/Airflow • The engine has had a failure because of a broken
Indicator Group”. The instruction is provided with the crankshaft.
tool.
• An analysis of the oil has revealed that the front
Keep a record of the results. bearing of the crankshaft is badly worn.
For assistance, consult your Caterpillar dealer. • There is a large amount of gear train wear that is
not caused by a lack of oil.
i01949731
Removal and Installation
Crankshaft Vibration Damper
- Inspect Refer to the Service Manual, “Disassembly and
Assembly” or consult your Caterpillar dealer for
information about damper replacement.
SMCS Code: 1205-040
The crankshaft vibration damper limits the torsional i01664707

vibration of the crankshaft. The visconic damper has
a weight that is located inside a fluid filled case. Cylinder Pressure -
Damage to the crankshaft vibration damper or failure
Measure/Record
of the damper can increase torsional vibrations. This SMCS Code: 1223-082-CC; 1223; 7450-082
can result in damage to the crankshaft and to other
engine components. A deteriorating damper can Measure the cylinder pressure of new engines.
cause excessive gear train noise at variable points Record the data. Continue to periodically measure
in the speed range. the cylinder pressure. Comparing the recorded data
to the new data provides information about the
A damper that is hot is due to excessive torsional condition of the engine.
vibration. Monitor the temperature of the damper
during operation. Cylinder pressure can be measured during inspection
of the spark plugs. Use the following guidelines for
The 8T-2821 Temperature Indicator or the 8T-2822 checking the cylinder pressure:
Temperature Indicator are recommended for
monitoring the temperature of the damper. Evenly
space four of the adhesive indicators around the • Remove all of the spark plugs.
outer diameter of the damper.
• Fully open the throttle plate.
Note: If you use an infrared thermometer to monitor
the temperature of the damper, use the thermometer • Minimize the cranking time to 3 or 4 revolutions.
This will enable a maximum consistent cranking
during operation with similar loads and speeds. Keep speed for the check. Also, the battery power will
a record of the data. If the temperature begins to rise, be conserved.
reduce the interval for inspecting the damper.
A loss of cylinder pressure or a change of pressure
If the temperature of the damper reaches 110 °C in one or more cylinders may indicate the following
(230 °F), consult your Caterpillar dealer. conditions. These conditions may indicate a problem
with lubrication:
Inspect the damper for evidence of dents, cracks,
and leaks of the fluid.
• Excessive deposits
If a fluid leak is found, repair the damper or
replace the damper. The fluid in the damper is • Guttering of valves
silicone. Silicone has the following characteristics:
transparent, viscous, smooth, and sticky. • A broken valve
• A piston ring that sticks
SEBU8099-01 57
Maintenance Section
Engine Air Cleaner Element - Replace
• A broken piston ring i01749609
• Worn piston rings Engine Air Cleaner Element -

Replace
• Worn cylinder liners
SMCS Code: 1051-510; 1054-510
If the cylinder pressure has risen by one or more
compression ratios, the engine needs a top end
overhaul in order to remove deposits. Failure to NOTICE
remove the deposits will increase the chance for Never run the engine without an air cleaner element
detonation. Severe guttering of the valves will occur. installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
To measure the cylinder pressure, use the 193-5859 damaged pleats, gaskets or seals. Dirt entering the
Cylinder Pressure Gauge Gp. Follow the procedure engine causes premature wear and damage to engine
in the Special Instruction, NEHS0798 that is included components. Air cleaner elements help to prevent air-
with the gauge group. Record the pressure for borne debris from entering the air inlet.
each cylinder. Use the Operation and Maintenance
Manual, “Valve Data Sheet” (Reference Materials
NOTICE
Section). Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Illustration 44 is a graph of typical cylinder pressures
for engines with different compression ratios.
Servicing the Air Cleaner Elements
If the air cleaner element becomes plugged, the air
pressure can split the filter material of the element.
Unfiltered air will drastically accelerate internal
engine wear. Your Caterpillar dealer has the proper
air cleaner elements for your application.
The air cleaner may be mounted high above the

engine. If necessary, use a ladder or a platform to
reach the air cleaner.
• Check the precleaner (if equipped) daily for

accumulation of dirt and debris. Remove any dirt
and debris, as needed.
• Operating conditions (dust, dirt and debris) may

require more frequent service of the air cleaner
element.
• The air cleaner element may be cleaned up to

six times if the element is properly cleaned and
inspected.
• The air cleaner element should be replaced at least

one time per year. This replacement should be
performed regardless of the number of cleanings.
g00828960
Illustration 44
Replace the dirty paper elements with clean
(Y) Cylinder pressure in kPa elements. Before installation, thoroughly inspect the
(X) Compression ratio
(1) Normal range for cylinder pressure
element for tears and/or holes in the filter material.
Inspect the gasket or the seal of the element for
damage. Maintain a supply of suitable elements for
replacement purposes.
58 SEBU8099-01
Maintenance Section
Engine Air Cleaner Element - Replace
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.
NOTICE
g00317608
Illustration 45 Do not clean the air cleaner elements by bumping or
Fasteners for the air cleaner cover tapping. This could damage the seals. Do not use el-
ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the elements before cleaning. Inspect

the elements for damage to the seal, the gaskets,
and the outer cover. Discard any damaged elements.
Air cleaner elements can be cleaned with pressurized

air and with a vacuum.
Pressurized Air
Pressurized air can be used to clean elements
g00781084
Illustration 46 that have not been cleaned more than two times.
(1) Cover Pressurized air will not remove deposits of carbon
(2) Element and oil. Use filtered, dry air with a maximum pressure
(3) Air inlet of 207 kPa (30 psi).
1. Release the fasteners for cover (1).
2. Remove the cover and element (2).
3. Cover air inlet (3) with tape in order to keep dirt

out.
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.

g00281692
Illustration 47
7. If necessary, reset the air cleaner service indicator.
Note: When the elements are cleaned, always begin
with the clean side (inside) in order to force dirt
particles toward the dirty side (outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
of air directly at the primary air cleaner element. Dirt
could be forced into the pleats.
SEBU8099-01 59
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
elements which require daily cleaning because of a
dry, dusty environment. Cleaning with pressurized air
is recommended prior to vacuum cleaning. Vacuum
cleaning will not remove deposits of carbon and oil.
Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.
Inspecting the Primary Air Cleaner Illustration 49

g00281694
Elements
Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. Restricted air flow
may result. To protect against dirt and damage, wrap
the elements in Volatile Corrosion Inhibited (VCI)
paper.
Place the element into a cardboard box for storage.

For identification, mark the outside of the container
and mark the element. Include the following
information:
• Date of cleaning
• Number of cleanings
g00281693
Illustration 48 Store the container in a dry location.
Inspect the clean, dry element. Use a 60 watt blue For more detailed information on cleaning the primary
light in a dark room or in a similar facility. Place air cleaner element, refer to Special Publication,
the blue light in the element. Rotate the element. SEBF8062, “Procedure to Inspect and Clean Air
Inspect the element for tears and/or holes. Inspect Filters”.
the element for light that may show through the filter
material. If it is necessary in order to confirm the
result, compare the element to a new element that i02408845
has the same part number.
Engine Air Cleaner Service
Do not use an element that has any tears and/or Indicator - Inspect
holes in the filter material. Do not use an element with
damaged pleats, gaskets or seals. Discard damaged SMCS Code: 7452-040
elements.
A service indicator may be mounted on the air
Storing Primary Air Cleaner Elements cleaner element or in a remote location.
If an element that passes inspection will not be used

immediately, store the element for future use.
60 SEBU8099-01
Maintenance Section
Engine Crankcase Breather - Clean
Inspect the service indicator daily for cracks, holes, or

loose fittings. If any of these conditions are present,
replace the service indicator.
Test the Service Indicator

Service indicators are important instruments.
• Apply vacuum (suction) to the service indicator.

• Reset the service indicator.
If the yellow core does not latch at the greatest
vacuum, or if service indicator does not reset easily,
Illustration 50
g00760342 obtain a new service indicator. If the new service
Service indicator
indicator will not reset, the fitting for the service
indicator may be plugged.
Some engines may be equipped with a different
service indicator.
Observe the service indicator. Clean the air cleaner

element or replace the element when any of the
following conditions occur:
• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.
• The air restriction reaches 3.75 kPa
(15 inch of H2O).
g00351792
Illustration 52
Porous filter
A porous filter is part of the fitting that is used for

mounting of the service indicator. Inspect the filter
for cleanliness. Clean the filter, if necessary. Use
compressed air or a clean, nonflammable solvent.
Note: When service indicator is installed, excessive

tightening may crack the top of the service indicator.
Tighten the service indicator to a torque of 2 N·m
(18 lb in).
Illustration 51
g00760341 Replace the service indicator annually regardless of
Service indicator on an air cleaner for crankcase ventilation
the operating conditions.
Some engines are equipped with an air cleaner for i01225429

the crankcase ventilation intake air. The air cleaner is
mounted on a camshaft cover. Clean the air cleaner Engine Crankcase Breather -
element or replace the element when any of the
following conditions occur:
Clean
SMCS Code: 1317-070
• The yellow diaphragm enters the red zone.
If the crankcase breather is not maintained on a
• The red piston locks in the visible position. regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
• The air restriction reaches 0.25 kPa (1 inch of H2O). excessive crankcase pressure that may cause
crankshaft seal leakage.
• The air cleaner is saturated with oil.
SEBU8099-01 61
Maintenance Section
Engine Mounts - Check
Inspect the hose tee for cracks. If the tee is

cracked, discard the old tee and obtain a new tee
for installation.
5. Turn the breathers upside-down in order to inspect

the condition of the breather elements.
Clean the breather elements with clean,

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

g00597463
installation.
Illustration 53
Note: Coat the rubber parts with clean engine oil or
1. Loosen clamp (1). Slide the clamp down on tube petroleum jelly in order to make installation easier.
(2).
6. Place clamps (6) over the parts of hose tee (7)
2. Loosen clamps (3). Remove both breathers as a that will receive breathers (5). Install the breathers
unit. into the tee. Tighten the clamps to the torque that
is listed in the Service Manual, “Specifications”.
7. Coat O-ring seals (4) with clean engine oil. Place

the O-ring seals on the valve covers.
8. Place clamps (3) around the parts of the breathers

that will be attached to the valve covers. Install
both breathers as a unit. Tighten the clamps.
9. Place clamp (1) on the part of the hose tee that

will receive tube (2). Install the tube into the hose
tee. Tighten the clamp to the torque that is listed
in the Service Manual, “Specifications”.
g00597465
Illustration 54 i02017664
3. Remove O-ring seals (4) from the valve covers. Engine Mounts - Check
Inspect the O-ring seals for good condition. Obtain
new O-ring seals, if necessary. SMCS Code: 1152-535
g00736591
Illustration 56
(1) Mounting bolts for the engine
(2) Mounting bolts for the generator
(3) Levelling bolts for the isolators
Misalignment of the engine and the driven equipment

will cause extensive damage. Excessive vibration
g00597466
Illustration 55 can lead to misalignment. Excessive vibration of the
engine and the driven equipment can be caused by
4. Remove two clamps (6). Remove both breathers the following conditions:
(5) from hose tee (7).
• Improper mounting
62 SEBU8099-01
Maintenance Section
Engine Oil - Change
• Loose bolts Note: If a suction device is used in order to remove

the oil from the oil pan, ensure that the suction device
• Deterioration of the isolators is clean. This will prevent dirt from entering into the
oil pan. Be careful not to strike the engine oil suction
Ensure that the mounting bolts are tightened tubes or the piston cooling jets.
to the proper torque. For standard torques, see
Specifications, SENR3130, “Torque Specifications”. a. If the engine has an oil drain valve, open the
valve in order to drain the oil. After the oil has
Ensure that the isolators are free of oil and drained, close the valve.
contamination. Inspect the isolators for deterioration.
Ensure that the bolts for the isolators are tightened to b. If the engine has a pump for removing dirty
the proper torque. oil, connect a hose to the outlet of the pump.
Place the hose in a suitable container. Open
Replace any isolator that shows deterioration. For the valve for the drain line. Operate the pump
more information, see the literature that is provided until the crankcase is empty. Close the valve to
by the OEM of the isolators. Also see the Application the drain line. Disconnect the hose.
and Installation Guide for the engine. Consult your
Caterpillar dealer for assistance. c. If the oil drain valve has a “quick connect”
coupling, attach the coupling. Open the drain
valve in order to drain the crankcase. After
i02017618
the oil has drained, close the drain valve.
Engine Oil - Change Disconnect the coupling.
SMCS Code: 1348-044; 1348 d. If the engine does not have a drain valve or a
pump, remove an oil drain plug. Allow the oil to
drain. After the oil has drained, clean the drain
plug and clean the fitting for the drain plug.
Install the drain plug. Tighten the drain plug to
Hot oil and components can cause personal in- 145 ± 15 N·m (105 ± 10 lb ft).
jury.
Note: Ensure that the dirty oil is thoroughly drained
Do not allow hot oil or components to contact from the pan. Caterpillar recommends a thorough
skin. cleaning of the oil pan with a vacuum and with rags
in order to completely remove all of the old oil. This
will help prevent inaccurate oil analysis results and/or
NOTICE shortened life of the oil.
Ensure that the engine is stopped before performing
this procedure. Attach a DO NOT OPERATE tag to the 3. Replace the engine oil filter elements before filling
starting controls. the crankcase with new oil.
Do not drain the oil when the engine is cold. As the oil a. For the procedure to change the engine oil
cools, suspended waste particles settle on the bottom filters, refer to the Operation and Maintenance
of the oil pan. The waste particles are not removed Manual, “Engine Oil Filter - Change” topic
when the cold oil is drained. Drain the crankcase with (Maintenance Section).
the oil warm, immediately after the engine is stopped.
This draining method allows the waste particles
that are suspended in the oil to be drained properly.
Failure to follow this recommended procedure will
allow the waste particles to be recirculated through
the engine lubrication system with the new oil.
1. After the engine has been operated at normal

operating temperature, STOP the engine.
Note: Drain the oil into a suitable container. Dispose

of fluids according to local regulations.
2. Drain the oil by using one of the following

methods. Use the method that corresponds to the
equipment on the engine.
SEBU8099-01 63
Maintenance Section
Engine Oil Filter - Change
i02509100
NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip-
SMCS Code: 1308-510; 1308
stick).
An overfull crankcase can cause the crankshaft to dip Replace the engine oil filters when any of the
following conditions are met:
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re- • Every oil change
duction of the oil’s ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the • The engine oil filter differential pressure reaches
crankcase breathers, and excessive oil consumption. 100 kPa (15 psi).
Excessive oil consumption will cause deposits to form • The engine oil filters have been used for 1500
on the pistons and in the combustion chamber. De- operating hours.
posits in the combustion chamber lead to the following
Service tools are available to aid in the service of oil
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner. filters. Consult your Caterpillar dealer for the part
names and the part numbers. Follow the instructions
that are supplied with the service tools. If the service
If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately. tools are not used, perform the following appropriate
procedure.
Note: For the appropriate oil to use, and for Replacing the Engine Oil Filters
the amount of oil to use, refer to this Operation
and Maintenance Manual, “Refill Capacities and With the Engine Stopped
Recommendations” article (Maintenance Section).
4. Remove the oil filler cap. Fill the crankcase

through the oil filler tube only. Clean the oil filler
Hot oil and components can cause personal in-
cap. Install the oil filler cap.
jury.
NOTICE Do not allow hot oil or components to contact

To prevent crankshaft damage and to prevent bearing skin.
damage, manually operate the prelube pump or crank
the engine with the fuel supply line closed for 15 to 30
seconds. This will ensure that all of the oil filters are Perform the following procedure after the oil has
filled with oil before the engine is started. been drained.
5. Close the fuel supply line. Crank the engine until

the oil pressure gauge indicates 70 kPa (10 psi).
Open the fuel supply line. Allow the starting motor
to cool for two minutes before cranking again.
6. Follow this Operation and Maintenance Manual,

“Starting The Engine” procedure (Operation
Section). Operate the engine at low idle for two
minutes. This will ensure that the lubrication
system and the oil filters are filled with oil. Inspect
the engine for oil leaks. Ensure that the oil level is
between the “ADD” and the “FULL” marks on the
“LOW IDLE” side of the oil level gauge. g01255948
Illustration 57
7. Stop the engine and allow the oil to drain back into (1) Plug
the sump for a minimum of ten minutes. (2) Drain valve
(3) Drain
(4) Bolt
8. Remove the oil level gauge and check the oil level. (5) Cover
Maintain the oil level between the “ADD” and the
“FULL” marks on the “ENGINE STOPPED” side of
the oil level gauge.
64 SEBU8099-01
Maintenance Section
1. Connect a hose to drain (3). Place the other end

of the hose into a suitable container in order to NOTICE
collect the oil. Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
2. Open drain valve (2). Remove plug (1). Allow the Caterpillar could result in severe engine damage to
oil to drain. Clean the plug and install the plug. the engine bearings, crankshaft, etc., as a result of
Close the drain valve. Remove the hose from the the larger waste particles from unfiltered oil entering
drain. the engine lubricating system. Only use oil filters
recommended by Caterpillar.
Note: Some oil will remain in the housing after the oil
has been drained. This oil will pour out of the housing
when cover (5) is removed. Prepare to catch the oil 6. Ensure that the new oil filter elements are in good
in a suitable container. Clean up any spilled oil with condition. Install the new oil filter elements.
absorbent pillows or towels. DO NOT use absorbent
particles to clean up the oil. 7. Inspect O-ring seal (6). Ensure that the surfaces
for the O-ring seal are clean. Install a new
O-ring seal if the old O-ring seal is damaged or
deteriorated.
Personal injury can result from parts and/or cov- 8. Install O-ring seal (6) and cover (5). Ensure that
ers under spring pressure. the cover’s retainer is properly seated.
Spring force will be released when covers are re- 9. Close drain valve (2).
moved.
10. Install plug (1).
Be prepared to hold spring loaded covers as the
bolts are loosened. 11. Start the engine. Check for oil leaks.
12. Check the oil level on the “LOW IDLE” side of the
oil level gauge. Maintain the oil level between the
“ADD” and “FULL” marks on the “LOW IDLE” side
of oil level gauge.
Replacing the Engine Oil Filters

During Engine Operation
Filter contains hot pressurized fluid when engine

is running.
g00760382
Illustration 58
Follow instructions on control valve to avoid per-
Section view sonal injury.
(4) Bolt
(5) Cover If rapid air movement exists to blow fluid, Stop the
(6) O-ring seal
(7) Oil filter element engine to avoid fire.
3. Be alert to the spring force. Gradually loosen but

do not remove bolts (4). Before removing bolts (4),
pry cover (5) loose or tap the cover with a rubber
mallet in order to relieve any spring pressure.
4. Remove bolts (4) and the washers in order to

remove cover (5) and O-ring seal (6). Remove oil
filter elements (7).
5. Clean cover (5), O-ring seal (6), and the inside

of the oil filter housing.
SEBU8099-01 65
Maintenance Section
Engine Oil Level - Check
Use a magnet to differentiate between the ferrous

metals and the nonferrous metals that are found
in the element. Ferrous metals may indicate wear
on the steel and the cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, the brass parts, or the bronze parts
of the engine. Parts that may be affected include the
following components: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Aluminum debris may indicate problems with the

bearings of the front gears. If an excessive amount
of aluminum debris is found, inspect the crankshaft
vibration damper and the bearings of the front idler
gear.
Due to normal wear and friction, it is not uncommon

to find small amounts of debris in the oil filter element.
If an excessive amount of debris is found in the oil
filter element, consult your Caterpillar dealer in order
to arrange for further oil analysis.
g00850266
Illustration 59
Selector lever for the duplex oil filter i02418058
If the engine is equipped with duplex oil filters, the Engine Oil Level - Check
engine oil filter elements can be changed while the
engine is operation. This is useful if the oil filter SMCS Code: 1348-535-FLV
elements require more frequent replacement than
the engine oil. The most accurate check of the engine oil level is
obtained when the engine is stopped.
1. Move the selector lever to the “AUX RUN” position
in order to change the main oil filter elements.
Move the selector lever to the “MAIN RUN”
position in order to change the auxiliary oil filter
elements.
2. Allow the oil pressure gauge for the oil filter that
is being changed to reach a “ZERO” pressure
reading.
3. Perform Step 1 through Step 12 of “Replacing the

Engine Oil Filters With the Engine Stopped”.
4. Open the “FILL” valve for a minimum of five

minutes in order to fill the new oil filter elements.
g01208341
Illustration 60
5. Close the “FILL” valve. Move the selector lever (1) Filler cap
to the “RUN” position for the oil filter that was (2) Engine oil level gauge (dipstick)
serviced.
1. Remove filler cap (1) in order to ensure that the
crankcase pressure is equal to the atmospheric
Inspect the Used Oil Filter Elements pressure.
Cut the used oil filter element open with a utility knife. Excess pressure or a slight vacuum will affect
Cut the filter element free from the end caps. Spread engine oil level that is measured.
apart the pleats and inspect the element for metal
debris. An excessive amount of debris in the element 2. Ensure that engine oil level gauge (2) is seated.
may indicate early wear or a pending failure.
66 SEBU8099-01
Maintenance Section
Engine Oil Sample - Obtain
3. If necessary, add engine oil. For the correct

engine oil to use, refer to this Operation and
Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section).
Do not fill the crankcase above the “FULL” mark
on the engine oil level gauge. Clean the filler cap
(1). Install the filler cap.
4. Record the amount of engine oil that is added. For

the next engine oil sample and analysis, include
the total amount of engine oil that has been added
since the previous oil change. This will help to
provide the most accurate analysis.
g00735162
Illustration 61 i01935337
(3) “ENGINE STOPPED WITH OIL COLD” side
(4) “ENGINE AT LOW IDLE WITH WARM OIL” side Engine Oil Sample - Obtain
(5) “ADD” mark
(6) “FULL” mark SMCS Code: 1348-554-SM
a. If the engine is stopped, remove the engine oil In addition to a good preventive maintenance
level gauge. Observe the engine oil level on program, Caterpillar recommends using S·O·S oil
“ENGINE STOPPED WITH OIL COLD” side analysis at regularly scheduled intervals in order
(3). to monitor the condition of the engine and the
maintenance requirements of the engine. S·O·S oil
b. If the engine is operating, reduce the engine analysis provides infrared analysis, which is required
speed to low idle. Remove the engine oil level for determining nitration and oxidation levels.
gauge and observe the engine oil level on
“ENGINE AT LOW IDLE WITH WARM OIL”
side (4).
Obtain the Sample and the Analysis
The engine oil level should be between “ADD”
mark (5) and “FULL” mark (6).
Hot oil and hot components can cause personal
NOTICE injury. Do not allow hot oil or hot components to
Engine damage can occur if the crankcase is filled contact the skin.
above the “FULL” mark on the oil level gauge (dip-
stick). Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
An overfull crankcase can cause the crankshaft to dip to help obtain the most accurate analysis, provide
into the oil. This will reduce the power that is devel- the following information:
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re- • Engine model
duction of the oil’s ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the • Service hours on the engine
crankcase breathers, and excessive oil consumption.
• The number of hours that have accumulated since
Excessive oil consumption will cause deposits to form the last oil change
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following • The amount of oil that has been added since the
problems: guttering of the valves, packing of carbon last oil change
under the piston rings, and wear of the cylinder liner.
To ensure that the sample is representative of the
If the oil level is above the “FULL” mark on the oil level oil in the crankcase, obtain a warm, well mixed oil
gauge, drain some of the oil immediately. sample.
To avoid contamination of the oil samples, the tools

and the supplies that are used for obtaining oil
samples must be clean.
SEBU8099-01 67
Maintenance Section
Engine Protective Devices - Check
Caterpillar recommends using the sampling valve

in order to obtain oil samples. The quality and the NOTICE
consistency of the samples are better when the During testing, abnormal operating conditions must be
sampling valve is used. The location of the sampling simulated.
valve allows oil that is flowing under pressure to be
obtained during normal engine operation. The tests must be performed correctly in order to pre-
vent possible damage to the engine.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are To prevent damage to the engine, only authorized
needed for obtaining oil samples. Instructions are service personnel or your Caterpillar dealer should
also provided. perform the tests.
NOTICE Visual Inspection

Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling. Visually check the condition of all gauges, sensors
Using the same pump for both types of samples may and wiring. Look for wiring and components that
contaminate the samples that are being drawn. This are loose, broken, or damaged. Damaged wiring
contaminate may cause a false analysis and an incor- or components should be repaired or replaced
rect interpretation that could lead to concerns by both immediately.
i02209352
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is Engine Speed/Timing Sensor -
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
Clean/Inspect
into the sump. SMCS Code: 1905-040; 1905-070; 1907-040;
1907-070
For instructions, see Special Publication, PEHP6001,
“How To Take A Good Oil Sample”. Consult your An engine speed/timing sensor is mounted in the
Caterpillar dealer for complete information and flywheel housing. The speed/timing sensor provides
assistance in establishing an S·O·S program for your information about engine speed and the position of
engine. the crankshaft to the ECM.
i00626013
Engine Protective Devices -

Check
SMCS Code: 7400-535
Alarms and shutoffs must function properly. Alarms

provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices. Illustration 62
g00760464
A calibration check of the engine protective devices 1. Remove engine speed/timing sensor (1). Inspect
will ensure that the alarms and shutoffs activate the condition of the end of the magnet. Look for
at the setpoints. Ensure that the engine protective signs of wear and contaminants.
devices are functioning properly.
2. Clean any debris from the face of the magnet.
68 SEBU8099-01
Maintenance Section
Engine Valve Lash and Bridge - Adjust
i02151241
Engine Valve Lash and Bridge

- Adjust
SMCS Code: 1102-025; 1102
g01115363
Illustration 63
3. Check the tension of the sliphead. Gently extend Ignition systems can cause electrical shocks.
sliphead (2) for a minimum of 4 mm (0.16 inch). Avoid contacting the ignition system components
Then push back the sliphead. and wiring.
When the sliphead has the correct tension, at Do not attempt to remove the valve covers when
least 22 N (5 lb) of force is required to push in the the engine is operating. The transformers are
sliphead from the extended position. 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
NOTICE engine operation. The engine will not operate
The sliphead must be fully extended when the speed/ without the valve covers.
timing sensor is installed so that the sensor maintains
the correct clearance with the speed-timing wheel.
If the correct clearance is not maintained, the signal For procedures on adjusting the valve bridge and the
from the sensor will not be generated. engine valve lash, refer to the following publications:
Do not install the sensor between the teeth of the • Special Instruction, REHS0128, “Using the
speed-timing wheel. Damage to the sensor would re- 147-5482 Indicator Gauge for Valve Lash and
sult. Before installing the sensor, ensure that a tooth Valve Bridge Adjustment”
of the wheel is visible in the mounting hole for the sen-
sor. • The Systems Operation/Testing and Adjusting
manual for the engine
4. Install the engine speed/timing sensor.
• The Specifications manual for the engine
a. Ensure that a tooth on the speed-timing wheel Consult your Caterpillar dealer for assistance.
is visible in the mounting hole for the sensor.
b. Extend sliphead (2) by a minimum of 4 mm Valve Bridge

(0.16 inch).
Check the valve bridge and adjust the valve bridge,
c. Coat the threads of the sensor with 4C-5597 if necessary. Perform the procedure for both valve
Anti-Seize Compound. bridges for each cylinder.
Note: The sliphead is designed to contact a tooth After the valve bridge for each cylinder is satisfactory,
during the first revolution of the speed-timing wheel. measure the valve lash.
For the maximum allowable clearance between
the sliphead and the tooth, refer to the engine’s Engine Valve Lash
Specifications manual.
d. Install the sensor. Tighten the locknut to NOTICE

40 ± 5 N·m (30 ± 4 lb ft). Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
Operation of Caterpillar engines with improper valve

adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life. Improper
valve lash may also lead to valve failure, and result in
catastrophic failure.
SEBU8099-01 69
Maintenance Section
Exhaust Bypass - Inspect
If the valve lash is within the tolerance, an adjustment 3. Inspect diaphragm (1). If the diaphragm is worn or
of the valve lash is NOT necessary. cracked, replace the diaphragm.
Perform valve lash adjustment if the dimension is not 4. Inspect valve stem (2) and the valve guide. If the
within the tolerance. The valve bridge adjustment parts are excessively worn, replace the parts.
must be performed before making a valve lash
adjustment. 5. Clean breather (3).
Perform the valve lash setting when the engine is 6. Assemble the valve.
cold. After the engine has been shut down and the
valve covers are removed, the engine is considered 7. Install the valve.
cold.
i01505536
Before performing maintenance, prevent the entry of
foreign matter into the top of the cylinder head and
the valve mechanism. Thoroughly clean the area
Fuel System Fuel Filter
around the valve mechanism covers. Differential Pressure - Check
For the valve lash setting, refer to this Operation and SMCS Code: 1261-535
Maintenance Manual, “Specifications” section and/or
the Specifications manual for the engine. A fuel filter differential pressure gauge must be
installed in order to determine when the fuel filter
requires service. This gauge and the fuel filter are
i01505507 supplied by the customer.
Exhaust Bypass - Inspect A fuel filter differential pressure gauge indicates the
difference in fuel pressure between the inlet side
SMCS Code: 1057-040
and the outlet side of the fuel filter. The differential
pressure increases as the fuel filter becomes
For instructions on removal and installation, see the
plugged.
Service Manual, “Disassembly and Assembly”.
Operate the engine at the rated speed and at the
1. Remove the exhaust bypass valve.
normal operating temperature. Check the fuel filter
differential pressure. Service of the fuel filter depends
on the pressure of the fuel system:
The exhaust bypass valve cover is under spring • For low pressure gas fuel systems, service the
compression. To prevent personal injury, use cau- fuel filter when the fuel filter differential pressure
tion when removing the cover. reaches 1.7 kPa (0.25 psi).
2. Disassemble the valve.

• For high pressure gas fuel systems, service the
fuel filter when the fuel filter 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.
i01642256
Gas Pressure Regulator

Condensation - Drain
SMCS Code: 1270-543
Illustration 64
g00781274 To collect condensation, drip legs should be installed
in the following locations:
Exhaust bypass valve
(1) Diaphragm
(2) Valve stem
• Supply line for the gas pressure regulator
(3) Breather
• Balance line for the gas pressure regulator
70 SEBU8099-01
Maintenance Section
Hoses and Clamps - Inspect/Replace
• Supply line to the gas shutoff valve

NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
ommended torque.
Check for the following conditions:
• End fittings that are damaged or leaking

• Outer covering that is chafed or cut
Illustration 65
g00829869
• Exposed wire that is used for reinforcement
(1) Cap on the drip leg for the balance line
(2) Cap on the drip leg for the gas supply line to the gas pressure • Outer covering that is ballooning locally
regulator
• Flexible part of the hose that is kinked or crushed
1. Close the main gas supply valve.
• Armoring that is embedded in the outer covering
2. Remove caps (1) and (2) from the drip legs.
A constant torque hose clamp can be used in place
3. Allow the moisture to drain into a suitable of any standard hose clamp. Ensure that the constant
container. Inspect the drip legs for debris. Clean torque hose clamp is the same size as the standard
the drip legs, if necessary. clamp.
4. Clean the caps. Install the caps. Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
5. Perform Step 2 through Step 4 for the drip leg on This can result in leaks. A constant torque hose
the supply line to the gas shutoff valve. clamp will help to prevent loose hose clamps.
6. Open the main gas supply valve. Each installation application can be different. The
differences depend on the following factors:
i02121526
• Type of hose
Hoses and Clamps -
• Type of fitting material
Inspect/Replace
• Anticipated expansion and contraction of the hose
SMCS Code: 7554-040; 7554-510
• Anticipated expansion and contraction of the
Inspect all hoses for leaks that are caused by the fittings
following conditions:
• Cracking
Replace the Hoses and the Clamps
• Softness
• Loose clamps Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
Replace hoses that are cracked or soft. Tighten any stop the engine and wait until the cooling system
loose clamps. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Stop the engine. Allow the engine to cool.

SEBU8099-01 71
Maintenance Section
Ignition System Spark Plugs - Inspect/Adjust/Replace
2. Loosen the cooling system filler cap slowly in • Normal level of emissions
system filler cap. • Maximum service life of the spark plugs
Note: Drain the coolant into a suitable, clean The service life of the spark plugs is affected by
container. The coolant can be reused. fouling due to deposits from the oil and by peak
voltage. Maintenance of the ignition system is also
3. Drain the coolant from the cooling system to a affected by voltage. Higher voltage is required by
level that is below the hose that is being replaced. higher inlet manifold air pressure and a higher
compression ratio. Higher voltage reduces the
4. Remove the hose clamps. service life of components such as spark plugs,
wires, and transformers.
5. Disconnect the old hose.
6. Replace the old hose with a new hose.

Removing the Spark Plug
7. Install the hose clamps with a torque wrench.
Note: Refer to the Specifications, SENR3130,

“Torque Specifications” in order to locate the proper
torques.
8. Refill the cooling system.
9. Clean the cooling system filler cap. Inspect the

cooling system filler cap’s gaskets. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
10. Start the engine. Inspect the cooling system for Illustration 66
g00787369
leaks.
(1) Bolt
(2) Valve cover
(3) O-ring seal
i02509455
Ignition System Spark Plugs - 1. Remove bolts (1). Remove valve cover (2).
Inspect O-ring seal (3). If the seal appears to be
Inspect/Adjust/Replace worn or damaged, discard the seal and use a new
(Spark Plugs with Adjustable seal for assembly.
Electrode Gaps) NOTICE
SMCS Code: 1555-040 Pulling on the wiring harness may break the wires. Do
not pull on the wiring harness.
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.
Maintenance of the spark plugs is required in order

to achieve the following benefits:
• Normal fuel consumption

72 SEBU8099-01
Maintenance Section
5. Debris may have collected in the spark plug well.

Thoroughly remove any debris. Use compressed
air. The maximum air pressure for cleaning
purposes must be below 207 kPa (30 psi). Ensure
that the area around the spark plug is clean and
free of dirt and debris.
6. Use a 177.8 mm (7/8 inch), 4C-4601 Spark Plug

Socket, an extension, and a breaker bar to loosen
spark plug (7). After the spark plug has been
loosened, use the socket and extension to remove
the spark plug by hand in order to detect problems
with the threads. After the spark plug has been
removed, discard the used spark plug gasket.
g00787367
Illustration 67 If the spark plug resists removal by hand, apply
(4) Wiring harness penetrating oil to the threads. To help the oil penetrate
(5) Transformer the threads, turn the spark plug back and forth until
(6) Lip seal
(7) Spark plug the spark plug is loose.
2. Disconnect wiring harness (4) from transformer If the spark plug cannot be removed by hand, clean
(5). Be careful to completely depress the retainer the threads with 9U-7511 Spark Plug Seat Cleaner.
clip away from the connector. Pull transformer (5) This tool scrapes debris from the seat and from the
straight away from the cylinder head. threads in the cylinder head. Be sure to clean any
debris from the cylinder.
3. Inspect lip seal (6). If the seal is worn or damaged,
discard the seal and use a new seal for assembly. NOTICE
Do not use a thread tap. A thread tap will remove metal
unnecessarily. The threads could be stripped and the
cylinder head could be damaged.
Inspecting the Spark Plug

Inspect the spark plug closely for damage. The
condition of the spark plug can indicate the operating
condition of the engine.
g00787371
Illustration 68
(8) O-ring seal
4. Inspect O-ring seal (8). If the seal is hard, cracked,

or melted, install a new seal.
Pressurized air can cause personal injury. When

pressurized air is used for cleaning, wear a pro- Illustration 69
g00838300
tective face shield, protective clothing, and pro-
(1) Terminal post
tective shoes. (2) Insulator
(3) Shell
(4) Gasket
Note: Excessive buildup of oil in the spark plug (5) Electrode
well is an indication of a damaged lip seal on the
transformer. If this condition is found, clean the
surface of the seal groove. Replace seal (6).
SEBU8099-01 73
Maintenance Section
Terminal post (1) must not move. If the terminal post A spark plug can operate despite a buildup of ash.
can be moved by hand, carefully tighten the post into However, a buildup of ash can cover the electrode
the threads of the insulator. If the post cannot be gap. This will cause misfire. Large deposits may
tightened, discard the spark plug. retain heat which can cause premature fuel ignition.
This can lead to uncontrollable detonation.
Inspect insulator (2) for cracks. If a crack is found,
discard the spark plug. Cleaning the Spark Plug
Faint marks may extend from shell (3) onto the
Thoroughly clean the spark plug. Do not use a wire
insulator. The marks may be a result of corona that brush. Glass beads are the preferred method for
forms at the top of the shell. The conductor will
cleaning.
develop a corona when a very high voltage potential
ionizes the air. This is a normal condition. This is not Follow these guidelines for using glass beads:
an indication of leakage between the shell and the
insulator.
• Always use clean glass beads.
Inspect shell (3) for damage. Cracks can be caused
by overtightening the spark plug. Overtightening can • Only use glass beads on the electrode and the
insulator near the electrode.
also yield the metal which loosens the shell. Discard
any spark plug that has a shell that is cracked or
loose. • Do not use glass beads on any other area of the
spark plug.
• Clean the rest of the spark plug with nonflammable

solvent.
Installing the Spark Plug

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

g00787372
Illustration 70 gap according to the engine’s Specifications
(6) Precious metal tips on the electrode and the ground strap manual.
Caterpillar spark plugs have precious metal tips (6) Adjust the electrode gap, if necessary. Bend the
on the electrode and the ground strap. This material ground strap at the existing bend. Then bend the
will gradually erode. Use extreme care when you set strap near the weld in order to achieve proper
the electrode gap. Maintain even spacing and proper alignment and even spacing between the two
alignment between the two precious metal surfaces. precious metal surfaces. Measure the electrode
gap after the alignment. Correct the electrode
Replace the spark plug if the precious metal is worn gap, if necessary.
off.
Note: Do not use anti-seize compound on spark
A light brown deposit or a beige deposit around the plugs. Most of the heat is transferred through the
electrode is produced by normal operation. threads and the seat area of the spark plug. Contact
of the metal surfaces must be maintained in order to
Deposits that are gray or black may be caused by provide the heat transfer that is required.
the following substances:
2. Ensure that the spark plug is clean and free of
• Excessive oil dirt and oil.
• Use of the wrong oil

• A substance that is introduced through the fuel
system or the air system
• Poor combustion because of a rich air/fuel mixture

74 SEBU8099-01
Maintenance Section
Ignition System Timing - Check/Adjust
3. Always use a new gasket when a spark plug is

installed. If a used spark plug is installed, place a
new 9Y-6792 Spark Plug Gasket on the spark
plug. Orient the tabs of the gasket toward the
spark plug’s electrode gap. Otherwise, the gasket
may not seat properly. If a gasket for a spark plug
is installed incorrectly, do not increase the torque
on the spark plug in order to improve the seal. Do
not reuse the gasket. Install a new gasket.
NOTICE
Do not overtighten the spark plug. The shell can be
cracked and the gasket can be deformed. The met-
al can deform and the gasket can be damaged. The
shell can be stretched. This will loosen the seal that is Illustration 71
g00838130
between the shell and the insulator, allowing combus- Retainer on the transformer’s connector for the wiring harness
tion pressure to blow past the seal. Serious damage
to the engine can occur. 7. Install the valve cover.
Use the proper torque.
i01005974
4. Install the spark plug by hand until the spark plug Ignition System Timing -
bottoms out. Tighten the spark plug according to
the engine’s Specifications manual. Check/Adjust
5. Ensure that the transformer and the extension are SMCS Code: 1550-025; 1550-535
clean and free from dirt and oil. Lubricate O-ring
seal (8) (Illustration 68) with one of the following After maintenance has been performed on the
lubricants: ignition system, check the timing of the ignition
system. Adjust the timing, if necessary.
• 4C-9504 Dielectric Grease
The optimum ignition timing for a gas engine varies
• 5N-5561 Silicone Lubricant according to several factors:
• 8T-9020 Dielectric Grease • Compression ratio of the engine

6. Observe the lip seal as you install the transformer. • Inlet air temperature
Verify that the lip seal does not move out of
the groove. Orient the transformer toward the • Methane number of the gas
wiring harness. Carefully align the socket of the
transformer with the wiring harness connector. For the proper timing, see the Engine Performance
Connect the wiring harness. publication for the engine.
Note: If the connector’s locking tab or the Adjust the timing according to the Service Manual,
transformer’s connector are damaged, install a “Systems Operation/Testing and Adjusting” module.
retainer onto the transformer’s connector for the Consult your Caterpillar dealer for assistance.
wiring harness. For connectors with a width of
22.3 mm (0.88 inch), use the 178-0565 Retainer. i01113853
For connectors with a width of 17.1 mm (0.67 inch),
use the 179-1500 Retainer. Inlet Air System - Inspect
SMCS Code: 1058-040; 1071-040; 1087-040
Inspect the components of the air inlet system for

the following conditions:
• Cracks
• Leaks
SEBU8099-01 75
Maintenance Section
Overhaul (In-Frame)
• Loose connections The following changes in the three conditions

normally require a scheduled overhaul:
Inspect the following components:
• A 300 percent increase in oil consumption
• Piping between the air cleaner and the turbocharger
• A 200 percent increase in crankcase blowby
• Turbocharger
• A 20 percent loss of cylinder compression
• Piping between the turbocharger and the
aftercooler Note: These indications do not require an engine
to be shut down for service. These indications
• Aftercooler only mean that an engine should be scheduled for
service in the near future. If the engine operation
• Connection of the aftercooler to the air plenum is satisfactory, an immediate overhaul is not a
requirement.
• Connection of the air plenum to the cylinder head
Monitor the engine as the engine accumulates
Ensure that all of the connections are secure. Ensure service hours. Consult your Caterpillar dealer about
that the components are in good condition. scheduling a major overhaul.
Make repairs, if necessary. For information regarding Usually, an in-frame overhaul does not require
removal and installation of the components, see removal of the engine. Instead, the service is
the Service Manual, “Disassembly and Assembly” performed with the engine in place. If the customer
module. Consult your Caterpillar dealer for requires a minimum disruption in the production of
assistance. power, the engine can be replaced with a rebuilt
model of identical specifications.
i01950722
Note: The generator or the driven equipment may
Overhaul (In-Frame) also require service when the engine overhaul is
performed. Refer to the literature that is provided by
SMCS Code: 1000-020 the OEM of the driven equipment.
Scheduling an In-Frame Overhaul In-Frame Overhaul Information

Generally, an in-frame overhaul is performed for An in-frame overhaul includes all of the work that is
every third top end overhaul. Scheduling an in-frame done for a top end overhaul. Additionally, some other
overhaul normally depends on the following three components that wear are replaced. The condition
conditions: of components is inspected. Those components are
replaced, if necessary.
• An increase of oil consumption Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
• An increase of crankcase blowby that the components are operating within the
appropriate specifications.
• A decrease and a variation of cylinder compression
Each individual condition may not indicate a need The following definitions explain the terminology for
for an overhaul. However, evaluating the three the services that are performed during an overhaul:
conditions together is the most accurate method of
determining when an overhaul is necessary. Inspect – Inspect the components according to
the instructions that are in Caterpillar reusability
The engine does not require an overhaul if the publications. Refer to Guidelines for Reusable
engine is operating within acceptable limits for Parts and Salvage Operations, SEBF8029, “Index
oil consumption, crankcase blowby, and cylinder of Publications on Reusability or Salvage of Used
compression. Parts”. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
Periodically measure each of the three conditions. unnecessary expenditures. New parts are not
The first measurement should occur during the required if the existing parts can still be used,
engine commissioning. This establishes a baseline reconditioned, or repaired. If the components are
for future measurements. Additional measurements not in the reusability guidelines, refer to the Service
are scheduled at regular intervals in order to Manual, “Specifications” module.
determine a schedule for the next in-frame overhaul.
76 SEBU8099-01
Maintenance Section
Overhaul (Major)
Rebuild – The component can be reconditioned in i01642396

order to comply with reusability guidelines.
Overhaul (Major)
Replace – The service life of the part is exhausted.
The part may fail before the next maintenance SMCS Code: 7595-020-MJ
interval. The part must be replaced with a part that
meets functional specifications. The replacement Scheduling a Major Overhaul
part may be a new part, a CAT remanufactured part,
a rebuilt part, or a used part. Some worn components Note: For information on estimating operating hours
may be exchanged with your Caterpillar dealer. before an overhaul, see Maintenance Management
Consult your Caterpillar dealer about repair options Schedules, SEBU6127.
for your engine.
Generally, a major overhaul is performed at the sixth
If you elect to perform an overhaul without the top end overhaul. The need for a major overhaul is
services of a Caterpillar dealer, be aware of the determined by several factors. Some of those factors
recommendations in Table 15. are the same factors that determine the in-frame
overhaul:
Table 15
In-Frame Overhaul • An increase of oil consumption
Clean Oil suction screen
• An increase of crankcase blowby
Clean Aftercooler core
Inspect • A decrease and variation of cylinder compression
Test
Inspect Compressor bypass valve
Other factors must also be considered for determining
Rebuild a major overhaul:
Replace Fuel metering valve
Electrohydraulic actuator • The service hours of the engine
Hydraulic oil pump • The wear metal analysis of the lube oil
Oil cooler
• An increase in the levels of noise and vibration
Oil pump
An increase of wear metals in the lube oil indicates
Pistons
that the bearings and the surfaces that wear may
Transformers need to be serviced. An increase in the levels of
noise and vibration indicates that rotating parts
Rebuild Exhaust bypass
require service.
Prelube pump
Note: It is possible for oil analysis to indicate a
Starting motor
decrease of wear metals in the lube oil. The cylinder
Turbochargers liners may be worn so that polishing of the bore
occurs. Also, the increased use of lube oil will dilute
Water pumps
the wear metals.
Replace Connecting rod bearings
Monitor the engine as the engine accumulates
Cylinder head assemblies
service hours. Consult your Caterpillar dealer about
Cylinder liners scheduling a major overhaul.
Main bearings
Note: The driven equipment may also require service
Oil temperature regulators when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
Piston rings
Water temperature regulators Major Overhaul Information

A major overhaul includes all of the work that is done
for top end overhauls and in-frame overhauls. A
major overhaul includes additional parts and labor.
Additional parts and labor are required in order to
completely rebuild the engine. In some cases, the
engine is relocated for disassembly.
SEBU8099-01 77
Maintenance Section
Overhaul (Top End)
For the major overhaul, all of the bearings, • Starting motor

seals, gaskets, and components that wear are
disassembled. The parts are cleaned and inspected. • Turbochargers
If necessary, the parts are replaced. The crankshaft
is measured for wear. The crankshaft may require • Water pumps
regrinding. Alternatively, the crankshaft may be
replaced with a Caterpillar replacement part. Note: 1. Replace the crankshaft vibration damper if
the damper cannot be rebuilt.
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure Inspecting Components
that the components are operating within the
appropriate specifications. Inspect the following components according to
If you elect to perform an overhaul without the publications. Refer to Guidelines for Reusable
services of a Caterpillar dealer, be aware of the Parts and Salvage Operations, SEBF8029, “Index
following recommendations. of Publications on Reusability or Salvage of Used
Parts”.
Replacing of Components
• Aftercooler
Replace the following components during the major
overhaul. • Camshafts
• Camshaft bearings • Camshaft followers
• Connecting rod bearings • Connecting rods
• Coupling (tandem engines) • Crankshaft
• Cylinder liners • Gear train
• Piston rings • Governor
• Cylinder heads, gaskets, and bolts • Inlet air piping
• Gaskets and seals • Oil cooler
• Gear train bearings • Oil pump
• Main bearings • Pistons
• Oil temperature regulators • Transformers
• Water temperature regulators i02408862
• Wiring harnesses Overhaul (Top End)

Rebuilding or Replacing of Components SMCS Code: 7595-020-TE
Rebuild the following components during the major

overhaul. Scheduling a Top End Overhaul
Top end overhauls are scheduled according to
• Carburetor the recession of the exhaust valve stems. This
measurement provides an accurate indication of the
• Crankshaft vibration damper 1. rate of valve wear. This measurement can be used to
predict when a cylinder head requires replacement.
• Exhaust bypass
• Gas regulator
• Prelube pump
78 SEBU8099-01
Maintenance Section
Overhaul (Top End)
Measure the projection of the exhaust valve stems • Buildup in the cylinders from contamination of the
within the first 250 service hours. This measurement fuel
is the baseline. The baseline is a reference for
subsequent measurements. Measure the projection • Plugging of the aftercooler from coolant that is
again at the initial 1000 service hour mark. Use poorly maintained
this measurement to determine when the next
measurement should be taken. • Plugging of the aftercooler from contamination of
the inlet air
The maximum limit for the increase in the valve stem
projection is 2.3 mm (0.09 inch). Plan for the top end • Degradation of the oil cooler from hydrogen sulfide
overhaul as the valve stem projection approaches in the fuel
70% of the maximum limit, or 1.6 mm (0.06 inch).
Perform the top end overhaul before the valve stem • Leaks in the internal coolant passages in water
projection has reached the 2.3 mm (0.09 inch) limit. cooled exhaust manifolds
Do not allow the projection of the exhaust valve
stems to exceed this limit. Inspect the following components according to
Note: Generally, cylinder heads wear out at different publications. Refer to Guidelines for Reusable
rates. In some cases, servicing the cylinder heads at Parts and Salvage Operations, SEBF8029, “Index
different times may be the most economic decision. of Publications on Reusability or Salvage of Used
This depends on the valve stem projection of the Parts”.
individual cylinders. However, this decision must
include the costs of additional downtime that is Your Caterpillar dealer can provide these services
caused by this procedure. Perform an economic and components. Your Caterpillar dealer can ensure
analysis in order to determine if cylinder heads should that the components are operating within the
be serviced as a group or divided into smaller groups. appropriate specifications.
Note: The generator or the driven equipment may If you elect to perform an overhaul without the
also require service when the engine overhaul is services of a Caterpillar dealer, be aware of the
performed. following recommendations.
Top End Overhaul Information Replacing of Components
A top end overhaul involves servicing the cylinder Replace the following components during a top end
heads and turbochargers. Also, some other engine overhaul.
components are inspected.
• Cylinder heads and gaskets
Top end overhauls require more tools than preventive
maintenance. The following tools are needed for • Oil temperature regulators
restoring the engine to factory specifications:
• Water temperature regulators
• Torque wrenches
Rebuilding of Components
• Dial indicators
Rebuild the following components during a top end
• Accurate measurement tools overhaul:
• Cleaning equipment • Carburetor

• Rebuilding equipment • Exhaust bypass
Caterpillar dealers are equipped with these tools. • Gas regulator
Caterpillar dealers can provide a flat rate price for
a top end overhaul. • Prelube pump
Unexpected problems may be found during a top • Starting motor
end overhaul. Plan to correct these problems, if
necessary. • Turbochargers
• Buildup in the cylinders from excessive oil • Water pumps
consumption
SEBU8099-01 79
Maintenance Section
Overhaul (Top End)
Note: Periodic inspection of the turbocharger is

recommended for determining when the turbocharger
will require an overhaul. In a few applications, the
Personal injury can result from air pressure.
turbocharger may require rebuilding prior to the top
end overhaul. An example is an application with
Personal injury can result without following prop-
loads that vary frequently. In these cases, rebuilding
er procedure. When using pressure air, wear a pro-
the turbocharger normally occurs separately from
tective face shield and protective clothing.
rebuilding the cylinder heads. Some applications
can operate longer before the turbocharger requires
Maximum air pressure at the nozzle must be less
rebuilding. Only experience can determine the actual
than 205 kPa (30 psi) for cleaning purposes.
need.
Inspecting of Components 6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
Clean the aftercooler core and the oil cooler
core. Pressure test the components. Replace the Note: The test pressure for the oil cooler is 790 kPa
components. (115 psi). The maximum differential pressure of water
for the aftercooler is 44 kPa (6 psi). The maximum
Note: It is difficult to clean the aftercooler core when differential pressure of air for the aftercooler is
proper maintenance is not performed . The tank that 5.1 kPa (0.74 psi).
is opposite of the inlet port and the outlet port can not
be removed for cleaning. 7. Inspect the core in order to ensure cleanliness.
Pressure test the core. Many shops that service
Note: This procedure may be used for cleaning both radiators are equipped to perform pressure tests.
the aftercooler core and the oil cooler core. If necessary, repair the core.
1. Remove the core. For the procedure, see the 8. Install the core. For the procedure, see the Service
Service Manual, “Disassembly and Assembly” Manual, “Disassembly and Assembly” module.
module. Refer to the “Reference Materials” topic Refer to the “Reference Materials” topic for more
for more information. information.
2. Turn the core upside-down in order to remove For more information on cleaning the cores, consult
debris. your Caterpillar dealer.
Coupling
NOTICE
Do not use a high concentration of caustic cleaner to
For tandem engine arrangements, inspect the
clean the core. A high concentration of caustic cleaner
coupling for the engines according to the information
can attack the internal metals of the core and cause
that is provided by the OEM of the coupling. Check
leakage. Only use the recommended concentration of
the bolts for proper torque.
cleaner.
Governor
3. Back flush the core with cleaner.
Inspect the governor for proper operation. Make any
Caterpillar recommends the use of Hydrosolv repairs that are necessary.
liquid cleaner. Hydrosolv liquid cleaners are
available from your Caterpillar dealer.
Use a two to five percent concentration of the

cleaner at temperatures up to 93 °C (200 °F).
Refer to Application Guide, NEHS0526 or consult
your Caterpillar dealer for more information.
4. Steam clean the core in order to remove any

residue. Flush the fins of the core. Remove any
other trapped debris.
5. Wash the core with hot, soapy water. Rinse the

core thoroughly with clean water.
80 SEBU8099-01
Maintenance Section
Overhaul Considerations
Transformers
g00787412
Illustration 73
(1) Cover
(2) O-ring seal
(3) Screen assembly
Note: Approximately 1 L (1 qt) of oil will remain in the

housing after the sump has been completely drained.
g00850303
This oil will pour out of the housing when cover (1) is
Illustration 72 removed. Prepare to catch the oil in a pan. Clean up
any spilled oil with absorbent pillows or towels. DO
The transformers produce a voltage increase. For NOT use absorbent particles to clean up the oil.
good operation, the connections must be clean and
secure. Inspect the transformers for the following 1. Loosen the bolts from cover (1). Remove cover
conditions: (1) and O-ring seal (2). Discard the seal. Remove
screen assembly (3).
• Damaged connector
2. Wash screen assembly (3) in clean nonflammable
• Damaged O-rings solvent. Allow the screen assembly to dry before
installation.
• Dirty insulator
3. Remove the side covers from the engine block
• Loose connections and clean the inside of the oil pan. Install the side
covers.
• Loose screws in the top ground spring
4. Inspect screen assembly (3) for good condition.
• Moisture Obtain a new screen assembly, if necessary.
Install the screen assembly. Install a new O-ring
Test the resistance of the transformers according seal (2). Install cover (1).
to the Service Manual, “Electronic Troubleshooting”
module. Refer to the “Reference Materials” topic for
more information. Consult your Caterpillar dealer for i01950926
assistance.
Oil Suction Screen
SMCS Code: 7595-043
Overhaul Information
Hot oil and components can cause personal in-
jury. An overhaul is replacing the major worn components
of the engine. An overhaul is a maintenance interval
Do not allow hot oil or components to contact that is planned. The engine is rebuilt with certain
skin. rebuilt parts or new parts that replace the worn parts.
An overhaul also includes the following maintenance:

Clean the oil suction screen after the oil has been
drained. • Inspection of all the parts that are visible during
the disassembly
SEBU8099-01 81
Maintenance Section
• Replacement of the seals and gaskets that are Generally, engines that are operated at a reduced
removed load and/or speed achieve more service life before
an overhaul. However, this is for engines that are
• Cleaning of the internal passages of the engine properly operated and maintained.
and the engine block
Overhaul Inspection
Most owners will save money by overhauling the
engine at the intervals that are recommended in Refer to the Service Manual for the disassembly and
the Operation and Maintenance Manual. It is not assembly procedures that are necessary in order
practical to wait until the engine exhibits symptoms to perform the required maintenance on the items
of excessive wear or failure. It is not less costly to that are listed. Consult your Caterpillar dealer for
wait. A planned overhaul before failure may be the assistance.
best value for the following reasons:
To determine the reusability publications that are
• Costly unplanned downtime can be avoided. needed to inspect the engine, refer to Guidelines for
Reusable Parts and Salvage Operations, SEBF8029,
• Many original parts can be reused according to the “Index of Publications on Reusability or Salvage of
guidelines for reusable parts. Used Parts”.
• The service life of the engine can be extended The Guidelines For Reusable Parts and Salvage
without the risk of a major catastrophe due to Operations is part of an established Caterpillar
engine failure. parts reusability program. These guidelines were
developed in order to assist Caterpillar dealers and
• Achieve the best cost/value relationship per hour customers reduce costs by avoiding unnecessary
of extended service life. expenditures for new parts. If the engine parts comply
with the established inspection specifications, the
Overhaul Intervals parts can be reused. New parts are not necessary if
the old parts can be reused, repaired, or salvaged.
Top end overhauls are determined by the projection
of exhaust valve stems. In-frame overhauls are If the parts are not within the inspection specifications,
determined by cylinder compression, crankcase the parts should be salvaged, repaired, replaced,
blowby, and oil consumption. Major overhauls are or exchanged. The use of out-of-spec parts could
determined by the in-frame tests, and by results of result in unscheduled downtime and/or costly repairs.
S·O·S oil analysis. The use of out-of-spec parts can also contribute to
increased fuel consumption and reduction of engine
Some other factors that are important for determining efficiency.
the overhaul intervals include the following
considerations: Your Caterpillar dealer can provide the parts that are
needed to rebuild the engine at the least possible
• Performance of preventive maintenance cost.
• Use of recommended lubricants Overhaul Programs

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

• Engine load • Connecting rods
• Engine speed • Crankshafts
Note: To avoid oil problems, engines that are • Cylinder heads
turbocharged and aftercooled must be operated at a
minimum of 60 percent of rated load. • Oil Pumps
82 SEBU8099-01
Maintenance Section
Radiator - Clean
• Starting motors Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction
• Turbochargers of the fan’s air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move the
• Water pumps air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.
Consult your Caterpillar dealer for details and for a
list of the remanufactured parts that are available. Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
Your Caterpillar dealer may be offering a variety of must be less than 275 kPa (40 psi). Use pressurized
overhaul options. water in order to soften mud. Clean the core from
both sides.
A Flat Rate Overhaul guarantees the maximum price
that you will pay for an overhaul. Flat rate prices on Use a degreaser and steam for removal of oil and
preventive maintenance programs or major repair grease. Clean both sides of the core. Wash the core
options are available from many servicing dealers with detergent and hot water. Thoroughly rinse the
for all Caterpillar Engines. Consult your Caterpillar core with clean water.
dealer in order to schedule a before failure overhaul.
After cleaning, start the engine and accelerate the
Overhaul Recommendation engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Caterpillar recommends a scheduled overhaul in Use a light bulb behind the core in order to inspect
order to minimize downtime. A scheduled overhaul the core for cleanliness. Repeat the cleaning, if
will provide the lowest cost and the greatest value. necessary.
Schedule an overhaul with your Caterpillar dealer.
Inspect the fins for damage. Bent fins may be opened
Overhaul programs vary between dealers. To obtain with a “comb”. Inspect these items for good condition:
specific information about the types of overhaul welds, mounting brackets, air lines, connections,
programs and services, consult your Caterpillar clamps, and seals. Make repairs, if necessary.
dealer.
For more detailed information on cleaning and
inspection, refer to Special Publication, SEBD0518,
i01604510
“Know Your Cooling System”.
Radiator - Clean
i01113939
SMCS Code: 1353-070
Starting Motor - Inspect
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. SMCS Code: 1451-040; 1453-040
Inspect the radiator for these items: damaged fins, If the starting motor fails, the engine may not start in
corrosion, dirt, grease, insects, leaves, oil, and other an emergency situation. A scheduled inspection of
debris. Clean the radiator, if necessary. the starting motor is recommended.
The starting motor pinion and the flywheel ring gear

must be in good condition in order for the engine
to start properly. The engine will not start if the
Personal injury can result from air pressure. starting motor pinion does not engage the flywheel
ring gear. The teeth of the starting motor pinion and
Personal injury can result without following prop- the flywheel ring gear can be damaged because of
er procedure. When using pressure air, wear a pro- irregular engagement.
tective face shield and protective clothing.
Inspect the starting motor for proper operation. Listen
Maximum air pressure at the nozzle must be less for grinding when the engine is started. Inspect the
than 205 kPa (30 psi) for cleaning purposes. teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth. Look
for teeth that are broken or chipped. If damaged teeth
are found, the starting motor pinion and the flywheel
ring gear must be replaced.
SEBU8099-01 83
Maintenance Section
Throttle Control Valve - Check
Electric Starting Motor i02148834
Note: Problems with the electric starting motor can Throttle Control Valve - Check
be caused by the following conditions: malfunction of
the solenoid and malfunction of the electric starting SMCS Code: 1269-535
system.
Inspect the electrical system for the following

conditions:
• Loose connections
• Corrosion
• Wires that are worn or frayed
• Cleanliness
Make repairs, if necessary.
g01090077
Illustration 74
Air Starting Motor
Check the throttle for leaks. If necessary, remove
the throttle according to the instructions in the
Disassembly and Assembly manual. Inspect the
throat of the throttle for wear marks. Check for free
Personal injury or death can result from improp- movement of the butterfly valve. If necessary, replace
erly checking for a leak. the bearings.
Always use a board or cardboard when checking Inspect the gaskets for wear or damage. If necessary,
for a leak. Escaping air or fluid under pressure, replace the gaskets. Reinstall the throttle according
even a pin-hole size leak, can penetrate body tis- to the instructions in the Disassembly and Assembly
sue causing serious injury, and possible death. manual.
If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of i01454354
injury.
Turbocharger - Inspect
Inspect all of the components in the air circuit for SMCS Code: 1052-040
the starting motor. Inspect all of the air lines and
connections for leaks. Periodic inspection and cleaning is recommended for
the turbocharger. Fouling of the turbine wheels can
If the teeth of the starting motor pinion and/or the contribute to loss of engine power and overall loss
flywheel ring gear are damaged, the air circuit for of engine efficiency.
the starting motor must be examined in order to
determine the cause of the problem. If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
Removal and Installation of the and/or to the engine may occur. Damage to the
turbocharger compressor wheel could allow parts
Starting Motor from the compressor wheel to enter an engine
cylinder. This can cause additional damage to the
Refer to the Service Manual, “Disassembly and pistons, the valves, and the cylinder head.
Assembly” module for information on removing the
starting motor and installing the starting motor.

84 SEBU8099-01
Maintenance Section
Valve Stem Projection - Measure/Record
The presence of oil may be the result of extended

NOTICE engine operation at low idle. The presence of oil
Turbocharger bearing failures can cause large quan- may also result from restriction of the inlet air
tities of oil to enter the air inlet and exhaust systems. (plugged air filters). This causes oil to leak past
Loss of engine lubricant can result in serious engine the seal for the turbocharger compressor.
damage.
If oil is found on the compressor wheel and/or
Minor leakage of a turbocharger housing under ex- at the air inlet, the source of the oil is the fuel
tended low idle operation should not cause problems compressor or the PCV system.
as long as a turbocharger bearing failure has not oc-
curred. Note: Deposits of ash and silicone can accumulate
on the turbine wheel. Turbine wheel will become
When a turbocharger bearing failure is accompanied unbalanced when the deposits flake off. The
by a significant engine performance loss (exhaust turbocharger cartridge must be replaced when this
smoke or engine rpm up at no load), do not continue occurs. However, remove deposits from the housing.
engine operation until the turbocharger is repaired or This will prevent wear on the blades of the new
replaced. turbine wheel.
4. Inspect the turbine wheel and the nozzle for

An inspection of the turbocharger can minimize deposits of ash and silicone. If deposits of 1.6 mm
unscheduled downtime. Also, the chance for potential (0.06 inch) thickness are found or if the turbine is
damage to other engine parts is reduced. in contact with the housing, the turbocharger must
be disassembled and cleaned. Removal of the
Note: Turbocharger components require clearances deposits can be difficult.
that are precise. The turbocharger cartridge must be
balanced due to high rpm. 5. Inspect the bore of the turbine housing for
corrosion and deposits.
The following conditions can cause the turbocharger
to be out-of-balance: 6. Clean the turbocharger compressor housing with
standard shop solvents and a soft bristle brush.
• The buildup of deposits
7. Fasten the air inlet piping and the exhaust outlet
• Chipping and/or flaking of deposits piping to the turbocharger housing.
If the turbocharger must be removed for inspection,
use caution. Do not break deposits from the turbine i02209685
wheel. Do not attempt to clean the turbine wheel. For
options regarding removal, installation, repair and Valve Stem Projection -
replacement, see the Service Manual or consult your Measure/Record
Caterpillar dealer.
SMCS Code: 1105-082
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually Valve Recession – The valves and the valve seats
inspect the piping for the presence of oil. are worn over time. This causes the valves to recede
into the cylinder head. This condition is called “valve
2. Turn the compressor wheel and the turbine wheel recession”.
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for The top end overhaul is scheduled according to
contact with the turbocharger housing. There the recession of the exhaust valves. However, it is
should not be any visible signs of contact between difficult to measure the actual valve recession in the
the turbine wheel or compressor wheel and the cylinder head. A simpler method is used to determine
turbocharger housing. If there is any indication of the valve recession:
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing, • Measure the projection of the valve rotator above
the turbocharger should be reconditioned. the cylinder head. It is not necessary to remove the
rocker arms in order to obtain this measurement.
3. Check the compressor wheel for cleanliness.
If only the inlet side of the wheel is dirty, dirt Measure the projection of the exhaust valve rotators
and/or moisture is passing through the air filtering with a 155-1536 Valve Recession Tool Group.
system. If oil is found only on the back side of the Follow the instructions that are provided with the tool
wheel, there is a possibility of a failed turbocharger group.
oil seal.
SEBU8099-01 85
Maintenance Section
Valve Stem Projection - Measure/Record
Record the measurements on the Operation and

Maintenance Manual, “Valve Data Sheet” (Reference
Materials Section).
• Measure the projection of the exhaust valve

rotators after 250 service hours. This measurement
is the baseline. The baseline is a reference for
subsequent measurements.
• Measure the projection of the exhaust valve

rotators at the first 1000 service hours.
• Illustration 75 shows schedules for determining

subsequent intervals. After determining the
increase in the valve stem projection from 250
service hours to 1000 service hours, find the
schedule that best fits the measured increase in
the valve stem projection.
• After 70 percent of the maximum limit has been

reached, measure the projection of the exhaust
valve rotators at every 1000 hours of operation.
The 70 percent is 1.60 mm (0.063 inch).
• Plan for the top end overhaul as the projection of

the valve rotator approaches the maximum limit.
Perform the top end overhaul when the projection
of the valve rotator has increased by a total of
2.3 mm (0.09 inch). Do not allow the recession
of the exhaust valves to exceed this limit. The
valve head can break. This will cause severe
damage in the combustion chamber.
86 SEBU8099-01
Maintenance Section
Walk-Around Inspection
g01115573
Illustration 75
(A) Schedule (Y) Valve recession in millimeters (inches) (2) 0.218 mm (0.0086 inch)
(B) Schedule (X) Hours of operation (3) 0.152 mm (0.0060 inch)
(C) Schedule (1) 0.254 mm (0.0100 inch)
To determine intervals, use the point on the graph in i01492446

Illustration 75 that is closest to the measurement for
each cylinder. Walk-Around Inspection
For example, the “Valve Data Sheet” (reference SMCS Code: 1000-040
section) shows that the increase in the valve
stem projection at the initial 1000 service hour Inspect the Engine for Leaks and
measurement shows a valve recession of 0.152 mm
(0.0060 inch). This would allow you to use Schedule for Loose Connections
(C). According to Schedule (C), the next interval for
measuring that cylinder is at 5000 service hours. A walk-around inspection should only take a few
Another cylinder may have a valve recession of minutes. When the time is taken to perform these
0.254 mm (0.0100 inch). According to Schedule (A), checks, costly repairs and accidents can be avoided.
the next interval for measuring that cylinder is at
3000 service hours. For maximum engine service life, thoroughly inspect
the engine room before starting the engine. Look for
When different cylinders require different schedules, items such as leaks, loose bolts, loose connections
the schedule that requires the most frequent and trash buildup. Make repairs, as needed.
measurements should be used for all cylinders.
Subsequent measurements can result in changing • The guards must be in the proper place. Repair
the schedule that is used. For example, if the first damaged guards or replace missing guards.
measurement indicates that Schedule (A) should
be used, the next measurement should be taken at • Wipe all caps and plugs before the engine is
3000 service hours. However, if the increase in the serviced in order to reduce the chance of system
projection that is measured at 3000 hours falls on contamination.
Schedule (B), then Schedule (B) can be used for the
next measurement.

SEBU8099-01 87
Maintenance Section
Water Pump - Inspect
• Inspect the exhaust system for leaks. If a leak is

NOTICE found, make repairs.
For any type of leak, clean up the fluid. If leaking is ob-
served, find the source and correct the leak. If leaking
i00524084
is suspected, check the fluid levels more often than
recommended until the leak is found or fixed, or until Water Pump - Inspect
the suspicion of a leak is proved to be unwarranted.
SMCS Code: 1361-040
NOTICE A failed water pump might cause severe engine
Accumulated grease and/or oil on an engine or deck is overheating problems that could result in cracks in
a fire hazard. Remove this debris with steam cleaning the cylinder head, a piston seizure or other potential
or high pressure water. damage to the engine.
• Ensure that cooling lines are properly clamped. Visually inspect the water pump for leaks. If leaking
Check for leaks. Check the condition of all pipes. of the water pump seals is observed, replace all of
the water pump seals. Refer to the Service Manual
• Inspect the water pumps for coolant leaks. for the disassembly and assembly procedure.
Note: The water pump seal is lubricated by coolant Inspect the water pump for wear, cracks, pin holes
in the cooling system. It is normal for a small amount and proper operation. Refer to the Service Manual or
of leakage to occur when the engine cools and the consult your Caterpillar dealer if repair is needed or
parts contract. replacement is needed.
Excessive coolant leakage may indicate the need i02509472

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

This will cause explosion and/or fire which could
result in severe personal injury or death.
• Check the fuel system for leaks. Look for loose fuel
line clamps.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed g01256184
Illustration 76
wires.
Replace the water temperature regulators before
• Inspect the ground straps for good connections the water temperature regulators fail. This is a
and for good condition. recommended preventive maintenance practice.
Replacing the water temperature regulators reduces
• Check the condition of the gauges. Replace any the chances for unscheduled downtime.
gauge that is damaged. Replace any gauge that
can not be calibrated.
88 SEBU8099-01
Maintenance Section
Water Temperature Regulator - Replace
A water temperature regulator that fails in a

partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed

position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or a seizure of the pistons.
A water temperature regulator that fails in the open

position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner. Also, a low temperature can
allow moisture to condense in the oil. This can form
damaging acids.
NOTICE
Failure to replace the water temperature regulator on
a regularly scheduled basis could cause severe en-
gine damage.
Never operate an engine without the water tempera-

ture regulator installed.
If the water temperature regulator is installed incor-

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

regulators, see the Service Manual, “Disassembly
and Assembly” module. Consult your Caterpillar
dealer for assistance.
Note: If only the water temperature regulators are

replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
SEBU8099-01 89
Customer Service
Reference Information Latin America, Mexico, Carribean

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

i02097871
Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000; 4450 CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
USA and Canada Fax: 22-849-4544
When a problem arises concerning the operation of Far East
an engine or concerning the service of an engine, Caterpillar Asia Pte. Ltd.
the problem will normally be managed by the dealer 7 Tractor Road
in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level without additional assistance, use the phone Hong Kong
number that is listed below to talk with a Field Phone: 852-2848-0333
Service Coordinator: Fax: 852-2848-0440
1-800-447-4986 Japan
Shin Caterpillar Mitsubishi Ltd.
The normal hours are from 8:00 to 4:30 Monday SBS Tower
through Friday Central Standard Time. 10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
3. If your needs have not been met still, submit the Japan
matter in writing to the following address: Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Caterpillar Inc.
Manager, Customer Service, Engine Division Japan
Mossville Bldg AC Caterpillar Power Systems, Inc.
P.O. Box 610 SBS Tower (14th floor)
Mossville, Illinois 61552-0610 4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Please keep in mind: probably, your problem will Phone: 81-3-5797-4300
ultimately be solved at the dealership, using the Fax: 81-3-5797-4359
dealership’s facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a Australia and New Zealand
problem is experienced. Caterpillar of Australia Ltd.
1 Caterpillar Drive
Outside of the USA and of Canada Private Mail Bag 4
Tullamarine, Victoria 3043
If a problem arises outside the USA and outside Australia
Canada, and if the problem cannot be resolved at the Phone: 03-9953-9333
dealer level, consult the appropriate Caterpillar office. Fax: 03-9335-3366
90 SEBU8099-01
Customer Service
i01028392
Ordering Replacement Parts

SMCS Code: 4450; 7567
When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers’ parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following

information:
• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance

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

dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
SEBU8099-01 91
Reference Materials
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

maintenance program that is well managed. Accurate
maintenance records can help your Caterpillar dealer
to fine tune the recommended maintenance intervals
in order to meet the specific operating situation. This
should result in a lower engine operating cost.
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
information: date, service hours, fuel consumption,
unit number, and engine serial number. Keep the
following documents as proof of maintenance or
repair for warranty:
• Dealer work orders and itemized bills

• Logs of engine performance
• Maintenance logs
• Owner’s repair costs
• Owner’s receipts
• Trend charts
92 SEBU8099-01
Reference Materials
i02209903
Maintenance Log
SMCS Code: 1000; 4450
Table 16
Engine Model Customer Identifier
Serial Number Arrangement Number
Service
Service Item Date Authorization
Hours
SEBU8099-01 93
Reference Materials
i00769479
Valve Data Sheet

SMCS Code: 1000
Table 17
Engine Model Serial Number Service Hours Authorization
Cylinder Valve Location Current Stem Rotator
Cylinder Wear
Pressure Measure Baseline Baseline
1 Pushrod Side
Exhaust Manifold
2 Pushrod Side
Exhaust Manifold
3 Pushrod Side
Exhaust Manifold
4 Pushrod Side
Exhaust Manifold
5 Pushrod Side
Exhaust Manifold
6 Pushrod Side
Exhaust Manifold
7 Pushrod Side
Exhaust Manifold
8 Pushrod Side
Exhaust Manifold
9 Pushrod Side
Exhaust Manifold
10 Pushrod Side
Exhaust Manifold
11 Pushrod Side
Exhaust Manifold
12 Pushrod Side
Exhaust Manifold
13 Pushrod Side
Exhaust Manifold
14 Pushrod Side
Exhaust Manifold
15 Pushrod Side
Exhaust Manifold
16 Pushrod Side
Exhaust Manifold
94 SEBU8099-01
Reference Materials
i02510232 • Application and Installation Guide, LEKQ7260,

“Low Energy Fuels”
Reference Material
• Special Publication, SEBU6400, “Caterpillar
SMCS Code: 1000; 4450 Gas Engine Lubricant, Fuel, and Coolant
Recommendations”
The following publications are available for order
through your Caterpillar dealer.
Coolants
Note: The information that is contained in the listed
publications is subject to change without notice. • Special Publication, PEDP7036, “S·O·S Fluid
Analysis”
Note: Refer to this publication, the respective
product data sheet, and to the appropriate Operation • Data Sheet, PEHJ0040, “Cat NGEC (Natural Gas
and Maintenance Manual for product application Engine Coolant) (Premix)”
recommendations.
• Data Sheet, PEHP7057, “Coolant Analysis”
Lubricants • Data Sheet, PEHP9554, “Cat DEAC (Diesel
Engine Antifreeze/Coolant) (Concentrate)”
Oils
• Special Publication, SEBD0518, “Know Your
• Special Publication, PEDP7036, “S·O·S Fluid Cooling System”
Analysis”
• Special Publication, SEBD0970, “Coolant and Your
• Special Publication, PEHP6001, “How To Take A Engine”
Good Oil Sample”
• Data Sheet, PEHP0004, “Cat NGEO” Gas Engine Lubricant, Fuel, and Coolant
Recommendations”
• Data Sheet, PEHJ0006, “Cat NGEO EL350”
Miscellaneous
Gas Engine Lubricant, Fuel, and Coolant
Recommendations” • Application and Installation Guide, LEKQ7250, “Air
Intake”
Grease • Engine Performance, LEBQ6117, “G3500

Industrial”
• Data Sheet, NEHP6010, “Cat Ultra 5Moly Grease”
(NLGI grades 1 and 2) • Engine Performance, LEBQ6169, “G3500
Generator Set”
• Data Sheet, NEHP6015, “Cat High Speed Ball
Bearing Grease” (NLGI grade 2) • Troubleshooting, RENR9353, “G3500 A3 Engines”
• Special Publication, PEGJ0035, “Grease Selection • Disassembly and Assembly, RENR9709, “G3500
Guide” A3 Engines”
• Data Sheet, PEHJ0088, “Cat Multipurpose Grease” • Electrical Schematic, RENR9553, “G3500 A3
(NLGI grade 2) Engine Electrical System”
• Data Sheet, PEHP0002, “Cat Advanced 3Moly • Electrical Schematic, RENR8118, “G3508 A3
Grease” (NLGI grade 2) Electrical Schematic”
• Special Publication, SEBU6400, “Caterpillar • Electrical Schematic, KENR6310, “G3512 A3

Gas Engine Lubricant, Fuel, and Coolant Electrical Schematic”
Recommendations”
• Electrical Schematic, KENR6311, “G3516 A3
Fuels Electrical Schematic”
• Application and Installation Guide, LEKQ7256, • Electronic Troubleshooting , SENR6517, “G3500

“Fuels, Fuel Systems” Air/Fuel Ratio Control”
SEBU8099-01 95
Reference Materials
• Software Program, LEKQ6378, “Methane Number Additional Reference Material

Program”
The “Engine Fluids Data Book” can be obtained from
• Special Publication, PECP9067, “One Safe the following locations: local technological society,
Source” local library, and local college. If necessary, consult
EMA at the following address:
• Specifications, SENR3130, “Torque Specifications”
Engine Manufacturers Association
• Specifications, KENR5387, “G3500 A3 Engines” Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602
• Specifications, SENR6417, “G3500 Engine E-mail: [email protected]
Attachments” (312) 827-8700
Facsimile: (312) 827-8737
• Special Instruction, GMG00694, “Analyzing
Cylinder Condition By Measuring Air Flow” The “Society of Automotive Engineers (SAE)
Specifications” can be found in your SAE handbook.
• Special Instruction, REHS0128, “Using the This publication can also be obtained from the
147-5482 Indicator Gauge For Valve Lash and following locations: local technological society, local
Valve Bridge Adjustment” library, and local college. If necessary, consult SAE
at the following address:
• Special Instruction, SEHS7332, “Do Not Operate
Tag” SAE International
400 Commonwealth Drive
• Special Instruction, SEHS7633, “Battery Test Warrendale, PA, USA 15096-0001
Procedure” Telephone: (724) 776-4841
• Special Instruction, SEHS8622, “Using the FT- The “American Petroleum Institute Publication No.
1984 Air-To-Air Aftercooler Leak Test Group” 1509” can be obtained from the following locations:
local technological society, local library, and local
• Special Instruction, SEHS8712, “Using the college. If necessary, consult API at the following
8T-2700 Blowby/Airflow Indicator Group” address:
• Special Instruction, SEHS9031, “Storage American Petroleum Institute

Procedure for Caterpillar Products” 1220 L St. N.W.
Washington, DC, USA 20005
• Special Instruction, SEHS9298, “Installation and Telephone: (202) 682-8000
Maintenance of Gaseous Fuel Filters”
The International Organization for Standardization
• Special Instruction, REHS2558, “Installation and (ISO) offers information and customer service
Initial Start-Up Procedure for G3500 A3 Engines” regarding international standards and standardizing
activities. ISO can also supply information on the
• Special Publication, NEHS0526, “Service following subjects that are not controlled by ISO:
Technician Application Guide” national standards, local standards, regulations,
certification, and related activities. Consult the
• Special Publication, NENG2500, “Caterpillar member of ISO in your country.
Dealer Service Tools Catalog”
International Organization for Standardization
• Special Publication, SEBF8029, “Index to (ISO)
Guidelines for Reusable Parts and Salvage 1, rue de Varembé
Operations” Case postale 56
CH-1211 Genève 20
• Special Publication, SEBF8062, “Procedure to Switzerland
Inspect and Clean Air Filters” Telephone: +41 22 749 01 11
Facsimile: +41 22 733 34 30
• Systems Operation/Testing and Adjusting, E-mail: [email protected]
RENR9352, “G3500 A3 Engines” Web site: http://www.iso.ch
European classifications are established by the

Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).
96 SEBU8099-01
Reference Materials
CIMAC Central Secretariat

Lyoner Strasse 18
60528 Frankfurt
Germany
Telephone: +49 69 6603 1567
Facsimile: +49 69 6603 1566
SEBU8099-01 97
Index Section
Index
A Cooling System Supplemental Coolant Additive
(SCA) - Test/Add.................................................. 54
Actuator Control Linkage - Lubricate ..................... 46 Add the SCA, If Necessary ................................ 55
Check the Linkage ............................................. 46 Test the Concentration of the SCA..................... 54
After Starting Engine ............................................. 37 Crankcase Blowby - Measure/Record ................... 55
Engaging the Driven Equipment ........................ 37 Crankshaft Vibration Damper - Inspect ................. 56
After Stopping Engine............................................ 40 Removal and Installation.................................... 56
Aftercooler Condensation - Drain .......................... 46 Crushing Prevention and Cutting Prevention ........ 13
Air Starting Motor Lubricator Bowl - Clean ............ 46 Customer Assistance............................................. 89
Air Starting Motor Lubricator Oil Level - Check ..... 47 Outside of the USA and of Canada.................... 89
Adjust the Lubricator .......................................... 48 USA and Canada ............................................... 89
Air Tank Moisture and Sediment - Drain................ 48 Customer Service .................................................. 89
Alternator - Inspect ................................................ 48 Cylinder Pressure - Measure/Record .................... 56
B E
Battery Electrolyte Level - Check .......................... 48 Electrical System ................................................... 15

Before Starting Engine .................................... 14, 33 Grounding Practices .......................................... 15
Air Inlet System.................................................. 33 Emergency Stopping ............................................. 39
Cooling System.................................................. 33 Emergency Stop Button ..................................... 39
Driven Equipment .............................................. 33 Engine Air Cleaner Element - Replace.................. 57
Electrical System ............................................... 33 Cleaning the Primary Air Cleaner Elements ...... 58
Fuel System ....................................................... 33 Servicing the Air Cleaner Elements ................... 57
Lubrication System ............................................ 34 Engine Air Cleaner Service Indicator - Inspect...... 59
Starting System.................................................. 34 Test the Service Indicator................................... 60
Walk-Around Inspection..................................... 33 Engine Crankcase Breather - Clean...................... 60
Belts - Inspect/Adjust/Replace............................... 49 Engine Mounts - Check ......................................... 61
Adjusting the Alternator Belt .............................. 49 Engine Oil - Change .............................................. 62
Adjusting the Fan Drive Belt .............................. 49 Engine Oil Filter - Change ..................................... 63
Inspection........................................................... 49 Inspect the Used Oil Filter Elements.................. 65
Replacement...................................................... 50 Replacing the Engine Oil Filters During Engine
Burn Prevention...................................................... 11 Operation ......................................................... 64
Batteries.............................................................. 11 Replacing the Engine Oil Filters With the Engine
Coolant................................................................ 11 Stopped............................................................ 63
Oils...................................................................... 11 Engine Oil Level - Check ....................................... 65
Engine Oil Sample - Obtain ................................... 66
Obtain the Sample and the Analysis.................. 66
C Engine Operation................................................... 38
Operating the Engine and the Driven
Cold Weather Starting ........................................... 34 Equipment ........................................................ 38
Control Panel......................................................... 31 Partial Load Operation ....................................... 38
Engine Monitoring System ................................. 31 Engine Protective Devices - Check ....................... 67
Cooling System Coolant (NGEC) - Change .......... 50 Visual Inspection................................................ 67
Clean the Cooling System ................................. 51 Engine Speed/Timing Sensor - Clean/Inspect....... 67
Cleaning a Cooling System that has Heavy Engine Starting ................................................ 14, 33
Deposits or Plugging ........................................ 51 Engine Stopping .............................................. 15, 39
Drain the Cooling System .................................. 50 Engine Valve Lash and Bridge - Adjust ................. 68
Fill the Cooling System ...................................... 52 Engine Valve Lash ............................................. 68
Cooling System Coolant Level - Check ................. 52 Valve Bridge....................................................... 68
Add Coolant ....................................................... 53 Exhaust Bypass - Inspect ...................................... 69
Obtain .................................................................. 53
Cooling System Coolant Sample (Level 2) - F
Obtain .................................................................. 54
Features and Controls ........................................... 26
98 SEBU8099-01
Index Section
Fire Prevention and Explosion Prevention ............ 12 Manual Stop Procedure......................................... 40

Fire Extinguisher ................................................ 13 Model View Illustrations......................................... 18
Lines, Tubes and Hoses .................................... 13 Model Views and Specifications ............................ 18
Foreword ................................................................. 5 Mounting and Dismounting.................................... 14
California Proposition 65 Warning ....................... 4
Literature Information........................................... 4
Maintenance ........................................................ 4 O
Maintenance Intervals.......................................... 4
Operation ............................................................. 4 Operation Section.................................................. 24
Overhaul .............................................................. 5 Ordering Replacement Parts ................................. 90
Safety................................................................... 4 Overhaul (In-Frame) .............................................. 75
Fuel System Fuel Filter Differential Pressure - In-Frame Overhaul Information.......................... 75
Check................................................................... 69 Scheduling an In-Frame Overhaul ..................... 75
Overhaul (Major).................................................... 76
Major Overhaul Information ............................... 76
G Scheduling a Major Overhaul............................. 76
Overhaul (Top End) ............................................... 77
Gas Pressure Regulator Condensation - Drain ..... 69 Scheduling a Top End Overhaul ........................ 77
General Hazard Information .................................... 9 Top End Overhaul Information ........................... 78
Asbestos Information ......................................... 10 Overhaul Considerations ....................................... 80
Containing Fluid Spillage ................................... 10 Overhaul Information ......................................... 80
Dispose of Waste Properly ................................. 11
Fluid Penetration................................................ 10
Pressurized Air and Water ................................. 10 P
General Information............................................... 16
General Maintenance Information ......................... 44 Performance Parameters ...................................... 26
Space Heaters ................................................... 44 Air/Fuel Ratio ..................................................... 26
Angle of the Throttle Plate ................................. 27
Oil Consumption ................................................ 27
H Optional Air/Fuel Ratio Control .......................... 27
Setting of the Exhaust Bypass (Wastegate) ...... 27
Hoses and Clamps - Inspect/Replace ................... 70 Plate Locations and Film Locations....................... 22
Replace the Hoses and the Clamps .................. 70 Engine Identification........................................... 22
Information Plate................................................ 22
Serial Number Plate........................................... 22
I Product Identification Information .......................... 22
Product Information Section .................................. 16
Ignition System Spark Plugs - Inspect/Adjust/Replace Product Lifting........................................................ 24
(Spark Plugs with Adjustable Electrode Gaps) .... 71 Engine Lifting with a Generator.......................... 24
Cleaning the Spark Plug .................................... 73 Product Storage..................................................... 25
Inspecting the Spark Plug .................................. 72 Generator Storage ............................................. 25
Installing the Spark Plug .................................... 73
Removing the Spark Plug .................................. 71
Ignition System Timing - Check/Adjust .................. 74 R
Ignition Systems .................................................... 14
Important Safety Information ................................... 2 Radiator - Clean .................................................... 82
Inlet Air System - Inspect....................................... 74 Reference Information ........................................... 23
Reference Information Section .............................. 89
Reference Material ................................................ 94
L Additional Reference Material............................ 95
Coolants............................................................. 94
Lifting and Storage ................................................ 24 Fuels .................................................................. 94
Lubricants .......................................................... 94
Miscellaneous .................................................... 94
M Reference Materials .............................................. 91
Refill Capacities..................................................... 41
Maintenance Interval Schedule (Standard) ........... 45 Refill Capacities and Recommendations............... 41
Maintenance Log ................................................... 92 Cooling System.................................................. 42
Maintenance Recommendations ........................... 44 Fuel .................................................................... 41
Maintenance Records............................................ 91 Lubrication System ............................................ 41
Maintenance Section ............................................. 41
SEBU8099-01 99
Index Section
Safety Messages ..................................................... 6

Safety Section ......................................................... 6
Sensors and Electrical Components ..................... 28
Electronic System .............................................. 28
Sensors.............................................................. 29
Specifications ........................................................ 19
Crankshaft Positions for Valve Lash Setting ...... 21
General Engine Specifications........................... 19
Starting Motor - Inspect ......................................... 82
Air Starting Motor ............................................... 83
Electric Starting Motor........................................ 83
Removal and Installation of the Starting Motor .. 83
Starting the Engine ................................................ 35
Automatic Starting.............................................. 35
Manual Starting.................................................. 35
Operation of the Generator Set Control Panel... 35
Purging Unburned Gas ...................................... 35
Starting with Jump Start Cables ............................ 36
Table of Contents..................................................... 3
Throttle Control Valve - Check............................... 83
Turbocharger - Inspect .......................................... 83
Valve Data Sheet................................................... 93

Valve Stem Projection - Measure/Record.............. 84
Walk-Around Inspection ........................................ 86

Inspect the Engine for Leaks and for Loose
Connections ..................................................... 86
Water Pump - Inspect............................................ 87
Water Temperature Regulator - Replace ............... 87
Replace the Water Temperature Regulators in the
Water Temperature Regulator Housing and in the
Thermostatic Valve........................................... 87
Welding on Engines with Electronic Controls ........ 16
100 SEBU8099-01
Index Section
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
©2006 Caterpillar
All Rights Reserved Printed in U.S.A.

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What safety precautions should be taken when operating the engine?

What safety precautions should be taken when operating the engine?

What maintenance tasks are described in the manual?

What maintenance tasks are described in the manual?

SEBU8099-01

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Reference Materials .............................................. 91

General Hazard Information ................................... 9

Burn Prevention ..................................................... 11

Fire Prevention and Explosion Prevention ............ 12

Crushing Prevention and Cutting Prevention ........ 13

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

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

Before Starting Engine .......................................... 14

Engine Starting ..................................................... 14

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

Electrical System .................................................. 15

Product Information Section

Model Views and Specifications ........................... 18

Product Identification Information ........................ 22

Features and Controls .......................................... 26

Engine Starting ..................................................... 33

Engine Operation .................................................. 38

Engine Stopping ................................................... 39

Maintenance Recommendations .......................... 44

Maintenance Interval Schedule (Standard) .......... 45

Reference Information Section

Foreword Use service hours to determine intervals. Calendar

Operation See the section in the Operation and Maintenance

The operation section is a reference for operators.

Ensure that all of the safety messages are legible.

Do not operate or work on this engine or genera-

3. Center and restrain the loose parts.

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

Filter contains hot pressurized fluid when engine

Flash Fire (5) Do not allow unauthorized personnel on the engine,

Engine exhaust contains products of combustion

Cautiously remove the following parts. To help

General Hazard Information

• Wear a hard hat, protective glasses, and other

• Use all cleaning solutions with care. Containing Fluid Spillage

When pressurized air and/or pressurized water is

The maximum air pressure for cleaning purposes

Fluid Penetration Illustration 9

Caterpillar equipment and replacement parts that are

Use caution. Avoid inhaling dust that might be

• Avoid brushing materials that contain asbestos. i02088921

• Avoid grinding materials that contain asbestos. Burn Prevention

If the application has a makeup tank, remove the cap

i02377302 Store fuels and lubricants in properly marked

Exhaust shields (if equipped) protect hot exhaust

Do not weld on lines or on tanks that contain

Wiring must be kept in good condition. All electrical

Determine whether the engine will be operated in an

Remove all flammable materials such as fuel, oil,

Repair any lines that are loose or damaged. Leaks