1 CAT O&M Manual G3500 Engine 0

C•TERPILLAR® SEBU6711-10
July 2004
Operation and
Maintenance
Manual
63500 Engines
4WD1-Up (Engine)
5JD1-Up (Engine)
8LD1-Up (Engine)
9TG1-Up (Engine)
2TJ1-Up (Engine)
7NJ1-Up (Engine)
4EK1-Up (Engine)
6JW1-Up (Engine)
8PW1-Up (Engine)
9AW1-Up (Engine)
7SZ1-Up (Engine)
8BZ1-Up (Engine)
5ZZ1-Up (Engine)
8JZ1-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.
A WARNING
The meaning of this safety alert symbol is as follows:

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

ture failures, product damage, personal injury or
death.
3
Table of Contents
Table of Contents Maintenance Interval Schedule (Naturally

Aspirated) ............................................................ 63·
Foreword ................................................................. 4 Reference Information Section
Safety Section Customer Service ................................................ 114
Safety Messages ... ............... .................................. 6 Reference Materials ............................................. 116
General Hazard Information .................................. 11 Index Section
Burn Prevention .... ... .. ... .. .. ........ .. .. .. .. .. .... .. ... .. ... .. .. 13 Index ................................................................... 122
Fire Prevention and Explosion Prevention ............ 14
Crushing Prevention and Cutting Prevention ........ 14
Mounting and Dismounting .. .. ... .. .. .... .. ... .. ..... .. ...... 15
Ignition Systems ................................................... 15
Before Starting Engine .. ...... .. .. ... .. ... .. ........ .... .. ...... 15
Engine Starting ..................................................... 15
Engine Stopping .... ........ .. ... ............ ... ... .. .. ... .. ... .. .. 16
Electrical System .................................................. 16
Product Information Section

Model Views and Specifications .............. ...... ....... 17
Product Identification Information ........................ 23
Operation Section
Lifting and Storage ............. ..... .............................. 25
Gauges and Indicators .......................................... 27
Features and Controls .......................................... 30
Engine Starting ..................................................... 48
Engine Operation .................................................. 53
Engine Stopping ................................................... 54
Maintenance Section
Refill Capacities .................................................... 57
Maintenance Interval Schedule (Turbocharged

Aftercooled) ......................................................... 60
Maintenance Interval Schedule (Standby) ............ 61
Maintenance Interval Schedule (Bio-Gas) ............ 62

4
Foreword
Foreword Use service hours to determine intervals. Calendar

intervals shown (daily, annually, etc) may be used
instead of service meter intervals if they provide 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 lubr~cation 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 ~anual 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 whic.h 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.
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
Safety Section
Safety Messages
Safety Section
i02115145
Safety Messages
SMCS Code: 1000; 7405
1
2 3
lllPROP[R LW 1
Rlc;GING CAN
Al,~QW UNIT 10
1UN81.[ CAUSIN(;
INJURY AHD
DAMAG(.
1. 1.5[ PlrOPfft SPlrf~.DU
BAii 1.'ii SH:;>WN.
2. Am.ell TIO PROPER
i;.urn c;.rus m
'Sl"IU.DER fWi FROll 4
IATT!ll!•uvU•OCATUl•H•A·
IATOCO•••ITIUT9.••••uc1•C
••••••cuu•.••••YACO•UC1
•OllTN!(<)CUUTO•o•nw•t•)
T!UllAtOIUTT!UCOU!CTU
fOUUTUS<HUO"'AUIOOA·
THO(iCAIU'"OIUTUU•
IOHC!TOSTAOTUUOATN!f)
TUOllA·~•UCNIU•OT!QU"O!O
•1T•nu1uuoATl\l!TUOIUl,
co1 ..c11ouc•ouocK)ro•-
'o"'"ocuu .. ,,,otoHun:,.
Illustration 1 g01069751
There may be several specific safety messages Ensure that all of the safety messages are legible.
on your engine. The approximate location and a Clean the safety messages or replace the safety
description of the safety messages are reviewed in messages if the words cannot be read or if the
this section. Please become familiar with all of the illustrations are not visible. Use a cloth, water, and
safety messages. soap for cleaning the safety messages. Do not
use solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The·
safety messages that are loosened could drop off
of the engine.
7
Safety Section
Safety Messages
Replace any safety message that is damaged or Electrical Shock (2)

missing. If a safety message is attached to a part
of the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
--
A ---
WARNING
-- ---- - - - -
A WARNING
Do not operate or work on this engine unless you
have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the 109-4259
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.
g00305892
Illustration 3
The safety messages that may be attached on the
engine are illustrated and described below. The safety message for electrical shock is located
on the valve covers.
Engine Lifting (1)
A WARNING
A WARNING Ignition systems can cause electrical shocks.
IMPROPER LIFT Avoid contacting the ignition system components
RIGGING CAN
ALLOW UNIT TO and wiring.
TUMBLE CAUSING
INJURY AND
DAMAGE. Do not attempt to remove the valve covers when
1. USE PROPER SPREADER
BAR AS SHOWN. the engine is operating. The transformers are
2. AITACH TWO PROPER
RATEO CABLES TO
grounded to the valve covers. Personal injury or
SPREADER BAR FRON
ENGINE LIFTING EYE...
death may result and the ignition system will be
1 REMOVE AFTERCOOLER
WATER LINES IF LIFTING
damaged if the valve covers are removed during
APPARATUS INTERFERES. engine operation. The engine will not operate
_A1(431~~::. without the valve covers.
3508 ENG· 1112mm (43.8 IN)
3512 ENG· 1652mm (65 IN)
¢8
3508 ENG· 1112 REF
3512 ENG· 1652 REF
3516 ENG· 2t92 REF 1£m~
g01061192
Illustration 2
The safety message for engine lifting is located on

the valve covers.
A WARNING
Improper lift rigging can allow unit to tumble caus-
ing injury and damage.
If improper equipment is used to lift the engine, injury

and damage can occur. Use cables that are properly
rated for the weight. Use a spreader bar and attach
the cables according to the information on the safety
message.
8
Safety Section
Safety Messages
Read the Manual Before Operating Hot Pressurized Fluid (4)

(3)
A WARNING
DO NOT OPERA TE OR WORK ON THIS [NGJNE OR
GENERATOR SET UNLESS YOU HAVE READ AN)
UNDERSTAND Tl£ INSTRUCTIONS AND WARNINGS IN FILTER CONTAINS HOT
THE OPERATION AND llAINT[NANC[ llANUALS.
FAILURE TO FOLLOW Tl£ WARNINGS AN) INSTRUCTIONS
PRESSURIZED FLUID WHEN
COULD RESUI. T IN INJURY OR DEATH. CONTACT ENGINE IS RUNNING. FOLLOW
ANY CATERPILLAR DEALER FOR R[PLAC[ll[NT
llANUALS. PROPER CARE IS YOUR RESPONSIBILITY. INSTRUCTIONS ON CONTROL
VALVE TO AVOID INJURY
127-7071
IF RAPID AIR MOVEMENT
EXISTS TO BLOW FLUID. STOP
ENGINE TO AVOID FIRE.
g00306265
Illustration 4
4W-51372
The safety message for read the manual before

operating is located on the outside of the door of the
control panel.
g01061488
Illustration 5
A WARNING The safety message for hot pressurized fluid is

located on the cover of the oil filter.
Do not operate or work on this engine or genera-
tor set unless you have read and understand the
instructions and warnings in the Operation and
Maintenance Manuals.
A WARNING
Filter contains hot pressurized fluid when engine
Failure to follow the warnings and instructions is running. Follow instructions on control valve to
could result in injury or death. Contact any avoid injury if rapid air movement exists to blow
Caterpillar dealer for replacement manuals. Prop- fluid. Stop engine to avoid fire.
er care is your responsibility.
9
Safety Section
Safety Messages
Coupling (5) Jumper Cable Connections (6)
.;:._ WARNING
~ WARNING
IMPROPER JUMPER CABLE
CONNECTIONS CAN CAUSE
EXPLOSION RESULTING IN
PERSONAL INJURY.
BATTERIES NAY B6 LOCATED IN SEPA-

IF ENGINE RUNS AND COUPLING IS NOT PROPERLY RE- RATE COMPARTNENTS. MIEN USING
STRAINED. PERSONAL INJURY OR PROPERTY DAMAGE JUMPER CABLES, ALWAYS CONNECT
MAY RESUL L POS111VE{t) CABLE TO POSITIVE{•)
TERNINAL OF BATTERY CONNEC!Ell
BEFORE STARTING ENGINE, DO ONE OF THE FOLLOWING: TO STARTER SOLENOID AND NEGA-
TIVE(') CABLE FROM EXTERNAL
1. ALIGN AND COUPLE THE EQUIPMENT. SOURCE TO STARTER NEGATIVE(·)
2. REMOVE THE LOOSE PARTS. TERNINAL (IF MACHINE NOT EQUIPPED
WITH STARTER NEGATIVE TERMINAl,
5. CENTER AND RESTRAIN THE LOOSE PARTS. 0N1s95 2 GONNECT TO ENGINE BLOCK.) FOL-
LOW PROCEDURE IN THE OPERATION
MANUAL 6V461l
g00305692 g00897261
Illustration 6 Illustration 7
The safety message for the coupling is located on The safety message for the connections for the
the sides of the flywheel housing. jumper cables is located near the electric starting
motor. This motor can be located on either side of
the engine.
,A WARNING
If engine runs and coupling is not properly re- ,A WARNING
strained, personal injury or property damage may
result. IMPROPER JUMPER CABLE CONNECTIONS CAN
CAUSE EXPLOSION RESULTING IN PERSONAL
Before starting engine, do one of the following: INJURY.
1. Align and couple the equipment. BATTERIES MAY BE LOCATED IN SEPARATE

COMPARTMENTS. WHEN USING JUMPER CA-
2. Remove the loose parts. BLES, ALWAYS CONNECT POSITIVE (+) CABLE
TO POSITIVE(+) TERMINAL OF BATTERY CON-
3. Center and restrain the loose parts. NECTED TO STARTER SOLENOID AND NEGA-
TIVE (-) CABLE FROM EXTERNAL SOURCE TO
STARTER NEGATIVE (-) TERMINAL (IF MACHINE
NOT EQUIPPED WITH STARTER NEGATIVE TER-
MINAL, CONNECT TO ENGINE BLOCK.) FOLLOW
PROCEDURE IN THE OPERATION MANUAL.
10
Safety Section
Safety Messages
Flash Fire (7) Prelube Pump (8)
A WARNING
FLASH FIRE MAY RESULT IN PERSONAL MOTOR MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL ELECTRICAL
CODE AND LOCAL CODES. BY TRAINED PERSONNEL TO
INJURY, IF CRANKCASE COVERS ARE PREVENT SERIOUS ELECTRICAL SHOCKS.
LIFTING PROVISIONS ARE INTENDED FOR LIFTING THE MOTOR ONLY.
MOTOR HAS AN AUTOMATIC THERMAL PROTECTOR. IF MOTOR
REMOVED WITHIN FIFTEEN MINUTES OVERHEATS. THERMAL PROTECTOR WILL OPEN CIRCUIT.
AFTER MOTOR COOLS SUFFICIENTLY, THERMAL PROTECTOR WILL
AFTER EMERGENCY SHUT DOWN. RESET WITHOUT WARNING AND RESTART MOTOR.
TO SERVICE MOTOR. DISCONNECT POWER SOURCE FROM MOTOR AND ANY
DO NOT RESTART ENGINE UNTIL CAUSE ACCESSORY DEVICES AND ALLOW MOTOR TO COME TO A COMPLETE
STANDSTILL. •W-6762 1
FOR SHUT DOWN HAS BEEN CORRECTED.
1H4950 7
g01061123 g00306385
The safety messages for flash fire are located on the The safety message for the prelube pump is located
crankcase covers. on the prelube pump.
A WARNING A WARNING
Flash fire may result in personal injury, if Motor must be grounded in accordance with na-
crankcase covers are removed within fifteen tional electrical code and local codes, by trained
minutes after emergency shut down. Do not personnel to prevent serious electrical shocks.
restart engine until cause for shutdown has been
corrected. Lifting provisions are intended for lifting the motor
only.
Motor has an automatic reset thermal protector. If

motor overheats, thermal protector will open mo-
tor circuit.
After motor cools sufficiently, thermal protector

will reset without warning and restart motor.
To service motor, disconnect power source from

motor and any accessory devices and allow motor
to come to a complete standstill.
11
Safety Section
General Hazard Information
i02016074

SMCS Code: 1000; 4450; 7405
. -~,
- ~
.· ~.
- .
··~ ~
g00702020
Illustration 11
• Wear a hard hat, protective glasses, and other

protective equipment, as required.
g00104545
Illustration 10 • 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.
Do not allow unauthorized personnel on the engine, Glass containers can break.
or around the engine when the engine is being
serviced. • Use all cleaning solutions with care.
Engine exhaust contains products of combustion • Report all necessary repairs.

which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated Unless other instructions are provided, perform
area. If the engine is in an enclosed area, vent the the maintenance under the following conditions:
engine exhaust to the outside.
• The engine is stopped. Ensure that the engine
Cautiously remove the following parts. To help cannot be started.
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed. • Disconnect the batteries when maintenance
is performed or when the electrical system is
• Filler caps serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• Grease fittings
• Do not attempt any repairs that are not understood.
• Pressure taps Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
• Breathers
California Proposition 65 Warning
• Drain plugs
Some engine exhaust constituents are known to the
Use caution when cover plates are removed. State of California to cause cancer, birth defects, and
Gradually loosen, but do not remove the last two other reproductive harm.
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
12
Safety Section
Pressure 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 pressure air and/or pressure water is used for

cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a protective face shield.
The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
g00702022
Illustration 13
Fluid Penetration
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
asbestos that is used in these components is usually
Illustration 12
g00687600 bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause If dust that may contain asbestos is present, there
serious injury and possible death. A pin hole leak can are several guidelines that should be followed:
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment • Never use compressed air for cleaning.
from a doctor that is familiar with this type of injury.
• Avoid brushing materials that contain asbestos.
Containing Fluid Spillage • Avoid grinding materials that contain asbestos.
Care must be taken in order to ensure that fluids • Use a wet method in order to clean up asbestos
are contained during performance of inspection, materials.
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable • A vacuum cleaner that is equipped with a high
containers before opening any compartment or efficiency particulate air filter (HEPA) can also be
disassembling any component that contains fluids. used.
Refer to Special Publication, NENG2500, "Tools anq • Use exhaust ventilation on permanent machining
Shop Products Guide" for the following items: jobs.
• Tools that are suitable for collecting fluids and • Wear an approved respirator if there is no other
equipment that is suitable for collecting fluids way to control the dust.
• Tools that are suitable for containing fluids and

equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.

13
Safety Section
Burn Prevention
• Comply with applicable rules and regulations i02088921

for the work place. In the United States, use
Occupational Safety and Health Administration Burn Prevention
(OSHA) requirements. These OSHA requirements
can be found in "29 CFR 1910.1001". SMCS Code: 1000; 4450; 7405
• Obey environmental regulations for the disposal Do not touch any part of an operating engine.
of asbestos. Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure in
• Stay away from areas that might have asbestos the appropriate system before any lines, fittings or
particles in the air. related items are disconnected.
Softwrap Coolant
Keep the engine room ventilation operating at full When the engine is at operating temperature, the
capacity. Wear a National Institute of Occupational engine coolant is hot. The coolant is also under
Safety and Health (NIOSH) approved particulate pressure. The radiator and all lines to the heaters or
respirator. Wear appropriate protective clothing to the engine contain hot coolant. Any contact with
in order to minimize direct contact. Use good hot coolant or with steam can cause severe burns.
hygiene practices and wash hands thoroughly after Allow cooling system components to cool before the
handling softwrap. Do not smoke until washing hands cooling system is drained.
thoroughly after handling softwrap. Clean up debris
with a vacuum or by wet sweeping. Do not use Check the coolant level after the engine has stopped
pressurized air to clean up debris. and the engine has been allowed to cool. Ensure
that the filler cap is cool before removing the filler
Reference: The applicable material safety data cap. The filler cap must be cool enough to touch with
sheets can be found at the following web site by a bare hand. Remove the filler cap slowly in order
searching by the part number or the name of the to relieve pressure.
product:
Cooling system conditioner contains alkali. Alkali can
http://dsf2ws.cat.com/msds/servlet/ cause personal injury. Do not allow alkali to contact
cat.cis.ecs.msdsSearch.controller. the skin, the eyes, or the mouth.
UserldentificationDisplayServlet
Oils
Dispose of Waste Properly
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
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte

g00706404
Illustration 14 levels. Batteries give off flammable fumes which can
explode.
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be Always wear protective glasses when you work with
disposed of according to local regulations. batteries. Wash hands after touching batteries. The
use of gloves is recommended.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
14
Safety Section
Fire Prevention and Explosion Prevention
i01027886 Do not allow flammable materials to accumulate on

the engine.
Fire Prevention and Explosion
Prevention Do not expose the engine to flames.
SMCS Code: 1000; 4450; 7405 Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
A flash fire may result in personal injury if the a tube, or a seal failure. Exhaust shields must be
crankcase covers are removed within fifteen minutes installed correctly.
after an emergency shutdown.
Dispose of oil according to local regulations. Oil
Fire may result from lubricating oil or from fuel that filters and fuel filters must be properly installed. The
is sprayed on hot surfaces. Fire may cause personal housing covers must be tightened to the proper
injury and property damage. Inspect all lines and torque when the housing covers are reinstalled.
tubes for wear or for deterioration. The lines must
be properly routed. The lines must have adequate Batteries must be kept clean. The covers (if equipped)
support and secure clamps. Tighten all connections must be kept on the cells. Use the recommended
to the recommended torque. Leaks can cause fires. cables, connections, and battery box covers when
the engine is operated.
Determine whether the engine will be operated in an
environment that allows combustible gases to be Check the electrical wires daily for wires that are
drawn in through the air inlet system. These gases loose or frayed. Before the engine is operated,
could cause the engine to overspeed. This could tighten all loose electrical wires. Repair all frayed
result in bodily injury, property damage, or damage electrical wires.
to the engine.
Wiring must be kept in good condition. Wires must
If the application involves the presence of combustible be properly routed and securely attached. Routinely
gases, consult your Caterpillar dealer in order to inspect the wiring for wear or for deterioration. Loose
obtain additional information concerning suitable wiring, unattached wiring, or unnecessary wiring
protection devices. must be eliminated. All wires and all cables must be
of the recommended gauge. Do not use a wire or a
Leaking fuel or fuel that is spilled onto hot surfaces or cable that is smaller than the recommended gauge.
onto electrical components can cause a fire. The wires and cables must be connected to a fuse or
to a circuit breaker, as required. Do not bypass fuses
All fuels, most lubricants, and some coolant mixtures and/or circuit breakers. Arcing or sparking could
are flammable. Diesel fuel is flammable. Gasoline is cause a fire. Secure connections, recommended
flammable. The mixture of diesel fumes and gasoline wiring, and properly maintained battery cables will
fumes is extremely explosive. help prevent arcing or sparking.
Do not smoke while the engine is refueled. Do not Fire Extinguisher

smoke in the refueling area.
Ensure that fire extinguishers are available. Be
Store all fuels and all lubricants in properly marked familiar with the operation of the fire extinguishers.
containers. Store the protective containers in a safe Inspect the fire extinguishers and service the fire
place. extinguishers regularly. Service the fire extinguisher
according to the recommendations on the instruction
Do not smoke in battery charging areas. Batteries plate.
give off flammable fumes which can explode.
Do not smoke in areas that contain flammable i01359666

material.
Crushing Prevention and
Store oily rags and other flammable material in Cutting Prevention
protective containers.
SMCS Code: 1000; 4450; 7405
Do not weld on pipes or tubes that contain flammable
fluids. Do not flame cut pipes or tubes that contain Support the component properly when work beneath
flammable fluids. Before pipes or tubes are welded the component is performed.
or flame cut, clean the inside and clean the outside
of the pipes or tubes thoroughly with nonflammable
solvent.
15
Safety Section
Mounting and Dismounting
Unless other maintenance instructions are provided, Do not attempt to remove the valve covers when the
never attempt adjustments while the engine is engine is operating. The transformers are grounded
running. to the valve covers. Personal injury or death may
result and the ignition system will be damaged if the
Stay clear of all rotating parts and of all moving valve covers are removed during engine operation.
parts. Leave the guards in place until maintenance The engine will not operate without the valve covers.
is performed. After the maintenance is performed,
reinstall the guards.
i00659904
Keep objects away from moving fan blades. The fan

blades will throw objects or cut objects.
Before Starting Engine
SMCS Code: 1000
When objects are struck, wear protective glasses in
order to avoid injury to the eyes. Inspect the engine for potential hazards.
Chips or other debris may fly off objects when objects Before starting the engine, ensure that no one is on,
are struck. Before objects are struck, ensure that no underneath, or close to the engine. Ensure that the
one will be injured by flying debris. area is free of personnel.
i01372247 Ensure that the engine is equipped with a lighting

system that is suitable for the conditions. Ensure that
Mounting and Dismounting all lights work properly.
SMCS Code: 1000; 4450; 7405 All protective guards and all protective covers must
be installed if the engine must be started in order
Inspect the steps, the handholds, and the work area to perform service procedures. To help prevent an
before mounting the engine. Keep these items clean accident that is caused by parts in rotation, work
and keep these items in good repair. around the parts carefully.
Mount the engine and dismount the engine only at Do not bypass the automatic shutoff circuits. Do not
locations that have steps and/or handholds. Do not disable the automatic shutoff circuits. The circuits are
climb on the engine, and do not jump off the engine. provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
Face the engine in order to mount the engine or engine damage.
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one On the initial start-up of a new engine or an engine
hand or use one foot and two hands. Do not use any that has been serviced, be prepared to stop the
controls as handholds. engine if an overspeed condition occurs. This may
be accomplished by shutting off the fuel supply to the
Do not stand on components which cannot support engine, or shutting off the ignition system.
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the See the Service Manual for repairs and for
equipment will not move. adjustments.
Do not carry tools or supplies when you mount the

engine or when you dismount the engine. Use a hand i02136012
line to raise and lower tools or supplies. Engine Starting

i00702251 SMCS Code: 1000
Ignition Systems If a warning tag is attached to the engine start switch

or to the controls, DO NOT start the engine or move
SMCS Code: 1550 the controls. Consult with the person that attached
the warning tag before the engine is started.
Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and All protective guards and all protective covers must
·~ wiring. be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
16
Safety Section
Engine Stopping
If there is a possibility that unburned gas remains in i00887114

the exhaust system, refer to the purge procedure in
this Operation and Maintenance Manual, "Engine Electrical System
Starting" topic in the Operation Section.
SMCS Code: 1000; 1400
Start the engine from the operator's compartment or
from the engine start switch. Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
Always start the engine according to the procedure is operating. A spark can cause the combustible
that is described in the Operation and Maintenance gases that are produced by some batteries to ignite.
Manual, "Engine Starting" topic in the Operation
Section. Knowing the correct procedure will help to Check the electrical wires daily for wires that are
prevent major damage to the engine components. loose or frayed. Tighten all loose electrical wires
Knowing the procedure will also help to prevent before the engine is operated. Repair all frayed
personal injury. electrical wires before the engine is started.
To ensure that the jacket water heater (if equipped) Grounding Practices
and/or the lube oil heater (if equipped) is working
properly, check the water temperature and the oil Proper grounding is necessary for optimum engine
temperature during heater operation. performance and reliability. Improper grounding will
result in uncontrolled electrical circuit paths and in
Engine exhaust contains products of combustion unreliable electrical circuit paths.
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated Uncontrolled electrical circuit paths can result in
area. If the engine is started in an enclosed area, damage to main bearings, to crankshaft journal
vent the engine exhaust to the outside. surfaces, and to aluminum components. Uncontrolled
electrical circuit paths can also cause electrical
activity that may degrade the engine electronics and
i00659907
communications.
Engine Stopping
For the starting motor, do not attach the battery
SMCS Code: 1000 negative terminal to the engine block.
To avoid overheating of the engine and accelerated Use a ground strap to ground the case of all control
wear of the engine components, stop the engine panels to the engine block.
according to the instructions in this Operation and
Maintenance Manual, "Engine Stopping" topic Ground the engine block with a ground strap that is
(Operation Section). furnished by the customer. Connect this ground strap
to the ground plane.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency Use a separate ground strap to ground the battery
Stop Button for normal engine stopping. After an negative terminal for the control system to the ground
emergency stop, DO NOT start the engine until the plane.
problem that caused the emergency stop has been
corrected. Rubber couplings may connect the steel piping of
the cooling system and the radiator. This causes the
On the initial start-up of a new engine or an engine piping and the radiator to be electrically isolated.
that has been serviced, make provisions to stop Ensure that the piping and the radiator is continuously
the engine if an overspeed occurs. This may be grounded to the engine. Use ground straps that
accomplished by shutting off the fuel supply to the bypass the rubber couplings.
engine, or shutting off the ignition system.
Ensure that all grounds are secure and free of
corrosion.
17
Model Views and Specifications
I
Product Information
Section
Model Views and

S pacifications
i01626872
Model View Illustrations

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

G3500 Engines. The illustrations do not show all of
the options that are available.
18
(1) Exhaust bypass (8) Oil filler (15) Exhaust

(2) Aftercooler (9) Lifting eye (16) Turbocharger
(3) Instrument panel (10) Oil level gauge (dipstick) (17) Auxiliary water pump
(4) Crankcase breather (11) Air cleaner (18) Gas shutoff valve
(5) Oil filter (12) Jacket water pump (19) Gas regulator
(6) Guard (crankshaft vibration damper) (13) Oil screen (20) Flywheel housing
(7) Engine control module (ECM) (14) Oil drain
i01627027 Fuel System

Product Description The engines can be equipped with a high pressure
SMCS Code: 1000; 4450 gas fuel system or a low pressure gas fuel system.
Three different fuel systems are available:
The Caterpillar G3500 Engines were developed
in order to provide gas engines for industrial • Low Emission (LE) with high pressure gas
applications and for generator set applications. The
engines have the ability to burn a wide variety of • LE with low pressure gas
gaseous fuels.
• Standard (stochiometric) with high pressure gas
19
The LE engine with high pressure gas requires Ignition System

a gas pressure within a range of 207 to 310 kPa
(30 to 45 psi). The air/fuel ratio is adjusted so that The engine is equipped with an Electronic Ignition
there is excess oxygen in the engine exhaust. This System (EIS). The EIS provides dependable firing
reduces the NO. emissions. and low maintenance. The EIS provides precise
control of the following factors:
The LE engine with low pressure gas requires a gas
pressure within a range of 10 to 34 kPa ( 1.5 to 5 psi). • Spark voltage
The LE engines with NO. ratings of two grams have • Spark duration
a nominal air/fuel ratio that results in approximately
eight percent of free oxygen in the exhaust. The LE • Ignition timing
engines are turbocharged and aftercooled.
The EIS also provides diagnostic capability that
The Standard engines require gas pressure within a enhances troubleshooting. The primary ignition wiring
range of 138 to 172 kPa (20 to 25 psi). The nominal is routed internally through the engine.
air/fuel ratio results in approximately two percent of
free oxygen in the exhaust. The Standard engines The engines are equipped with protection from
are available with natural aspiration or turbocharged detonation (combustion knock). The detonation
with aftercooling. sensors are mounted on each side of the cylinder
block. The ignition timing is retarded when excessive
The engines can be equipped with a dual fuel system detonation is sensed. If detonation continues after full
in one of the following configurations: retardation, then the engine control module (ECM)
shuts down the engine.
• A carburetor for high pressure gas and a carburetor
for low pressure gas Lubrication System
• Two parallel carburetors for low pressure gas The engine lubrication oil is supplied by a pump
that is driven by a gear. The oil is cooled and the
For low pressure gas engines, the carburetor is oil is filtered. A bypass valve provides unrestricted
located between the air cleaner and the turbocharger. flow of lubrication oil to the engine parts if the oil
For high pressure gas engines, the carburetor is filter elements become plugged. The bypass valve
located after the aftercooler and above the throttle. will open if the oil filter differential pressure reaches
A governor and an actuator controls the carburetor. 276 kPa (40 psi).
The governor maintains the engine rpm. The two
following types of carburetors are available:
Cooling System
• Fixed venturi
The standard cooling system has a centrifugal pump
• Adjustable jet that is driven by a gear. Four temperature regulators
regulate the temperature of the coolant.
The low pressure gas engines can use either the
fixed venturi or the adjustable jet. Standard engines The turbocharged engine has a Separate Circuit
and LE engines with high pressure gas use the Aftercooler (SCAC). The aftercooler is required to
adjustable jet. operate at one of the following three temperatures.
The temperature depends on the engine rating and
The turbocharged aftercooled engines are equipped the application.
with flame arrestors. The flame arrestors are installed
at the entrance of each inlet port. The flame arrestors • 32 °C (90 °F)
prevent the engine backfire. The Engine backfire can
occur in the following circumstances: • 54 °C (129 °F)
• Malfunction of ignition • 70 °C (158 °F)
• Engine shutdown
The flame arrestors will extinguish the flame before

the flame can ignite in the inlet manifold.
20
Cogeneration uses energy from heat which would i02151232

otherwise be wasted. In a cogeneration engine, the
oil cooler is not in the jacket water circuit because Specifications
the jacket water is too hot. The circuit for the oil
cooler and the circuit for the aftercooler may be SMCS Code: 1000
either a combined circuit or a separate circuit. In
the combined system, the auxiliary pump circulates General Engine Specifications
water through both the aftercooler and oil cooler
cores. The combined system uses a thermostatic
control to regulate the oil temperature. This prevents 8-6-4--2
overcooling. r6evo9\(o~ r69\
~~~~
Jacket water for cogeneration can be supplied
at temperatures up to 127 °C (260 °F max). The
customer must supply a pump for circulating the c
heated jacket water. The temperature of the jacket
water is controlled by the customer.
teO\r.O\ feO\ feO\
For engines that use landfill gas, the jacket water ~-0)~_0)~0) ~O)
7-5-3--1
coolant temperature is maintained at approximately
110 °C (230 °F min). This temperature depends on A-0 B-9
the design of the cooling system and the ambient
conditions. This temperature is required in order to g00845204
Illustration 16
prevent condensation of the water vapor that is in the (1 through 8) Cylinder numbers
fumes of the crankcase. Condensation of the water (A) Inlet valves
enables acids to form. Acids are more likely to form (B) Exhaust valves
because landfill gas contains contaminants such as (C) Flywheel
chlorides, fluorides, and halides. Acids will cause
Table 1
severe internal damage to the engine.
G3508 Engine Specifications
For engines that use landfill gas, the coolant that
Rated rpm 1000 to 1800
is supplied to the aftercooler is maintained at
a temperature of 54 °C (129 °F). This prevents Cylinders and arrangement 65 degree Vee 8
condensation of moisture in the inlet air piping.
Bore 170 mm (6. 7 inch)
Engine Service Life Stroke 190 mm (7.5 inch)

Displacement 34.5 L (2105 cubic inch)
Engine efficiency and maximum utilization of engine
performance depend on adherence to proper Compression ratio 7.5:1
operation and maintenance recommendations. This 8:1
includes the use of recommended lubricants, fuels,
and coolants. 11 :1
12.5:1
For the engine maintenance that is required,
refer to the Operation and Maintenance Manual, Aspiration Naturally aspirated
"Maintenance Interval Schedule" in the Maintenance Turbocharged aftercooled
Section. 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)
21
12-10-8-6-4-2
(b~rQ~r69' (09\ (69\ r6•\ 16-14-12-10-8-6-4-2
~~~~~~ (09\tbe'Vbe'\(09\(69\(6~(69\(69\
~~~~~\Q!J~~
c c
t90\t9()\t90\t90\ t90\ t90\ fiO\ fiO\fiO\fi0\!90\fiO\ !90\ fiO\
~O)~p)~-qJ~qJ ~p) ~,0) ~gJ~gJ~gJ~~91~9)~9'~~9'~.9'
11-9-7-5-3-1 15-13-11-9-7-5-3-1
A-0 B • • A-O s-e
Illustration 17 g00845207 g00845212

Illustration 18
(1 through 12) Cylinder numbers (1 through 16) Cylinder numbers
(A) Inlet valves (A) Inlet valves
(B) Exhaust valves (B) Exhaust valves
(C) Flywheel (C) Flywheel
Table 2 Table 3
G3512 Engine Specifications G3516 Engine Specifications
Rated rpm 1000 to 1800 Rated rpm 1000 to 1800
Cylinders and arrangement 65 degree Vee 12 Cylinders and arrangement 65 degree Vee 16
Bore 170 mm (6.7 inch) Bore 170 mm (6. 7 inch)
Stroke 190 mm (7.5 inch) Stroke 190 mm (7.5 inch)
Displacement 51.8 L (3158 cubic inch) Displacement 69 L (4210 cubic inch)
Compression ratio 7.5:1 Compression ratio 7.5:1
8:1 8:1
11 :1 11 :1
12.5:1 12.5:1
Aspiration Naturally aspirated Aspiration Naturally aspirated
Turbocharged aftercooled Turbocharged aftercooled
Separate circuit Separate circuit
aftercooling aftercooling
Rotation (flywheel end) Counterclockwise rotation Rotation (flywheel end) Counterclockwise rotation
is standard. is standard.
Clockwise rotation is Clockwise rotation is
optional. optional.
Inlet valve lash 0.51 mm (0.020 inch) Inlet valve lash 0.51 mm (0.020 inch)
Exhaust valve lash 1.27 mm (0.050 inch) Exhaust valve lash 1.27 mm (0.050 inch)
22
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
(1l For the complete procedure, refer to the Service Manual, "Systems Operations Testing and Adjusting".
23
Product Identification Information
Product Identification
Information ENGINE
MODEL
SERIAL
NUMBER
i01627115
Plate Locations and Film oC.i.TERPILLAR ®C.i.T®o

Locations ARRANGEMENT
NUMBER
SMCS Code: 1000; 4450

(ALWAYS GIVE ALL NUMBERS)
MADE IN U.S.A. 3N-3790 12
Engine Identification
Caterpillar engines are identified with serial numbers, Illustration 20
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 21
(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 19
(1) Location of the Serial Number Plate
The Serial Number Plate is on the left side of the SER. NO.
cylinder block near the rear of the engine. AR COllP.
NO. RATIO TO I
AFTERCOOLER TEllPERATURE I IGNITION 'l'llllNG B'l'DC

CONSULT FUEL USAGE GUIDE
DEG.C DEG.F
'---~~~~~~~~---!
POl!IR k• BP
FULL LOAD RPll
159-8314
g00361974
Illustration 22
24
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
Turbocharger
SMCS Code: 1000; 4450
Fuel Filter Element
Identification of the items in Table 5 may be needed
Lubrication Oil Filter
in order to obtain parts and service. Some of the
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.
25
Operation Section
Lifting and Storage
Operation Section Engine Lifting with a Generator
NOTICE
Do not use the engine lifting eyes to remove the en-
Lifting and Storage 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
g00103219 package is lifted. This may cause the locking nuts
Illustration 23
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.
26
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.
27
Operation Section
Gauges and Indicators
Gauges and Indicators Jacket Water Coolant Temperature -
i01663514 ®
$ This gauge indicates the temperature of the
engine coolant at the outlet for the jacket
water. The temperature may vary according to the
Gauges and Indicators load. The temperature should never be allowed to
exceed the boiling temperature of the pressurized
SMCS Code: 7450 cooling system. The operating range is 88 to 100 °C
(190 to 210 °F). Higher temperatures may occur
Gauges provide indications of engine performance. under certain conditions. Engines that use fuel with
Ensure that the gauges are in good working order. a low Btu content may have temperatures up to
Determine the normal operating range by observing 11 O °C (230 °F). Cogeneration engines may have a
the gauges over a period of time. maximum temperature up to 127 °C (260 °F).
Noticeable changes in gauge readings can indicate

potential gauge or engine problems. Problems may The engine should operate within the normal
also be indicated by gauge readings that change temperature range. The sensor for jacket water
even if the readings are within specifications. coolant temperature must be fully submerged in order
Determine and correct the cause of any significant to detect the temperature correctly. If the engine
change in the readings. Consult your Caterpillar is operating above the normal temperature range,
dealer for assistance. perform the following procedure:
Your engine may not have the same gauges or all of 1. Reduce the load and/or the engine rpm.
the gauges that are described below.
2. Inspect the cooling system for leaks.
NOTICE 3. Determine if the engine must be shut down

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

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

pressure. The gauge pressure is the difference
between the barometric pressure and the absolute
pressure.
28
Operation Section
The Digital Diagnostic Tool can be used to display the

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

Pressure and Inlet Manifold Vacuum, see one of the Note: The rated rpm is stamped on the engine
following two publications: Information Plate.
• Engine Performance, LEBQ6117, "G3500 Service Hour Meter - The meter indicates
Industrial" the total number of clock hours of engine
operation.
• Engine Performance, LEBQ6169, "G3500
Generator Set" Fuel Filter Differential Pressure - This gauge is
provided by the customer. This gauge indicates the
Pyrometer - The pyrometer indicates the exhaust difference in fuel pressure between the inlet side
stack temperature at the exhaust elbows. For engines and the outlet side of the fuel filter. As the fuel filter
with two exhaust stacks, the two exhaust stack element becomes plugged, the difference in pressure
temperatures may vary slightly. This may be due to between the two sides of the fuel filter increases.
variation of the sensitivity of the two thermocouples.
For high pressure gas fuel systems, service the fuel
• For Low Emission engines, the nominal exhaust filter when the fuel filter differential pressure reaches
stack temperature is less than 554 °C (1030 °F). 34 kPa (5 psi).
• For Standard engines, the nominal exhaust stack For low pressure gas fuel systems, service the
temperature is less than 51 O °C (950 °F). fuel filter when the fuel filter differential pressure
reaches1. 7 kPa (.25 psi).
• The exhaust stack temperature of NA engines
depends on the engine rpm and the oxygen that is
in the exhaust. For NA engines, the nominal range Optional Gauges
is 538 to 649 °c (1000 to 1200 °F).
Air Cleaner Differential Pressure -
The pyrometer also indicates the temperature of This gauge indicates the difference in air
the exhaust gas of each individual cylinder. These pressure between the inlet side and the
temperatures are measured at the exhaust port of engine side of the air filter element. The pressure
each cylinder head. The exhaust temperature will is measured from the turbocharger air inlet. As the
vary slightly between the cylinders. Table 6 lists air filter element becomes plugged, the difference
nominal temperatures and maximum temperatures. in pressure between the two sides of the air
cleaner element will increase. For optimum engine
Table 6 performance, replace the air filter elements or clean
the air filter elements when the air cleaner pressure
Exhaust Port Temperatures differential reaches 2.5 kPa (10 inches of H20).
Engine Nominal Maximum Maximum air cleaner differential pressure is 3. 7 kPa
Temperature Temperature (15 inches of H20).
Low Emission 621°C(1150°F) 670 °C (1238 °F)
Ammeter - This gauge indicates the
Standby (Low
Emission)
621°C(1150°F) 700 °C (1292 °F) (f)
7 amount of charge or discharge in the
battery charging circuit. Operation of the
Standard 643 °C (1190 °F) 700 °C (1292 °F) indicator should be to the right side of "O"(zero).
Standby
643 °C (1190 °F) 730 °C (1346 °F) Engine Oil Temperature - This gauge
(Standard)
indicates the engine oil temperature after
the oil has passed through the oil cooler.
Tachometer - This gauge indicates the The oil cooler is thermostatically controlled. The
engine rpm. oil temperature is controlled by an 82 °C (180 °F)
temperature regulator that is in contact with the oil.
The maximum oil temperature at rated rpm and rated
load is 104 °C (220 °F).
29
Operation Section
Coolant Pressure - This gauge can be

@
.e.. used for jacket water pressure or auxiliary
water pressure. On cogeneration engines,
this gauge is a differential pressure gauge.
30
Operation Section
Features and Controls
Features and Controls Gas Pressure Regulator
The gas pressure regulator maintains a pressure

i02015329 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 H20) 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 H20). The higher differential pressures will
Adjusting" or see Special Instruction, SEHS9769, give better engine response to load changes.
"Installation and Initial Start-Up Procedure for G3500
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 H20).
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.
31
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
• Btu of the fuel the setting of the exhaust bypass valve. The proper
angle depends on the type of governor or actuator
• Air/fuel setting that is used.
• Carburetor jet • For the Woodward 3161 Governor and the EG3P
Actuator, adjust the angle of the throttle plate
• Ignition timing between 60 and 65 degrees.
• Deposits in the combustion chamber The following factors affect the angle of the throttle:
To reduce the risk of detonation during loading, adjust
• LHV of the fuel
the ramp time so that the load is applied over five
to ten minutes. • Setting of the air/fuel ratio (inlet manifold air
pressure)
If detonation still occurs, or if startability is inhibited,
the air/fuel ratio for partial load operation can be • Setting of the exhaust bypass (wastegate)
made leaner. Install 7E-1569 Washers behind each
gas valve of the carburetor. Use a maximum of three • Altitude
washers per valve. After the washers are installed,
adjust the setting for the oxygen at full load. Ensure that the angle of the throttle plate is properly
set. This will maintain the margin for detonation. This
Optional Air/Fuel Ratio Control will also enable the engine to accept load changes
without lugging.
The engine may be equipped with an air/fuel ratio
control system. The system provides the following Setting of the Exhaust Bypass
capabilities:
(Wastegate)
• Control of exhaust emissions
The engines are equipped with exhaust bypass
• Adjustment for changes in the fuel BTU valves that are adjustable. This enables the throttle
position to be correctly set for the application.
• Engine speed governing Adjustments must be made for the following
variables:
The system consists of the following components:
• Altitude
• Electronic Control Module (ECM)
• Setting of the air/fuel ratio
• Oxygen sensor
• Methane number of the fuel
• Oxygen buffer
The exhaust bypass is adjusted in order to achieve
• Speed sensor the proper angle of the throttle plate when the engine
is operating under a rated load.
• Inlet manifold pressure sensor
Oil Consumption
• Inlet manifold temperature sensor
High loads will cause the engine to consume more oil.
• Fuel valve
32
Operation Section
The rate of oil consumption is called the Brake • Precise control of ignition timing
Specific Oil Consumption (BSOC). The unit of
measure is grams per brake kilowatt hour (pounds The electronic ignition system provides control for the
per brake horsepower hour). The BSOC depends on following activities:
the following factors: engine model, aspiration, and
operating load. • Diagnostics of the engine control system
Table 7 lists the normal mid-life BSOC for G3500 • Ignition timing
Engines under the following conditions:
• Protection from detonation
• Load factor of 100 percent
If operating parameters are outside of acceptable
• Maintenance is performed according to this limits, the electronic ignition system provides
Operation and Maintenance Manual, "Maintenance warnings. The system may inhibit the engine
Interval Schedule" (Maintenance Section). operation or may shut down the engine. Also, the
system can display some of the operating parameters
Table 7 of the engine.
BSOC for G3500 Engines
The electronic ignition system includes the following
Naturally Aspirated Engine 0.913 g/bkw h components:
(0.0015 lb/bhp h)
Turbocharged Aftercooled Engine 0.426 g/bkw h • Detonation sensors
(0.0007 lb/bhp h)
• EIS control module
i02015359 • Engine speed/timing sensor
Sensors and Electrical • Ignition harness

Components • Manifold air pressure sensor
SMCS Code: 1900; 7400
• Sensor harnesses
Note: This section contains some general information
about the engine electronic system and sensors. For • Spark plugs
more information, see the following publications:
• Transformers
• Systems Operation/Testing and Adjusting,
SENR6412, "G3500 Engines" Control of the Electronic Ignition System
• Specifications, SENR6417, "G3500 Engine

Attachments"

SENR6418, "G3500 Engine Attachments"
• Electronic Troubleshooting, SENR6413, "G3500

Engines"
Electronic Ignition System (EIS)

The Caterpillar Electronic Ignition System was
designed to replace the type of ignition system that
has a magneto. The following benefits are the most Illustration 24 g00309805
significant advantages of the electronic ignition
EIS control module
system:
• Addition of more extensive system diagnostics
• Elimination of parts that are prone to mechanical

wear
33
Operation Section
The EIS control module is a sealed unit with no Junction Box

serviceable parts. Sensors are used in order to
monitor engine operation. Wiring harnesses connect
the sensors to the control module. The module uses
information from the sensors in order to determine
the ignition timing. The information is also used to
provide diagnostics.
Note: On newer engines, there is a small door on

the front face of the control module. Replace the
computer chip inside the control module if updates or
special modifications are required.
The primary ignition wiring is routed through the

engine block. Ignition timing is based on the following
variables: g00787967
Illustration 25
• Map of ignition timing that is desired (1) Junction box
(2) Emergency stop button
• Engine parameters
Junction box (1) contains these components:
The operator can use an electronic service tool to
change the following parameters: • Gauges
• Desired timing • Meters
• Map of speed and timing • Indicators
The EIS control module has outputs to each ignition • Switches

transformer. The module also uses sensors and
internal circuitry to monitor the system components. The junction box also contains the electrical terminal
If a problem develops in a component or a wiring strips that connect the sensors, pickups, and relays
harness, the control module will sense the problem. to the gauges. In addition, the junction box provides
The control module will notify the operator by creating shutoff protection for the engine.
a diagnostic code.
Emergency stop button (2) is mounted on the junction
box. When this button is pressed, both the fuel and
Ignition Transformers the ignition are s_hut off.
Each cylinder has an ignition transformer that is
located under the valve cover. To initiate combustion NOTICE
in each cylinder, the engine control module sends a Do not use this method to stop the engine unless
pulse to the primary coil of the ignition transformer. an emergency has occurred. Continuous emergency
The transformer increases the voltage which creates shutdowns can cause damage to some engine com-
a spark across the spark plug electrode. ponents. This will leave unburned fuels in the combus-
tion chambers and in the exhaust system. If an emer-
For the electronic ignition system, the transformers gency shutdown occurs, purge the system by cranking
are grounded through the valve cover. Use caution the engine for 5 to 10 seconds with the ignition shutoff.
when a valve cover is removed.
The emergency stop button must be reset before
Always disconnect the ignition harness from the the engine will start. Turn the button clockwise. The
transformer when a valve cover is removed. spring-loaded button will move to the reset position.
An ignition harness connects each transformer to the G3500 Engines use an energize-to-run system.
engine control module. The harness is routed inside The system can also be configured as an
the engine along the camshaft. energize-to-shutoff system.
34
Operation Section
g00310783
Illustration 26
Gas shutoff valve (GSOV)
For an energize-to-run system, the gas shutoff valve -+@

(GSOV) must remain energized in order to supply
fuel to the engine.
g00851236
Illustration 27
For an energize-to-shutoff system, the GSOV must
be energized in order to shut off the fuel to the engine. The coolant level sensor is mounted in the expansion
tank. If the coolant level is too low, the sensor can
The junction box is used to monitor the following activate an alarm or a shutoff. Coolant must be added
parameters: to the cooling system in order to correct the condition.
• Engine oil pressure
Detonation
• Engine coolant temperature
If the engine oil pressure is too low, or if the coolant

0 00
temperature is too high, a relay will shut off the fuel.
Sensors
Sensors provide information to the junction box and
the engine control module. The information enables
the module to control the engine as efficiently as
possible over a wide range of operating conditions.
The information is used for monitoring engine
operation via gauges and indicators on the junction
box and/or the control panel.
g00455704
Illustration 28
The sensors also enable the activation of alarms and Detonation sensor
shutoffs in response to abnormal operation.
The detonation sensors monitor the engine for
Air Inlet Temperature detonation. One sensor is mounted in the center of
each cylinder bank. The sensor produces a voltage
A probe for monitoring the air inlet temperature is signal that is proportional to the engine detonation.
located in the air inlet manifold. No adjustment can This information is processed by the engine control
be made to the temperature range. Excessive inlet module in order to determine detonation levels. To
air temperature can activate an alarm or a shutdown. eliminate detonation, the engine control module
retards the engine timing, if necessary. If excessive
Coolant Level detonation continues, the engine control module will
shut down the engine.
Monitoring of the coolant level is an optional
attachment.
35
Operation Section
Engine Oil Pressure Manifold Air Pressure
00
g00455784 g00309908
Oil pressure sensor Manifold air pressure sensor
The engine oil pressure sensor is located in the side The manifold air pressure sensor is connected to the
of the engine block. The sensor measures the oil air inlet manifold. The sensor monitors the absolute
pressure in the bearing oil gallery. Low oil pressure manifold air pressure. This is the atmospheric
will cause a shutdown. pressure plus the gauge pressure. The information is
used by the engine control module to determine the
engine load. The output of the sensor can be read
Engine Speed/Timing Sensor with the Digital Diagnostic Tool.
Overs peed
@
g00309907
Illustration 30
Engine speed/timing sensor
g00318743
Illustration 32
The engine speed/timing sensor provides accurate
information about the speed of the crankshaft and the (1) Magnetic pickup for the governor
(2) Magnetic pickup for the service meter
position of the crankshaft. A ring that is mounted on
the camshaft provides the information that is detected
by the sensor. The engine control module uses the Two magnetic pickups are mounted in the flywheel
information in order to determine ignition timing. housing. The magnetic pickups monitor the rpm of
the flywheel ring gear. The following conditions will
cause a shutdown:
• The engine rpm exceeds the setpoint for

overspeed.
• The control system does not receive a signal from

the magnetic pickup.
36
Operation Section
Water Temperature
A WARNING
Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal
. injury and/or property damage may result.
Before starting an engine that may contain un-

burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the. topic on
purging unburned gas in the "Starting the Engine"
section.
If an engine protective device shuts off the engine,

always determine the cause of the shutoff. Make
the necessary repairs before attempting to start the
g00455866
Illustration 33 engine.
Water temperature sensor
Become familiar with the following information:
The water temperature sensor is located in the
water temperature regulator housing. To monitor • Types of the alarm and shutoff controls
the coolant temperature, the element must be in
contact with the coolant. If overheating occurs due to • Locations of the alarm and shutoff controls
low coolant level or no coolant, the sensor will not
function properly. The sensor can be wired into an • Conditions which cause each control to function
alarm system or an indicator in order to indicate high
water temperature. After an overheated engine is • Resetting procedure that is required before starting
allowed to cool, the contactor is automatically reset. the engine
i02145508 Testing Alarms and Shutoffs

Alarms and Shutoffs Alarms must function properly in order to provide
timely warning to the operator. Shutoffs help to
SMCS Code: 7400 prevent damage to the engine. It is impossible
to determine if the engine protective devices are
Engines may be equipped with optional engine in good working order during normal operation.
protective devices that are not included in this section. Malfunctions must be simulated in order to test the
This section contains some general information about engine protective devices.
the function of typical engine protective devices.
NOTICE
Alarms and shutoffs are electronically controlled. During testing, abnormal operating conditions must be
The operation of all alarms and shutoffs utilize simulated.
components which are actuated by a sensing unit.
The alarms and shutoffs are set at critical operating The tests must be performed correctly in order to pre-
temperatures, pressures, or speeds in order to vent possible damage to the engine.
protect the engine from damage.
The alarms function in order to warn the operator Periodic testing of engine protective devices for
when an abnormal operating condition occurs. The proper operation is recommended maintenance. To
shutoffs function in order to shut down the engine prevent damage to the engine, only authorized
when a more critical abnormal operating condition service personnel or your Caterpillar dealer
occurs. The shutoffs help to prevent damage to the should perform the tests.
engine.
Shutoffs may cause unburned gas to remain in the

air inlet and in the exhaust manifold.
37
Operation Section
Setpoints for Alarms and Shutoffs Table 9

Setpoints For Cogeneration Engines
Inlet Manifold Air Temperature
Condition Setpoint
Table 8 lists information on the operating Alarm signal of differential 34.5 kPa (5 psi)
· temperatures and the shutdown temperatures for pressure of jacket water
inlet manifold air temperature. The temperatures pressure
are associated with different water temperature
Alarm signal of jacket 127 °C (260 °F)
regulators for separate circuit aftercoolers. The water coolant temperature
temperatur.es are also associated with different types
of gas engines. Alarm signal of engine oil 102 °C (215 °F)
temperature
Table 8
Shutdown temperature of 104 °C (220 °F)
Approximate Operating Temperatures And engine oil
Shutdown Temperatures For G3500 Engine
Inlet Manifold Air Temperature Alarm signal of inlet air 68 °C (154 °F)
temperature or shutdown<1)
Opening Approximate Shutdown
<1l High inlet air temperature is a shutdown for NA engines. High
Temperature Operating Temperature inlet air temperature is an alarm for all other engines.
for the Water Temperature
Temperature Table 10
Regulator
(SCAC) Setpoints For Engines that use Bio-Gas Fuel
32 °C (90 °F) 43 °C (110 °F) 47 °C (117 °F) Condition Setpoint
Low Emission
Alarm signal of differential 48.3 kPa (7 psi)
engine
pressure of jacket water
54 °C (130 °F) 64 °C (147 °F) 68 °C (154 °F) pressure
Low Emission
Alarm signal of jacket 124 °C (255 °F)
engine
water coolant temperature
70 °C (158 °F) 78 °C (172 °F) 81 °C (178 °F)
Arming relay of jacket 98 °C (208 °F)
Low Emission
water pressure
engine
45 °C (113 °F) Shutdown temperature of 107 °C (225 °F)
32 °C (90 °F) 41 °C (106 °F)
Standard engine engine oil
Shutdown temperature of 68 °C (154 °F)
54 °C (130 °F) 62 °C (144 °F) 66 °C (151 °F)
Standard engine inlet air
Cogeneration and Bio-Gas Fuel Engines Without A Caterpillar Remote

Applications Control Panel (Status)
The customer must provide the relay logic for engines
G3500 Engines that are in cogeneration and bio-gas
that are not equipped with a Caterpillar Remote
applications operate with jacket water coolant
Control Panel (Status). The customer must provide
temperatures that are higher than normal. The
the relay logic for the following parameters:
protective system is optional for cogeneration
engines. The protective system is standard for
engines that use bio-gas fuel . • Oil pressure (high idle limit)
Table 9 lists the setpoints for cogeneration engines. • Oil pressure (low idle limit)
Table 10 lists the setpoints for engines that use
• Jacket water coolant temperature (high
bio-gas fuel.
temperature)
• Overspeed
The specific limits are listed in Table 11. Relay logic

must be provided for shutting off the engine in case
any of the limits are reached. Consult your Caterpillar
dealer for assistance.
38
Operation Section
Table 11
G3500 Engine Shutdown Setpoints

Rated Minimum Oil . Jacket Overs peed
RPM Pressure Water<1J RPM
Temp.
High Low
Idle Idle
RPM RPM
1000 275 100 105 °C 1200
kPa kPa (221 °F)
(40 psi) (15 psi)
1400 275
kPa
100
kPa
105 °C
(221 °F)
1680 @)
SI ENGINE STATUS CONTROL
~ .,~6
•
.i~ II
~ ·-·
(40 psi) (15 psi)
1500 275 100 105 °C 1800
kPa kPa (221 °F)
(40 psi) (15 psi)
Oe : O+~~
1800 275 100 105 °C 2160 Oi!6 ~~ 0 A "'="
kPa kPa (221 °F) oel~ o
(40 psi) (15 psi)
@) @)
(1) To prevent overheating, the coolant pressure must be a
minimum of 27.6 kPa (4 psi).
i02013999
Control Panel g00785285

Illustration 34
SMCS Code: 7451 Remote Control Panel (Status)
(1) "WARNING" indicator
(2) "SHUTDOWN" indicator
Remote Control Panel (Status) (3) "POWER ON" indicator
(4) "DIAGNOSTIC RESET" switch
This section contains some general information about (5) Status control module
the Remote Control Panel (Status). For more detailed (6) Engine control switch
(7) "EMERGENCY STOP" button
information, see these publications:
• Systems Operation/Testing and Adjusting, The yellow "WARNING" indicator (1) flashes or stays
SENR6420, "Control Panel (Status-Timing)" lighted in order to indicate the occurrence of an
abnormal operating condition. A warning is not severe
• Electronic Troubleshooting, SENR6413, "G3500 enough to cause a shutdown. However, this signifies
Engines". a serious problem. If a warning occurs, a diagnostic
code for the condition is logged in the engine control
module. Correct the cause of the warnings as soon
as possible in order to avoid problems with operation.
The red "SHUTDOWN" indicator (2) illuminates

continuously when an adverse operating condition
causes a shutdown. A diagnostic code for the
condition is logged in the engine control module. If
the engine is shut down due to parameters that are
out of acceptable limits, the red indicators on the
status control module (5) will also illuminate.
"POWER ON" indicator (3) illuminates continuously

when power is supplied to the control panel.
39
Operation Section
"DIAGNOSTIC RESET" switch (4) is a toggle switch

that is used to clear diagnostic codes from the engine
control module. The switch cannot clear individual @ @
codes. Use of the switch will clear all codes that are
active in the engine control module. Do not clear the CONTROL 2
codes until the problems that caused the codes
are addressed.
Status control module (5) has several engine

monitoring and control functions.
3
Engine control switch (6) is used to control starting
the engine and stopping the engine. sITTo® r.~
"EMERGENCY STOP" button (7) is used to stop the ~II ,."~",~ ~
Oil'.i) '"';,o;:c' I
engine in an emergency situation. When the button is 7~ ~ J ~....,,,,,-;-i-t-8
pressed, the status control module shuts off the fuel I ITV e H•OH
c~'i:,!'' 0- ,•.,;.-.;,;~ I
via the gas shutoff valve. The module also terminates
the ignition. The "EMERGENCY STOP" button must @ @
be reset before the engine will start.
g00785287
Status Control Module Illustration 35
(1) Liquid crystal display (LCD)
The status control module receives information from (2) Switch
the following sources: (3) "OVERCRANK" indicator
(4) "LOW OIL PRESSURE" indicator
(5) "OVERSPEED" indicator
• The operator (6) "EMERGENCY STOP" indicator
(7) "HIGH COOLANT TEMPERATURE" indicator
• Magnetic pickups (8) "AUXILIARY SHUTDOWN" indicator
• Transducers (oil pressure and water temperature) Liquid Crystal Display (LCD) - Symbols for the
following parameters are located under LCD (1).
• Optional remote sources The LCD provides a digital display of the status of
these parameters. When the status of a parameter is
The basic performance of the status control module displayed, an arrow at the bottom of the LCD points
includes the following functions: the corresponding symbol. The display can be in
metric units or English units.
When the status control module receives a signal to
start the engine, the module enables fuel to flow to Hour meter - When the arrow points to
the engine. The module activates the starting motor. this symbol, the hours of engine operation
After the rpm for crank termination is achieved, the are displayed.
module deactivates the starting motor.
Engine speed - When the arrow points to
When the status control module receives a signal to this symbol, the engine rpm is displayed.
stop the engine, the module shuts off the fuel. The
module sends a signal to the engine control module.
The engine control module terminates the ignition. System battery voltage - When the arrow
points to this symbol, the voltage of the
electrical system's battery is displayed.
Engine oil pressure - When the arrow

points to this symbol, the engine oil
pressure is displayed.
Coolant temperature - When the

arrow points to this symbol, the Coolant
temperature is displayed.
40
Operation Section
The parameters are displayed sequentially. To lock Note: A verify button for overspeed is located on the
the display onto one of the parameters, press switch back of the status control module. This enables a test
(2). To resume the sequential display, press the of the overspeed protection system to be performed.
switch again. See Systems Operation/Testing and Adjusting,
SENR6420, "Control Panel (Status-Timing)" for
The LCD is also used to display diagnostic codes. information on the service procedure.
A diagnostic code indicates that the system has
detected a problem with a component that is "EMERGENCY STOP" - Indicator (6) will
associated with the status control module. When a
diagnostic code is displayed, the arrow that indicates
the display of the parameters will be missing. A
® flash if the "EMERGENCY STOP" button is
used to stop the engine.
flashing "dlAG" will be displayed. If more than one Note: Do not use the coolant temperature sensor
diagnostic code is present, the diagnostic codes will to monitor the operation of jacket water heaters (if
be displayed in sequence. equipped).
To clear the diagnostic codes from the LCD, turn the "HIGH COOLANT TEMPERATURE" -
engine control switch to the "OFF/RESET' position.
For information on diagnostic codes, see these @
Qi If the coolant temperature exceeds the
setpoint, the fuel will be shut off. Indicator
publications: (7) will flash.
SENR6420, "Control Panel (Status-Timing)" "AUXILIARY SHUTDOWN" indicator (8) indicates
that an external request was used to stop the engine.
• Electronic Troubleshooting, SENR6413, "G3500 If the auxiliary shutdown is not used, the "AUXILIARY
Engines". SHUTDOWN" indicator can be used as a spare
indicator.
• Electronic Troubleshooting, SENR6517, "G3500
Air/Fuel Ratio Control". Engine Control Switch
The status control module has six indicators
(Illustration 35) that indicate engine shutdowns. The
@OFF
shutdowns that are associated with the indicators are
described below.
8 \g/RESET 8
11
@
"OVERCRANK" - If the engine fails to
start within a programmed amount of time or
®
COOL DOWN ~• AUTe
AUTO
if the number of crank cycles are exceeded, STOP
the status control module will deactivate the starting
sequence. Indicator (3) will flash. The engine control 8 g MAN.
UST ART
8
switch must be turned to the "OFF/RESET" position
before another attempt to start the engine can be
made.
"LOW OIL PRESSURE" - There are two
@~ setpoints for low oil pressure. The setpoints
depend on the engine rpm. One setpoint
Engine control switch in the "OFF/RESET' position
is for engine rpm that is below the oil step speed The engine control switch is a rotary switch that has
setting. The other setpoint is for engine rpm that is four positions:
above the oil step speed setting. If the engine oil
pressure decreases below the setpoint, the fuel to • "OFF/RESET'
the engine will be shut off. Indicator (4) will flash.
• "AUTO"
"OVERSPEED" - If the engine rpm
®~ exceeds the setpoint for overspeed, the fuel

and the ignition will be shut off. Indicator
(5) will flash.
• "MAN. START'
• "COOLDOWN/STOP"
41
Operation Section
Note: Only the indicators on the status control

module are reset when the engine control switch
is turned to the "OFF/RESET' position. Diagnostic
codes must be cleared with the "DIAGNOSTIC
RESET' switch (Illustration 34).
"OFF/RESET" - When the engine control switch is

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

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

is turned to this position (6 o'clock), the engine will
start. The engine will continue to operate when the
switch is in this position. However, if a setpoint for a
shutdown is exceeded, the engine will shut down.
"COOLDOWN/STOP" - This is the preferred

method for normal stopping. When the engine control
switch is turned to this position (9 o'clock), the
engine will continue to operate until a programmable
cooling cycle has elapsed. The cooling cycle can be
programmed for a O to 30 minute period. The default
setting is five minutes.
42
Operation Section
Electronic Modular Control Panel II

(EMCP II)
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g01041282
Illustration 37
Electronic Modular Control Panel II (EMCP II)
(1) Generator set control (GSC) (5) Optional alarm module (ALM) (8) Panel light switch (PLS)
(2) Diagnostic reset switch (6) Optional synchronizing lights module (9) Emergency stop push button (ESPB)
(3) Engine control switch (ECS) (SLM) (10) Voltage adjust rheostat (VAR)
(4) Panel lights (7) Optional speed potentiometer
The electronic modular control panel II (EMCP II) is Diagnostic Reset Switch (2) - The diagnostic
located above the generator distribution housing. The reset switch is a toggle switch that is used to clear
control panel consists of a main panel with indicators, diagnostic codes from the engine control module.
meters and control switches. This control panel may The switch cannot clear individual codes. Use of the
be equipped with optional modules in order to match switch will clear all the codes that are active in the
the customers' needs and requirements. engine control module.
The left side of the control panel contains the Note: Do not clear the codes until the problems that
Generator Set Control (GSC). This is the main caused the codes are addressed.
component of the system. The GSC displays
the following information: generator output, fault Engine Control Switch (3) - The engine control
conditions, and key engine parameters. The center switch (ECS) determines the status of the control
section of the control panel contains switches and an panel. In the AUTOMATIC position, the engine will
optional alarm module. The right side of the control start automatically when a contact is closed. The
panel may be blank, or the right side of the control engine will shut down after two of the following
panel may contain the Synchronizing Lights Module conditions are met:
or the Custom Alarm Module.
• The contact opens.
The main control panel may not contain all of the
components which are shown. Some components • A programmable cooldown period has elapsed.
are optional. The optional components may not be
required for your particular application. The cooldown period can be programmed to give a
0 to 30 minute cooldown period before the engine
Generator Set Control (1) - The generator set shuts down.
control (GSC) is the main component of the EMCP
II. See the topic "Generator Set Control (GSC)" in In the MANUAL START position, the engine will start
this section. and the engine will run. The engine will continue to
run while the ECS is in that position.
43
Operation Section
In the STOP position, the fuel solenoid will shut down Generator Set Control (GSC)
the engine after a programmable cool down time
period has elapsed. Functions and features of the GSC
In the OFF/RESET position, the fault lights are reset The left side of the control panel contains the
and the engine shuts down immediately. generator set control (GSC). The GSC is the main
component of the system. The GSC displays the
Panel Lights (4) - Panel lights (PL) are controlled following information: generator output, generator
by panel lights switch (8). The panel lights switch (8) set functions, fault conditions, and key engine
is an ON/OFF switch. parameters. The GSC accepts information from the
following sources: operator, engine speed sensor,
Alarm Module (5) - The alarm module (ALM) is engine oil pressure sensor, water temperature
optional. The ALM provides a visible, audible warning sensor, and optional remote sources. This information
of engine conditions before these conditions become is used to determine the "on/off" state of the engine's
severe enough to shut down the engine or severe air, fuel, and starter.
enough to keep the engine from starting.
During normal operating conditions, a signal tells the
Synchronizing Lights Module (6) - The GSC to start the generator set. The GSC turns on
synchronizing lights module uses synchronizing lights the engine's fuel and the engine's starter. When the
for paralleling the generator sets. The synchronizing engine speed reaches the crank termination speed,
lights module is optional. the starter is disengaged. When the GSC receives a
signal to stop the engine, the GSC shuts the fuel off.
Speed Potentiometer (7) - The speed
potentiometer (SP) is optional. The SP can be The functions of the GSC are listed below:
used with the generator set that has an electronic
governor. When the governor is equipped with a • The GSC controls the starting and the stopping of
speed adjusting motor, the governor switch (GS) the engine (normal conditions).
can be mounted instead of the SP. The GS raises
or the GS lowers the engine speed. The GS is also • The GSC shows engine conditions and generator
an option. output information on two displays. The displays
also show fault codes and GSC programming
Panel Light Switch (8) - The panel lights switch information.
controls the panel lights (4).
• The GSC monitors the system for faults. If a
Emergency Stop Push Button (9) - The fault occurs, the GSC performs a controlled fault
emergency stop push button (ESPB) is used to shut shutdown or the GSC provides a fault alarm. The
down the engine during an emergency situation. The GSC uses indicators and displays in order to
ESPB shuts off the fuel. The ESPB also activates the describe the fault.
optional air shutoff, if equipped.
• The GSC contains programmable features
Voltage Adjust Rheostat (10) - The voltage adjust for certain applications or requirements of the
rheostat (VAR) is used to adjust the generator output customers.
voltage to the desired level.
The features of the GSC are listed below:
Below, you can find the descriptions of the following
main modules of the EMCP II: • Cycle Crank: The GSC can be programmed to
crank for adjustable time periods.
• Generator Set Control (GSC)
• Governor Control: When the engine oil pressure
• Alarm Module (ALM) increases past the low oil pressure setpoint,
the GSC will indicate to the governor. The GSC
• Synchronizing Lights Module indicates that the governor should increase the
engine speed from idle rpm to rated RPM.
• Cooldown: When the GSC receives a signal to

perform a normal shutdown, the GSC will wait for
an amount of time that has been preprogrammed
before shutting down the engine via the fuel control.
44
Operation Section
• Automatic Operation: In the automatic mode, the The fault indicators are used to show that a fault is
GSC can be started by a remote initiating signal. present. The fault indicators also describe the fault.
Upon loss of the signal (contact opening), the GSC The fault indicators are divided into three groups.
will perform a normal shutdown. The three groups are listed below:
• Alarm Module Communication: The GSC can • Fault alarm indicator (17)
transmit fault conditions and alarm conditions to
an alarm module (AM). • Fault shutdown indicator (18)
• Power Down.: The EMCP II system is designed • Dedicated shutdown indicators (19)
to remove power from the GSC when the engine
control switch (ECS) is in the OFF/RESET mode The yellow fault alarm indicator (17) FLASHES when
and when the proper jumper wire is removed. The the GSC detects an alarm fault. The alarm fault does
GSC will not allow the generator set to power down not cause the engine status to change. The engine
until both the crank termination relay and the fuel can be started. The engine will continue operating,
control relay are off for about 70 seconds. The GSC only if the engine is running at the time of the alarm
will remain up if the jumper wire is not removed. fault. Fault alarm indicator (17) is accompanied by an
alarm fault code that is shown on upper display (20).
• Fuel Solenoid Type: The GSC can be The fault code is shown when the alarm codes key
programmed to work with an "energized to run" fuel (21) is pressed.
system or programmed to work with an "energized
to shutdown" fuel system. The red fault shutdown indicator (18) FLASHES when
the GSC detects a shutdown fault. The engine will be
Fault indicators shut down if the engine is running. The engine will
not be allowed to start. Fault shutdown indicator (18)
is accompanied by a fault code that is immediately
shown on the upper display (20).
The red dedicated shutdown indicators (19) represent

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

certain setpoints in the GSC.
The conditions that are required to activate the

dedicated fault shutdowns and the results of each
g00787844 dedicated fault are in the following list:
Illustration 38
Display area of the GSC Low Oil Pressure - The engine oil pressure drops
(11) Low oil pressure indicator below the setpoints for low oil pressure shutdown
(12) Emergency stop indicator
that are programmed into the GSC. There are two
(13) High water temperature indicator
(14) Engine overspeed indicator low oil pressure setpoints. One setpoint is used when
(15) Low coolant level indicator the engine is at idle speed. The other setpoint is used
(16) Overcrank indicator when the engine is at rated speed. When a low oil
(17) Fault alarm indicator pressure fault occurs, the low oil pressure indicator
(18) Fault shutdown indicator
(19) Dedicated shutdown indicators FLASHES, and the engine is shut down. The engine
(20) Upper display is not allowed to start until the fault is corrected.
(21) Alarm codes key
45
Operation Section
Emergency Stop - The operator presses the Display

emergency stop push button (ESPB) on the front
panel. When an emergency stop condition occurs,
the emergency stop indicator FLASHES and the
engine is shut down. The engine is not allowed to
start until the condition is corrected.
20
High Water Temperature - The engine coolant
temperature rises above the setpoint for high water
temperature shutdown that is programmed into the
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22
GSC. When the high water temperature fault occurs,
the high water temperature indicator FLASHES. The
engine is shutdown and the engine is not allowed to
start until the fault is corrected.
Engine Overspeed - The engine speed exceeds

the setpoint for engine overspeed that is programmed
into the GSC. When a fault for engine overspeed
occurs, the engine overspeed indicator FLASHES.
The engine is shutdown and the engine is not allowed
to start until the fault is corrected. 25
Low Coolant Level - The engine coolant level g00787849
Illustration 39
drops below the probe of the coolant loss sensor.
When the low coolant level fault occurs, the engine Display area of the GSC
coolant level indicator FLASHES. The engine is shut (20) Upper display
(22) Lower display
down. The engine is not allowed to start until the fault
(23) The leftmost key
is corrected. (24) The phase select key
(25) The engine meter key
Overcrank - The engine does not start within the
setpoint for total cycle crank time that is programmed The display consists of the upper display and
into the GSC. When the overcrank fault occurs, the the lower display. Both displays are used for
overcrank indicator FLASHES. The engine is not programming functions when the GSC is in the
allowed to start until the fault is corrected. service mode.
Note: The GSC can be programmed to override Upper display

the shutdown for low oil pressure and high water
temperature faults. When the operator overrides The upper display (20) shows the following
the shutdown faults, the GSC responds to the parameters: AC voltage, current, and frequency of
faults as though the faults are alarm faults. The one phase of the generator output. Each phase can
corresponding dedicated shutdown indicator is be viewed one at a time by pushing phase select key
ON CONTINUOUSLY. The engine continues to (24). The upper display (20) is also used to show the
run. The engine can be restarted, if necessary. various fault codes for system faults.
When the dedicated shutdown indicator is ON
CONTINUOUSLY, the setpoint for shutdown has Lower display
been exceeded, but the GSC is programmed to
override the shutdown fault. The GSC does not treat The lower display (22) shows system battery voltage,
the shutdown fault as a shutdown fault. The GSC engine hours, engine speed, engine oil pressure,
treats the shutdown fault as an alarm fault. At the engine coolant temperature and the relay status.
factory, the GSC is programmed to treat a low oil
pressure fault and a high water temperature fault The value for one of these conditions is shown for
as shutdown faults. The operator or the service two seconds. Then, the display scrolls to the value
technician must decide to override these shutdown for the next condition. A small pointer identifies
faults. The operator or the service technician must the engine condition that corresponds to the value
program the GSC to treat the shutdown faults as which is showing. When the engine meter key (25) is
alarm faults. pressed, the lower display (22) stops scrolling. The
lower display (22) continuously shows one particular
value. The pointer flashes above the condition of the
value that is showing. When engine meter key (25)
is pressed for a second time, the display (22) will
return to scrolling.
46
Operation Section
The relay status indicators are on the bottom of the Phase Select Key (24) - This key selects the phase
lower display (22). When a GSC relay is activated, of the generator output that is displayed on the GSC.
the corresponding indicator is shown on lower display When you press this key, the display shows the
(22). When a relay is not activated, the corresponding voltage, current, and frequency of each phase one
indicator is not shown. at a time.
Keypad Engine Meter Key (25) - This key controls the

viewing of engine parameters on the lower display.
Pressing the key stops the scrolling of engine
conditions. The value for one particular engine
condition will show continuously. The pointer flashes
20 indicating that the scrolling is stopped. The scrolling
of the engine conditions will resume when the engine
O LOWOIL,.,.....
PllESSUR[~
meter key is pressed again.
A. 22
O EMERGENCY
STOP~ 0
Lamp Test Key (26) - Pressing this key performs a
lamp test on the GSC and the optional alarm module.
On the GSC, the eight fault indicators are ON
CONTINUOUSLY. Every segment of upper display
(20) and lower display (22) is ON. On the optional
alarm module, all of the indicators are ON and the
horn sounds. The lamp test function turns off if an
operator presses the key and the operator holds the
key for more than ten seconds.
Exit Key (27) - This key only functions when the

GSC is in Service Mode.
Service Mode Key (28) - Pressing this key causes

g00787845
Illustration 40 the GSC to enter service mode.
Keypad area of the GSC
(17)
(18)
Fault alarm indicator
Fault shutdown indicator
Alarm Module
(20) Upper display
(21) Alarm codes key The alarm module (ALM) is optional. The alarm
(22) Lower display module provides visible warnings and the alarm
(23) Leftmost key module provides audible warnings of engine
(24) Phase select key
(25) Engine meter key
conditions before these conditions become severe
(26) Lamp test key enough that the engine will shut down or the engine
(27) Exit key will be unable to start.
(28) Service mode key
(29) Keypad One basic alarm module is used to satisfy the
requirements for the following modules: standby
Keypad (29) is used to control the information that is NFPA 99 alarm module, standby NFPA 110 alarm
shown on upper display (20) and lower display (22). module, NFPA 99 remote annunciator panel, and
The seven keys have two sets of functions: normal prime power alarm. This is accomplished by using
functions and service functions. The normal functions different inputs to the module and different decals on
of the keys are described in the following paragraphs: the front of the module in order to indicate alarms
or shutdown conditions.
Alarm Codes Key (21) - If fault alarm indicator
(17) is FLASHING, pressing this key causes upper The front of the alarm module consists of the
display (20) to show the corresponding alarm fault following indicators: .
code. If this key is pressed again, the generator AC
output information will be shown on the upper display • Four amber indicators
(20). If fault alarm indicator (17) is OFF, this key has
no function. • Four red indicators
Leftmost Key (23) - This key only functions when • An audible alarm
the GSC is in service mode. This key is used to scroll
right. • Acknowledge/Silence switch
47
Operation Section
The amber indicators may display the following The synchronizing lights module contains the
parameters: synchronizing lights (30) and the synchronizing
switch (31).
• High Coolant Temperature
Synchronizing Lights (30) - The synchronizing
• Low Coolant Temperature lights (30) are used as an aid in paralleling units at
no load and under load. Each light is connected to
• Low Coolant Level the side with the load of the generator output circuit
breaker. The lights are used to indicate when the
• Low Oil Pressure voltages are in-phase. Close the circuit breaker in
order to connect the generator with the load.
• Generator On Load
Synchronizing Switch (31) - The synchronizing
• Charger Malfunction switch has two positions: ON ("I") and OFF
("O"). When this switch is in the ON position, the
• Low Engine Oil Level synchronizing lamps are enabled. The generator
circuit breaker can be closed manually when
• Low Fuel Level the synchronizing switch is on and the lights are
synchronized.
The red indicators may display the following
conditions: Note: Refer to Operation Section, "Parallel
Operation" for information regarding the paralleling
• Not In AUTO of two generators.
• Low DC Voltage When a reverse power relay is added to

a synchronizing lights module, the original
• Air Damper Closed synchronizing lights module will change in the
following ways:
• Low Oil Pressure Shutdown
• The reverse power relay is mounted on the control
• Overcrank Shutdown panel interior.
• High Coolant Temperature Shutdown • A reverse power fault is indicated by the Fault
Shutdown Indicator on the front of the GSC.
• Overspeed Shutdown
The reverse power relay is a single phase protective
relay. This relay is energized by power in only one
Synchronizing Lights Module direction. In a reverse power fault, the relay contacts
close and the engine shuts down. This will take the
generator off the line. The reverse power relay is
equipped with a test switch and adjustments.
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g00787922
Illustration 41
The location of the Synchronizing Lights Module on the EMCP II
(30) Synchronizing lights
(31) Synchronizing switch
The optional synchronizing lights module is mounted

on the right side of the control panel.
48
Operation Section
Engine Starting
Engine Starting • Ensure that all clamps and connections are secure.
• Inspect the air cleaner service indicator (if

i02151084 equipped). Service the air cleaner filter element
when the yellow diaphragm enters the red zone, or
Before Starting Engine the red piston locks in the visible position.
SMCS Code: 1000; 1400; 1450

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

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

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

,A WARNING for good condition. Reset any shutoff or alarm
components.
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- ,A WARNING

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.
• Ensure that the air inlet piping and the air filters This will cause explosion and/or fire which could
are in place. result in severe personal injury or death.
49
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
Lubrication System nondetergent 1OW oil. For temperatures below
oc0
(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 42
Oil level gauge (dipstick) • Loose connections
(1) "ADD" mark
(2) "FULL" mark
• Wires that are worn or frayed
• Corrosion
NOTICE
Excessive engine oil will increase oil consumption and
result in excessive deposits in the combustion cham- i01857649
ber. Do not overfill the engine with oil.
Cold Weather Starting
• Check the engine crankcase oil level. Maintain the SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
oil level between the "ADD" and "FULL" marks on
the "ENGINE STOPPED WITH OIL COLD" side of Note: Oil pan immersion heaters are not
the oil level gauge. For information on the proper recommended for heating the lube oil. To ensure the
oil to use, see this Operation and Maintenance compatibility of the components, only use equipment
Manual, "Refill Capacities and Recommendations" that is recommended by Caterpillar.
A jacket water heater is required for starting in
• Check for leaks at the following components: temperatures as low as 0 °C (32 °F). The jacket
crankshaft seals, crankcase, oil filters, oil gallery water heater can maintain the water temperature at
plugs, sensors, and valve covers. approximately 32 °C (90 °F). The heated water will
help to keep the oil in the engine block warm enough
• Inspect the tubes, tee pieces, and clamps on the to flow when the engine is started. A jacket water
crankcase breathers. heater is required for starting when the temperature
is less than 16 °C (60 °F).
Starting System For air starting motors, a larger volume of starting
air and/or a higher air pressure may be necessary in
Note: If the engine is equipped with a system for
order to start the engine at colder temperatures.
external support, prepare the system before starting
the engine. Ensure that all of the systems for engine
For electric starting, extra battery capacity may be
support are enabled. Perform all prestart checks for
the control system. necessary.
Consult your Caterpillar dealer for more information

on the starting aids that are available for cold weather
starting.
50
Operation Section
Engine Starting
i02151089 • Unsuccessful successive attempts to start the

engine
Starting the Engine
Unburned gas may remain in the air inlet and exhaust
SMCS Code: 1000; 1450 system after several unsuccessful attempts to start
the engine. The unburned gas may increase to a
A WARNING
concentration that may ignite during a successive
attempt to start the engine.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start Perform the following procedure in order to purge
and operate the engine in a well ventilated area the unburned gas:
and, if in an enclosed area, vent the exhaust to the
outside. 1. Turn the manual gas shutoff valve to the CLOSED
position.
NOTICE 2. Disable the ignition by disconnecting one of the

For initial start-up of a new or rebuilt engine, and for wires that is labelled "M200" from the emergency
start-up of an engine that has been serviced, make stop button.
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the 3. Turn the engine control switch to the START
fuel supply and/or the ignition to the engine. position. Crank the engine for one full crank cycle
in order to purge the unburned gas.
A WARNING 4. Enable the ignition by connecting the wire that

was disconnected in Step 2.
may ignite when the engine is started. Personal 5. Turn the manual gas shutoff valve to the OPEN
injury and/or property damage may result. position.
Before starting an engine that may contain un- 6. Continue with your previous procedure.
inlet and exhaust system. Refer to the topic on
Operation of the Generator Set
section. Control Panel
For information on operation for a specific generator
Note: Using the "EMERGENCY STOP" button will set control panel, refer to the Operation and
shut off both the fuel and the ignition. Maintenance Manual for the generator and the
control panel.
Do not start the engine or move any of the controls
if there is a "DO NOT OPERATE" warning tag or
similar warning tag attached to the start switch or to Automatic Starting
the controls.
Ensure that no one will be endangered before the A WARNING

engine is started and when the engine is started.
When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid personal
Perform the procedures that are described in this
injury, always remain clear of the the engine when
Operation and Maintenance Manual, "Before Starting
the engine is in the AUTOMATIC mode.
Engine" (Operation Section).
Purging Unburned Gas If the engine control switch is in the "AUTO" position,
the engine will automatically start when the remote
The following events cause unburned gas to remain starUstop initiate contact closes. The engine will
in the air inlet and in the exhaust manifold: accelerate to rated rpm when the oil pressure is
sufficient.
• Emergency stop
Manual Starting
• Engine overspeed
1. Ensure that fuel is supplied to the engine. Ensure
that no gas is leaking.
51
Operation Section
Engine Starting
2. Ensure that the driven equipment is unloaded. Starting Failure

a. For generator set engines, ensure that the Note: If the cycle crank feature is enabled, the Status
main circuit breaker is open. Control Module (SCM) will attempt to start the engine
for the programmed period. If the engine fails to start
b. For industrial engines, unload the compressor within the programmed period, the SCM will execute
or pump. Disengage the clutch (if equipped). an overcrank fault. The "OVERCRANK" indicator on
Place the transmission and/or other the Remote Control Panel (Status) will illuminate. The
attachments for the power take-off in SCM must be reset before the engine can be started.
NEUTRAL. Turn the engine control switch to the "OFF/RESET'
position.
Note: Before starting an industrial engine, move the
governor control lever to the position for 1/2 of rated If the engine fails to start after cranking for 30
rpm. seconds, stop cranking. Perform the following
procedure:
NOTICE
Do not engage the starting motor when flywheel is 1. Turn the engine control switch to the "OFF/RESET'
turning. Do not start the engine under load. position.
If the engine fails to start within 30 seconds, release

2. Turn the gas supply OFF.
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
3. Allow the starting motor to cool for two minutes.
Crank the engine for approximately 15 seconds
start the engine again.
in order to disperse any unburned gas from the
engine and the exhaust system.
~OFF
8 \g'RESET 8 4. Allow the starting motor to cool for two minutes.
Turn the gas supply ON. Repeat the starting
procedure.
(8) AUTO i02097945

COOL DOWN
STOP AUTO Starting with Jump Start
Cables
8 g MAN. 8 SMCS Code: 1000; 1401; 1402; 1900
US TART
Illustration 43
g00319402 A WARNING
Engine control switch in the "Man. Start" position
Improper jump start cable connections can cause
an explosion resulting in personal injury.
3. Turn the engine control switch to the "Man. Start"
position in order to start the engine. Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
Note: After starting an industrial engine, move the cable ends to contact each other or the engine.
governor control lever to the position for low idle rpm.
4. Allow the engine to idle for three to five minutes. If the installation is not equipped with a backup
The engine speed should stabilize at low idle rpm. battery system, it may be necessary to start the
Check all of the pressure gauges. Inspect the engine from an external electrical source.
engine for leaks and listen for unusual noises.
When all systems are normal, the rpm may be Many batteries which are considered unusable are
increased. still rechargeable. After jump starting, the alternator
may not be able to fully recharge batteries that
Table 12 are severely discharged. The batteries must be
Rated RPM And Low Idle RPM charged to the proper voltage with a battery charger.
For information on testing and charging, refer to
Rated rpm 1000 1200 1400 1500 1800 the Special Instruction, SEHS7633, "Battery Test
Low idle rpm 700 900 1000 1000 1200 Procedure".
52
Operation Section
Engine Starting
i00914166
NOTICE
Using a battery source with the same voltage as the
After Starting Engine
electric starting motor. Use ONLY equal voltage for
SMCS Code: 1000
jump starting. The use of higher voltage will damage
the electrical system.
For new installations and engines that are recently
rebuilt, carefully monitor the engine in order to detect
Do not reverse the battery cables. The alternator can
any unusual engine performance.
be damaged. Attach ground cable last and remove
first.
The engine rpm can be increased from low idle rpm
to rated rpm after one minute.
When using an external electrical source to start the
engine, turn the engine control switch to the "OFF"
Engines that use pipeline natural gas are capable of
position. Turn all electrical accessories OFF before
ramping to full load in 30 seconds or less. For engines
attaching the jump start cables.
that use bio-gas, increased time for ramping the
load will help to provide protection from detonation.
Ensure that the main power switch is in the OFF posi-
Avoid detonation during loading. Generally, no load
tion before attaching the jump start cables to the en-
operation to full load operation can be accomplished
gine being started.
in five to ten minutes without any problems.
1. Turn the start switch on the stalled engine to the It may be necessary to apply some load in order to
OFF position. Turn off all accessories. attain normal operating temperatures. The operator
can ramp the load manually. For automatic loading,
2. Connect one positive end of the jump start cable programmable logic control can be used.
to the positive cable terminal of the discharged
battery. Connect the other positive end of the jump Engaging the Driven Equipment
start cable to the positive cable terminal of the
electrical source.
Generator Set Engines
3. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical 1. Increase the engine speed to rated rpm.
source. Connect the other negative end of the
jump start cable to the engine block or to the 2. Ensure that the outlet temperature of the jacket
chassis ground. This procedure helps to prevent water reaches 77 °C (170 °F). Ensure that the
potential sparks from igniting combustible gases gauges are in the normal ranges for the engine
that are produced by some batteries. rpm.
4. Charge the batteries. The engine will not continue 3. Close the main circuit breaker in order to apply
to run after starting if the batteries have not been the load.
charged.
Industrial Engines
5. Start the engine.
1. lncr~ase the engine rpm. Ensure that the gauges
6. Immediately after the stalled engine is started are in the normal ranges for the engine rpm.
disconnect the jump start cables in reverse order.
2. Engage the driven equipment with no load on the
Refer to the Electrical Schematic for your engine. driven equipment.
Consult your Caterpillar dealer for more information.
The engine can be loaded up to 50 percent of full
load before the outlet temperature of the jacket
water reaches 77 °C (170 °F). The temperature is
usually achieved in two to four minutes. After this
temperature is reached, begin to ramp the engine
to full load.
3. Ramp to full load after the outlet temperature of

the jacket water reaches 77 °C (170 °F). Five
minutes may be required.
53
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 13.
Proper operation and maintenance are key factors in Table 13

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 24 hours Continuous(1)
51 to 60%
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 13 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.
54
Operation Section
Engine Stopping
Engine Stopping
0 0 0 rn::u
i02145782
@ @ 2
Emergency Stopping SI iN~JN£ ST_Jlr ,i~
SMCS Code: 1000; 7418 ~'"' e6.'".:;e
NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.
g00786735
Ensure that any system that provides external Illustration 45
support to the engine is secured after the engine is Remote control panel (status)
stopped. (1) Emergency stop button
(2) Engine control switch
(3) "AUXILIARY SHUTDOWN" indicator
NOTICE
Do not start the engine until the problem necessitating
Emergency stop button (1) is in the OUT position
the emergency stop has been located and corrected.
for normal engine operation. Push the button for
emergency stopping. This shuts off both the fuel
Pressing the Emergency Stop Button may cause and the ignition. The engine will not start when the
unburned gas to remain in the air inlet and in the button is locked. To reset the button, turn the button
exhaust manifold. clockwise. The spring-loaded button will return to the
OUT position.
A WARNING
NOTICE
Unburned gas in the air inlet and exhaust system Do not use this method to stop the engine unless
may ignite when the engine is started. Personal an emergency has occurred. Continuous emergency
injury and/or property damage may result. shutdowns can cause damage to some engine com-
ponents. This will leave unburned fuels in the combus-
Before starting an engine that may contain un- tion chambers and in the exhaust system. If an emer-
burned gas, purge the unburned gas from the air gency shutdown occurs purge the system by cranking
1
inlet and exhaust system. Refer to the topic on the engine for 5 to 10 seconds with the ignition shutoff.
section.
The control panel must also be reset before the
engine will start. To reset the control panel turn
1
11
engine control switch (2) to the 0FF/RESET'
Emergency Stop Button position.
The customer may also provide other means for

emergency stopping. This will cause the fuel to be
e 1 e shut off, but the ignition may not be shut off. This
0000~
11
shutdown will cause "AUXILIARY SHUTDOWN
indicator (3) to illuminate. The control panel must
be reset before the engine will start. To reset the
0000 0 control panel, turn engine control switch (2) to the
"OFF/RESET' position.
0000
(1) Emergency stop button on a junction box

55
Operation Section
Engine Stopping
i00720970
Manual Stop Procedure ~OFF
SMCS Code: 1000; 7418

8 \g/RESET 8
NOTICE
Stopping the engine immediately after the engine has
been operating under a load can result in overheating
and accelerated wear of the engine components.
CO~WN ~
STOP
AUTa
AUTO
Allow the engine to gradually cool before stopping the

engine.
8 ~MAN.
VSTART
8
g00320124
Note: Remove the load at a rate that will avoid Illustration 46
detonation. Engine control switch in the "OFF/RESET" position
1. Disengage the driven equipment. b. Turn the engine control switch to the
"OFF/RESET" position. The engine will
a. For generator set engines, open the main immediately shut off.
circuit breaker.
c. If the engine control switch is in the "AUTO"
b. For industrial engines, unload the compressor position, open the remote start/stop initiate
or pump. Disengage the clutch (if equipped). contact. If the cooldown feature is utilized, the
Place the transmission and/or other engine will operate for a programmed period of
attachments for the power take-off in time before the engine stops. Otherwise, the
NEUTRAL. engine will immediately shut off.
Note: Extended idling can cause excessive oil The engine will coast to a stop. Ensure that any
consumption and related problems. See this system that provides external support to the engine
Operation and Maintenance Manual, "Engine is secured after the engine is stopped.
Operation" topic (Operation Section).
2. Reduce the engine rpm to low idle.
Note: If the cooldown feature is not utilized, operate

the engine at low idle rpm for a cooldown period
before stopping the engine. If the engine has been
operated at a low load, operate the engine at low idle
for approximately 30 seconds before stopping the
engine. If the engine has been operated at a high
load, operate the engine at low idle for three to five
minutes before stopping the engine.
3. Use one of the following methods in order to stop

the engine:
a. Turn the engine control switch to the

"COOLDOWN/STOP" position. If the cooldown
feature is utilized, the engine will operate for a
programmed period of time before the engine
stops. Otherwise, the engine will immediately
shut off.
56
Operation Section
Engine Stopping
i02150753
After Stopping Engine

SMCS Code: 1000
• Check the engine crankcase oil level. Maintain

the oil level between the "ADD" and "FULL" marks
on the "ENGINE STOPPED" side of the oil level
gauge.
• If necessary, perform minor adjustments. Repair

any leaks and tighten loose bolts.
• Note the service hour meter reading. Perform the

maintenance that is scheduled in this Operation
and Maintenance Manual, "Maintenance Interval
Schedule" (Maintenance Section).
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Refill Capacities and Recommendations section of
this manual. Failure to do so can cause engine dam-
age.
• Allow the engine to cool. Check the coolant level.
• If freezing temperatures are expected, check the

coolant for protection against freezing. The cooling
system must be protected against freezing to the
lowest expected outside temperature. Add the
proper coolanUwater mixture, if necessary.
• Perform all required periodic maintenance on all

driven equipment. Refer to the instructions that are
provided by the OEM of the driven equipment.
57
Maintenance Section
Refill Capacities
Maintenance Section LubricantCapacffies

The capacity of the engine crankcase includes the
capacity of the oil filters that are installed at the
Refill Capacities factory.
Table 15
i02156779
Lubrication System
Approximate Refill Capacities
Refill Capacities and
Engine Liters US Gallons
Recommendations
G3508 231 61
SMCS Code: 1348; 1395; 7560
G3512 338 89
G3516 423 112
Lubrication System
Lubricant Recommendations Auxiliary Oil Filters
Due to significant variations in the quality and in Table 16
the performance of commercially available oils, Approximate Capacities for Auxiliary Oil Filters
Caterpillar makes the following recommendations:
Capacity
Auxiliary Oil Filter Capacity With
• Caterpillar Natural Gas Engine Oil (NGEO) Without
System Elements Elements(1)
• Caterpillar EL250 Natural Gas Engine Oil 117 - 9550 Oil Filter 132 L 176 L
(NGEO) Assemblyl2l (35 US gal) (46.5 US gal)
1118-8419 Oil 132 L 176 L
• Caterpillar EL350 Natural Gas· Engine Oil Filter Assembly(3l (35 US gal) (46.5 US gal)
(NGEO)
119-2104 Oil Filter 178 L 244 L
The proper SAE viscosity grade of oil is determined Assembly(4J (47 US gal) (64 US gal)
by the minimum ambient temperature during (1) Auxiliary oil filter systems increase the oil capacity in order
cold engine start-up, and the maximum ambient to increase the service life of the oil. Caterpillar recommends
temperature during engine operation. To determine operation without the auxiliary oil filter elements.
the oil viscosity that is required for starting a cold (2) This assembly contains 14 elements. This assembly is for use
with G3508 Engines.
soaked engine, refer to the minimum temperature in (3) This assembly contains 14 elements. This assembly is for use
Table 14. To select the oil viscosity for operation at with G3512 Engines.
the highest anticipated ambient temperature, refer (4) This assembly contains 21 elements. This assembly is for use
to the maximum temperature in the Table. Use the with G3516 Engines.
highest oil viscosity that is available in order to meet
the required temperature during start-up. Fuel
Table 14
Engine Oil Viscosity
Fuel Recommendations
Caterpillar Ambient Temperature Caterpillar gas engines will operate successfully on
NGEO a broad range of gaseous fuels. Pipeline natural
Grade of Minimum Maximum gas has been used for many years. Commercial
Viscosity fuel gases are mixtures of gases. These fuels
SAE 30(1) 0 °C (32 °F) 40 °C (104 °F) consist primarily of hydrocarbons (combinations of
hydrogen and carbon) and some inert gases. The
SAE 40(1) 5 °C (41 °F) 50 °C (122 °F) compositions of these gas mixtures have extreme
(1) Caterpillar NGEO is available in these grades only. Multigrade variations. Fuels such as wellhead gas, bio-gas,
oils are NOT recommended for use in Caterpillar Gas Engines. and manufactured gas need to be reviewed for
If other grades of viscosity are selected, ensure that the oil acceptability. Analyze the fuel in order to determine
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
58
Maintenance Section
Refill Capacities
• Heat value Water
• Methane number Deionized water or distilled water is

recommended for use in engine cooling systems.
• Specific gravity If distilled water or deionized water is not available,
use water with the properties that are listed in Table
Field gas can have varying characteristics of 17.
combustion. Field gas can contain numerous
harmful impurities. The impurities can alter the BTU Table 17
content. The impurities can also alter the methane Caterpillar Minimum Acceptable Water Requirements
number. The impurities include everything from
water up to complex hydrocarbons that can lead to Property Maximum Limit ASTM Test
detonation and severe engine damage. To minimize 40 mg/L "0512",
these effects, Caterpillar recommends the following Chloride (Cl)
(2.4 grains per US gal) "04327"
guidelines:
100 mg/L
Sulfate (SO.) "0516"
(5.9 grains per US gal)
1. Evaluate the fuel with the Caterpillar Methane
Number Program, LEKQ6378. 170 mg/L
Total Hardness "01126"
(10 grains per US gal)
Methane values below 30 are not recommended
340 mg/L
for use in a Caterpillar engine. Fuels with a Total Solids "01888"
(20 grains per US gal)
methane number that is below 30 must first be
processed in order to remove harmful impurities Acidity pH of 5.5 to 9.0 "01293"
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.
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:
• Caterpillar dealer
Coolant Recommendations
• Local water utility company
During shipping and storage, the engine must be
protected from damage that can be caused by
• Agricultural agent
freezing of the cooling system. If the engine is
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.
59
Maintenance Section
Refill Capacities
Preferred - Caterpillar Natural Gas Engine Coolant Additives

(NGEC)
Preferred - Caterpillar Supplemental Coolant
Alternatively, use Caterpillar Diesel Engine Additive (SCA)
Antifreeze/Coolant (DEAC) or a commercial
heavy-duty coolant/antifreeze that meets "ASTM Acceptable - A commercial SCA that provides
D621 O" or "ASTM D4985" specifications. 1200 mg/L (70 grains per US gal) or 1200 ppm of
nitrites in the final mixture of coolant/antifreeze
NOTICE
Do not use a commercial coolant/antifreeze that only Note: A 50/50 concentration of Caterpillar
meets the ASTM "D3306" specification. This type of NGEC or of Caterpillar DEAC does not require a
coolant/antifreeze is made for light duty automotive treatment with an SCA at the initial fill. Commercial
applications. heavy-duty coolant/antifreeze that meets "ASTM
D6210" or "ASTM D4985" specifications may require
Use only the coolant/antifreeze that is recommended. a treatment with an SCA at the initial fill. Read the
label or the instructions that are provided by the OEM
of the product.
Acceptable - In applications that do not require
protection from boiling or from freezing, a mixture of To ensure that the correct amount of SCA is in the
Caterpillar SCA and water that meets the properties cooling system, the concentration of SCA must be
that are listed in Table 17 is acceptable. tested on a scheduled basis. Obtain an S·O·S coolant
analysis (Level 1) or use a test kit to check the
Note: The preferred coolant/antifreeze and the concentration of the SCA according to this Operation
acceptable mixture of SCA and water require and Maintenance Manual, "Maintenance Interval
different concentrations of SCA. Refer to the Special Schedule".
Publication, SEBU6400, "Supplemental Coolant
Additive (SCA)" topic. For further information on coolant, see Special
Table 18 is a list of the coolant/antifreeze that is Lubricant, Fuel, and Coolant Recommendations".
recommended for Caterpillar Gas Engines. The
service life of the coolant/antifreeze that is used in Coolant Capacities
Caterpillar Gas Engines is also listed. To achieve
this service life, the coolants must be properly To properly maintain the cooling system, the Total
maintained. The maintenance program includes Cooling System capacity must be determined. The
S·O·S coolant analysis. Total Cooling System capacity will vary between
individual installations. The Total Cooling System
Table 18
capacity equals the capacity of the Jacket Water
Recommended Coolant/Antifreeze and Service Circuit plus the Aftercooler Circuit plus the External
Life of the Coolant/Antifreeze System capacity. The External System capacity
Service Life includes the following components: expansion tank,
Coolant/Antifreeze (1)
heat exchanger, radiator, and piping. Refer to the
Caterpillar NGEC specifications that are provided by Caterpillar or by
Three Years the OEM of the equipment. Record the Total Cooling
Caterpillar DEAC
System capacity in the following Table:
Commercial Heavy-Duty
Coolant/Antifreeze that Two Years Table 19
meets "ASTM D6210"
Cooling System
Commercial Heavy-Duty Approximate Refill Capacities
Coolant/Antifreeze that One Year
System G3508 G3512 G3516
meets "ASTM D4985"
Jacket 114 L 148 L 205 L
Caterpillar SCA and 30 US gal 39 US gal 53 US gal
Two Years Water
Water
Circuit
Commercial SCA and
One Year Aftercooler 13 L 15 L 16.5 L
Water 4 US gal
Circuit 3.5 US gal 4.5 US gal
(1) The service life of coolant is also limited by use (service hours).
Refer to the specific engine's Operation and Maintenance External
Manual, "Maintenance Interval Schedule". System
Total
Cooling
System
60
Maintenance Section
Maintenance Interval Schedule
i02151040 Engine Valve Rotators - Inspect ........................... 92

Exhaust Piping - Inspect ....................................... 93
Maintenance Interval Schedule Gas Pressure Regulator - Check .......................... 93
(Turbocharged Aftercooled) Gas Pressure Regulator Condensation - Drain .... 94
Hoses and Clamps - Inspect/Replace .................. 94
SMCS Code: 1000; 4450; 7500 Ignition System Spark Plugs - Check/Adjust/
Replace ............................................................... 95
When Required Ignition System Timing - Check/Adjust ................. 99
Inlet Air System - Inspect ...................................... 99
Battery - Replace .......................... ........................ 67 Radiator - Clean .... ....... ... ... ..... .. .. ... .. .... .. ... .. .. ... .. . 107
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 74 Every 2000 Service Hours
Engine Air Cleaner Element - Replace ................. 79
Engine Oil Filter - Change .................................... 86 Actuator Control Linkage - Lubricate .................... 64
Overhaul Considerations .... ..... .. .. ... .. .. ... .. ... .. ...... 105 Cooling System Coolant Sample (Level 1) -
Valve Stem Projection - Measure/Record ............ 110 Obtain ................................................................. 73
Cooling System Supplemental Coolant Additive
Daily (SCA) - Test/Add ................................................. 74
Engine Speed/Timing Sensor - Clean/Inspect ...... 90
Air Starting Motor Lubricator Oil Level - Check .... 65 Speed Sensor - Clean/Inspect ... ... .. .. ... .. ... .. .. ... .. . 108
Air Tank Moisture and Sediment - Drain ............... 66
Control Panel - Inspect ......................................... 70 Every 4000 Service Hours
Cooling System Coolant Level - Check ................ 73
Driven Equipment - Inspect/Replace/Lubricate ... 78 Air Starting Motor Lubricator Bowl - Clean ........... 64
Engine Air Cleaner Service Indicator- Inspect ..... 81 Crankcase Blowby - Measure/Record .................. 75
Engine Air Precleaner - Clean .............................. 82 Cylinder Pressure - Measure/Record ................... 76
Engine Oil Level - Check ...................................... 89 Driven Equipment - Check .................................... 78
Fuel System Fuel Filter Differential Pressure - Engine Mounts - Check ........................................ 83
Check .................................................................. 93 Engine Protective Devices - Check ...................... 90
Power Take-Off Clutch - Check/Adjust/ Exhaust Bypass - Inspect ..................................... 92
Lubricate .......... .. ........... .. ... .. ... .. .. ... .. ... .. .. ..... ..... 107 Starting Motor - Inspect ...................................... 108
Walk-Around Inspection ....................................... 111 Water Pump - Inspect .......................................... 112
Every 250 Service Hours Every 8000 Service Hours
Battery Electrolyte Level - Check .......................... 68 Cooling System Coolant Sample (Level 2) -
Engine Oil Sample - Obtain .................................. 89 Obtain ................................................................. 74
Turbocharger - Inspect ........................................ 109
Initial 1000 Service Hours Water Temperature Regulator - Replace ............. 112
Cooling System Coolant Sample (Level 1) - Between 9000 and 16 000 Service Hours
Obtain ................................................................. 73
Cooling System Supplemental Coolant Additive Overhaul (Top End) .. ..... .... .. .. ... .. ... .. .. ... .. ... .. .. ... .. . 102
(SCA) - Test/Add ................................................. 74
Engine Mounts - Check ........................................ 83 Every 24 000 Service Hours or 3 Years
Speed Sensor - Clean/Inspect ............................ 108 Cooling System Coolant (NGEC) - Change .......... 70
Valve Stem Projection - Measure/Record ............ 11 O
Between 27 000 and 48 000 Service Hours
Every 1000 Service Hours Overhaul (In-Frame) ........................................... 100
Aftercooler Condensation - Drain ......................... 64
Alternator - Inspect ............................................... 66 Between 45 000 and 80 000 Service Hours
Belts - Inspect/Adjust/Replace .............................. 69
Overhaul (Major) ................................................. 101
Carburetor Air/Fuel Ratio - Check/Adjust ............. 70
Crankshaft Vibration Damper - Inspect ................. 76
Engine - Clean ...................................................... 78
Engine Crankcase Breather - Clean ..................... 82
Engine Oil - Change ............................................. 84
Engine Oil Filter (Auxiliary) - Change ................... 85
Engine Oil Filter - Change .................................... 86
Engine Valve Lash and Bridge - Adjust ................ 91
61
Maintenance Section
i02151050 Gas Pressure Regulator Condensation - Drain .... 94

Maintenance Interval Schedule Ignition System Spark Plugs - Check/Adjust/
(Standby) Replace ............................................................... 95
Ignition System Timing - Check/Adjust ................. 99
SMCS Code: 1000; 4450; 7500 Inlet Air System - Inspect ...................................... 99
Radiator - Clean .... ..... .. .. .. .. .. ... .. .. ... .. .... .. .... .. ... .. .. 107
When Required Starting Motor - Inspect ...................................... 108
Valve Stem Projection - Measure/Record ............ 110
Cooling System Coolant Sample (Level 2) - Water Pump - Inspect .......................................... 112
Obtain ................................................................. 74
Every 3 Years
Every Week
Battery - Replace .. .. .. ........... ... ................. ............. 67
Air Starting Motor Lubricator Oil Level - Check .... 65 Cooling System Coolant (NGEC) - Change .......... 70
Air Tank Moisture and Sediment - Drain ............... 66 Turbocharger - Inspect ........................................ 109
Battery Charger - Check ..................... ... .... .. .. .. .. ... 67 Water Temperature Regulator- Replace ............. 112
Battery Electrolyte Level - Check .... ... .. .. .... ........... 68
Control Panel - Inspect ......................................... 70 Every 8000 Service Hours
Engine Air Cleaner Service Indicator - Inspect ..... 81 Cooling System Coolant Sample (Level 2) -
Engine Air Precleaner - Clean .............................. 82 Obtain ................................................................. 74
Engine Oil Level - Check ...................................... 89
Fuel System Fuel Filter Differential Pressure -
Check .................................................................. 93
Walk-Around Inspection ....................................... 111
Initial 1000 Service Hours

Obtain ................................................................. 73
Every 2000 Service Hours

Obtain ................................................................. 73
Every Year
Actuator Control Linkage - Lubricate .................... 64
Aftercooler Condensation - Drain ........ ... ......... ..... 64
Air Starting Motor Lubricator Bowl - Clean ........... 64
Alternator - Inspect ............................................... 66
(SCA) - Test/Add ................................................. 74
Crankcase Blowby - Measure/Record .................. 75
Cylinder Pressure - Measure/Record ................... 76
Engine Air Cleaner Element - Replace ................. 79
Engine Mounts - Check ........................................ 83
Engine Oil Sample - Obtain .................................. 89
Engine Protective Devices - Check ...................... 90
Exhaust Bypass - Inspect ..................................... 92
62
Maintenance Section
i02151049 Engine Crankcase Breather - Clean ..................... 82

Maintenance Interval Schedule Engine Oil Filter - Change .................................... 86
(Bio-Gas) Engine Valve Lash and Bridge - Adjust ................ 91
Engine Valve Rotators - Inspect ........................... 92
SMCS Code: 1000; 4450; 7500 Exhaust Piping - Inspect ....................................... 93
Gas Pressure Regulator - Check .......................... 93
When Required Gas Pressure Regulator Condensation - Drain .... 94
Battery - Replace ....................................... ........... 67 Ignition System Spark Plugs - Check/Adjust/
Cooling System Coolant Sample (Level 2) - Replace ............................................................... 95
Obtain ................................................................. 74 Ignition System Timing - Check/Adjust ................. 99
Engine Air Cleaner Element - Replace ................. 79 Inlet Air System - Inspect ...................................... 99
Engine Oil - Change ............................................. 84 Radiator - Clean .. ..... ... ........ .. ... .. ... .. .. ... .. ... .. .. ... .. . 107
Fuel Filtration System - Service ............................ 93 Every 2000 Service Hours
Overhaul Considerations .. ...... ... .. ... ..... .. .. ... .. .. ... . 105
Valve Stem Projection - Measure/Record ............ 110 Actuator Control Linkage - Lubricate .................... 64
Daily Obtain ................................................................. 73
Air Starting Motor Lubricator Oil Level - Check .... 65 (SCA) - Test/Add ................................................. 74
Air Tank Moisture and Sediment - Drain ............... 66 · Engine Speed/Timing Sensor - Clean/Inspect ...... 90
Control Panel - Inspect ......................................... 70 Speed Sensor - Clean/Inspect .... .... .. .. .... .. .. .. ... .. . 108
Driven Equipment - Inspect/Replace/Lubricate ... 78 Every 4000 Service Hours
Engine Air Cleaner Service Indicator - Inspect ..... 81
Engine Air Precleaner - Clean .............................. 82 Air Starting Motor Lubricator Bowl - Clean .: ......... 64
Engine Oil Level - Check ...................................... 89 Crankcase Blowby - Measure/Record .................. 75
Fuel System Fuel Filter Differential Pressure - Cylinder Pressure - Measure/Record ..... .............. 76
Check .................................................................. 93 Cylinders - Inspect ................................................ 77
Power Take-Off Clutch - Check/Adjust/ Driven Equipment - Check .................................... 78
Lubricate .... .. ..... ..... ... ..... ... .. .. ... .. ... .. .. ..... ... ........ 107 Engine Mounts - Check ........................................ 83
Walk-Around Inspection ....................................... 111 Engine Protective Devices - Check ...................... 90
Exhaust Bypass - Inspect ..................................... 92
Every 125 Service Hours Starting Motor- Inspect ...................................... 108
Turbocharger - Inspect ........................................ 109
Engine Oil Sample - Obtain .................................. 89 Water Pump - Inspect .......................................... 112
Every 250 Service Hours Between 7500 and 8000 Service Hours
Battery Electrolyte Level - Check .......................... 68 Overhaul (Top End) .. ......... .. .. ... .. ... .. .. ... .. ... .. .. ... .. . 102
Initial 1000 Service Hours Every 8000 Service Hours

Cooling System Coolant Sample (Level 1) - Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 73 Obtain ................................................................. 74
Cooling System Supplemental Coolant Additive Water Temperature Regulator - Replace ............. 112
(SCA) - Test/Add ................................................. 74
Engine Mounts - Check ........................................ 83 Between 22 500 and 24 000 Service Hours
Speed Sensor - Clean/Inspect ............................ 108 Overhaul (In-Frame) ........................................... 100
Valve Stem Projection - Measure/Record ............ 110
Every 24 000 Service Hours or 3 Years
Cooling System Coolant (NGEC) - Change .......... 70
Aftercooler Condensation - Drain ......................... 64
Alternator - Inspect ............................................... 66 Between 37 500 and 40 000 Service Hours
Carburetor Air/Fuel Ratio - Check/Adjust ............. 70 Overhaul (Major) ................................................. 101
Engine - Clean ...................................................... 78
63
Maintenance Section
i02151047 Gas Pressure Regulator - Check .......................... 93

Gas Pressure Regulator Condensation - Drain .... 94
Maintenance Interval Schedule Hoses and Clamps - Inspect/Replace .................. 94
(Naturally Aspirated) Ignition System Spark Plugs - Check/Adjust/
Replace ............................................................... 95
SMCS Code: 1000; 4450; 7500 Ignition System Timing - Check/Adjust ................. 99
Inlet Air System - Inspect ...................................... 99
When Required Radiator - Clean .................................................. 107
Battery - Replace .................................................. 67 Every 2000 Service Hours

Obtain ................................................................. 74 Actuator Control Linkage - Lubricate .................... 64
Engine Air Cleaner Element - Replace ................. 79 Cooling System Coolant Sample (Level 1) -
Engine Oil Filter - Change .................................... 86 Obtain ................................................................. 73
Overhaul Considerations .. ... .. ... .. .. ... .. ... .. .. ... .. ... .. 105 Cooling System Supplemental Coolant Additive
Valve Stem Projection - Measure/Record ............ 11 O (SCA) - Test/Add ................................................. 74
Daily
Speed Sensor - Clean/Inspect ... ..... ...... .. ..... .... .. . 108
Air Starting Motor Lubricator Oil Level - Check .... 65
Air Tank Moisture and Sediment - Drain ............... 66 Every 4000 Service Hours
Control Panel - Inspect ......................................... 70
Cooling System Coolant Level - Check ................ 73 Air Starting Motor Lubricator Bowl - Clean ........... 64
Driven Equipment - Inspect/Replace/Lubricate ... 78 Crankcase Blowby - Measure/Record .................. 75
Engine Air Cleaner Service Indicator - Inspect ..... 81 Cylinder Pressure - Measure/Record ... .. ... ... ........ 76
Engine Air Precleaner - Clean .............................. 82 Driven Equipment - Check .................................... 78
Engine Oil Level - Check ...................................... 89 Engine Mounts - Check ........................................ 83
Fuel System Fuel Filter Differential Pressure - Engine Protective Devices - Check ...................... 90
Check .................................................................. 93 Exhaust Bypass - Inspect ..................................... 92
Power Take-Off Clutch - Check/Adjust/ Starting Motor - Inspect ...................................... 108
Lubricate ........................................................... 107 Water Pump - Inspect .......................................... 112
Every 250 Service Hours Cooling System Coolant Sample (Level 2) -
Battery Electrolyte Level - Check .. .. .... .. .. .. .. .. ... .. ... 68 Obtain ................................................................. 74
Engine Oil Sample - Obtain .................................. 89 Water Temperature Regulator - Replace ............. 112
Initial 1000 Service Hours Between 8000 and 10 000 Service Hours
Cooling System Coolant Sample (Level 1) - Overhaul (Top End) .. ........ .... .. .. ......... ... .. .. ..... ... .. . 102
Obtain ................................................................. 73
Cooling System Supplemental Coolant Additive Every 24 000 Service Hours or 3 Years
(SCA) - Test/Add ................................................. 74
Cooling System Coolant (NGEC) - Change .......... 70
Engine Mounts - Check ........................................ 83
Speed Sensor - Clean/Inspect ............................ 108
Between 32 000 and 40 000 Service Hours
Valve Stem Projection - Measure/Record ............ 11 O Overhaul (In-Frame) ........................................... 100
Every 1000 Service Hours Between 64 000 and 80 000 Service Hours
Alternator - Inspect ............................................... 66 Overhaul (Major) ................................................. 101
Engine - Clean ...................................................... 78
Engine Valve Rotators - Inspect ........................... 92
64
Maintenance Section
Actuator Control Linkage - Lubricate
i01516282
Actuator Control Linkage -

Lubricate
SMCS Code: 1265-086
g00786820
Illustration 48
(1) Plug
Remove plug (1 ). Drain the moisture into a suitable

container. Install the plug.
i01924136
Air Starting Motor Lubricator

Bowl - Clean
SMCS Code: 1451-070
g00786805
Illustration 47
Grease fittings on the linkage If the engine is equipped with an air starting motor,
use the following procedure:
Apply grease to the grease fittings. Use a hand
grease gun and lubricate the grease fittings with
MPGM. A WARNING
Personal injury can result from removing hoses or
i01516337 fittings in a pressure system.
Aftercooler Condensation - Failure to relieve pressure can cause personal in-
Drain jury.
SMCS Code: 1063 Do not disconnect or remove hoses or fittings un-

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

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

32 °c (90 °F) separate circuit aftercoolers. Consult
your Caterpillar dealer for details.
65
Maintenance Section
Air Starting Motor Lubricator Oil Level - Check
i01924142
Air Starting Motor Lubricator

Oil Level - Check
SMCS Code: 1451-535
NOTICE
Never allow the lubricator bowl to become empty. The
air starting motor will be damaged by a lack of lubrica-
tion. Ensure that sufficient oil is in the lubricator bowl.
g00745554
Illustration 49
( 1) Filler plug
(2) Bowl
(3) Drain valve
2. Slowly loosen filler plug (1) in order to release the

pressure from the lubricator.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to g00745561
collect the fluid with suitable containers before open- Illustration 50
ing any compartment or disassembling any compo-
nent containing fluids. 1. Observe the oil level in sight gauge (3). If the oil
level is less than 1/2, add oil to the lubricator bowl.
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar
A WARNING
products. Personal injury can result from removing hoses or
fittings in a pressure system.
Dispose of all fluids according to local regulations and
mandates. Failure to relieve pressure can cause personal in-
jury.
3. Place a suitable container under bowl (2) and
open drain valve (3) in order to drain the oil from Do not disconnect or remove hoses or fittings un-
the bowl. til all pressure in the system has been relieved.
4. Remove bowl (2). Clean the bowl with warm water. 2. Ensure that the air supply to the lubricator is OFF.
Slowly loosen filler plug (4) in order to release
5. Dry the bowl. Inspect the bowl for cracks. If the pressure from the lubricator bowl.
bowl is cracked, replace the damaged bowl with a
new bowl. 3. Remove filler plug (4). Pour oil into the lubricator
bowl. Use nondetergent "1 OW' oil for temperatures
6. Install the bowl. that are greater than 0 °C (32 °F). Use air tool oil
for temperatures that are below 0 °C (32 °F).
7. Make sure that drain valve (3) is closed.
4. Install filler plug (4).
8. For instructions on filling the lubricator, see this
Operation and Maintenance Manual, "Air Starting
Motor Lubricator Oil Level - Check" topic. Adjust the Lubricator
Note: Adjust the lubricator with a constant rate of air
flow. After the adjustment, the lubricator will release
oil in proportion to variations of the air flow.
66
Maintenance Section
Air Tank Moisture and Sediment - Drain
1. Ensure that the fuel supply to the engine is OFF. • Clean ports for cooling airflow
NOTICE • Proper charging of the battery

Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two Observe the ammeter during engine operation in
order to ensure proper battery performance and/or
minutes before cranking the engine again.
proper performance of the electrical system.
2. Operate the air starting motor. Observe the drops Make repairs, if necessary. See the Service Manual
of oil that are released in dome (1 ). for service procedures. Consult your Caterpillar
Note: Some lubricators have an adjustment screw
rather than a knob.
i02153996
3. If necessary, adjust the lubricator in order

to release from one to three drops of oil per
Battery - Replace
second. To increase the rate, turn knob (2) SMCS Code: 1401-510
counterclockwise. To decrease the rate, turn the
knob clockwise. S/N: 2TJ1-Up
i00351324 .A, WARNING

Air Tank Moisture and Batteries give off combustible gases which can
Sediment - Drain explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
SMCS Code: 1466-543-M&S jury or death.
Moisture and sediment in the air starting system can Ensure proper ventilation for batteries that are in
cause the following conditions: an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
• Freezing near batteries. Do not smoke when batteries are
serviced.
• Corrosion of internal parts
• Malfunction of the air starting system .A, WARNING

The battery cables or the batteries should not be
.A, WARNING removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
When opening the drain valve, wear protective ing is attempted.
gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could Removing the battery cables or the batteries with
cause debris to be blown and result in personal the cover in place may cause a battery explosion
injury. resulting in personal injury.
1. Open the drain valve that is on the bottom of the 1. Turn the key start switch to the OFF position.
air tank. Allow the moisture and sediment to drain. Remove the key and all electrical loads.
2. Close the drain valve. 2. Turn OFF the battery charger. Disconnect the
charger.
i02084374
3. The NEGATIVE"-" cable connects the NEGATIVE
Alternator - Inspect "-"battery terminal to the ground plane. Disconnect
the cable from the NEGATIVE "-" battery terminal.
SMCS Code: 1405-040
4. The POSITIVE "+" cable connects the POSITIVE
Inspect the alternator for the following conditions: "+" battery terminal to the starting motor.
Disconnect the cable from the POSITIVE "+"
• Proper connections battery terminal.
67
Maintenance Section
Battery - Replace
Note: Always recycle a battery. Never discard a 4. The POSITIVE "+" cable connects the POSITIVE
battery. Return used batteries to an appropriate "+" battery terminal to the starting motor.
recycling facility. Disconnect the cable from the POSITIVE "+"
battery terminal.
5. Remove the used battery.
Note: Always recycle a battery. Never discard a
6. Install the new battery. battery. Return used batteries to an appropriate
recycling facility.
Note: Before the cables are connected, ensure that
the key start switch is OFF. 5. Remove the used battery.
7. Connect the cable from the starting motor to the 6. Install the new battery.
POSITIVE "+" battery terminal.
Note: Before the cables are connected, ensure that
8. Connect the cable from the ground plane to the the key start switch is OFF.
NEGATIVE"-" battery terminal.
7. Connect the cable from the starting motor to the
POSITIVE "+" battery terminal.
i02156825
8. Connect the cable from the ground plane to the

Battery - Replace NEGATIVE"-" battery terminal.
SMCS Code: 1401-510
i01039758
A WARNING Battery Charger - Check

Batteries give off combustible gases which can
SMCS Code: 1401-535
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death. Checking Before Start-Up
Ensure proper ventilation for batteries that are in Check the battery charger for proper operation. If
an enclosure. Follow the proper procedures in or- the batteries are properly charged, the needle of the
der to help prevent electrical arcs and/or sparks ammeter will register near "O" (zero).
near batteries. Do not smoke when batteries are
serviced. The battery charger must not produce excessive
current during start-up. Alternatively, the charger
must be automatically disconnected for start-up.
A WARNING If the engine has an alternator, the charger must
be automatically disconnected during start-up and
The battery cables or the batteries should not be during engine operation.
removed with the battery cover in place. The bat-
tery cover should be removed before any servic- Charging the Battery
ing is attempted.
Removing the battery cables or the batteries with A WARNING

the cover in place may cause a battery explosion
resulting in personal injury. Never disconnect any charging unit circuit or bat-
tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an explo-
1. Turn the key start switch to the OFF position. sion from the flammable vapor mixture of hydro-
Remove the key and all electrical loads. gen and oxygen that is released from the elec-
trolyte through the battery outlets. Injury to per-
2. Turn OFF the battery charger. Disconnect the sonnel can be the result.
charger.
3. The NEGATIVE"-" cable connects the NEGATIVE Perform the following procedure to charge the
"-" battery terminal to the ground plane. Disconnect battery:
the cable from the NEGATIVE "-" battery terminal.
1. Ensure that the charger is turned OFF.
68
Maintenance Section
Battery Electrolyte Level - Check
2. Adjust the voltage of the charger in order to match Table 20

the voltage of the battery.
Effects of Overcharging Batteries
3. Connect the POSITIVE "+" lead of the charger Type of Battery Effect
to the POSITIVE "+" battery terminal. Connect
the NEGATIVE"-" lead of the charger to the
NEGATIVE "-" battery terminal. Caterpillar General Service All of the battery cells have
Batteries a low level of electrolyte.
Caterpillar Premium High
4. Turn ON the battery charger. Output Batteries
Overcharging of Batteries
Overcharging reduces the service life of batteries. When the plates of the
Use a battery charger that will not overcharge the battery are inspected
battery. DO NOT charge the battery if the meter of through the filler holes, the
the battery charger is in the RED zone. plates may appear to be
warped. This is caused by
Overcharging is indicated by the following symptoms: an excessive temperature.
The battery may not pass
• The battery is very warm to the touch. a load test.
• A strong odor of acid is present. Caterpillar Maintenance The battery may not accept
Free Batteries a charging current.
• The battery emits smoke or a dense vapor (gas). The battery may not pass
a load test.
Perform one of the following procedures if the battery
shows symptoms of overcharging:
Checking After Stopping
• Reduce the rate of charging by a significant
amount. Complete the charging at the reduced Ensure that the battery charger is connected
rate. properly. Observe the meter of the charger. Record
the amperage.
• Turn OFF the charger.
Table 20 describes the effects of overcharging on i01639002

different types of batteries.
Battery Electrolyte Level -
Check
SMCS Code: 1401-535-FLV
When the engine is not run for long periods of time or

when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries
are properly charged, ammeter reading should be
very near zero.
A WARNING
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the filler caps. Maintain the electrolyte

level to the "FULL" mark on the battery.
69
Maintenance Section
Belts - Inspect/Adjust/Replace
If the addition of water is necessary, use distilled Adjusting the Alternator Belt
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
2. Check the condition of the electrolyte with the 2

1U - 7298 Coolant/Battery Tester (°C) or the
1U-7297 Coolant/Battery Tester (°F).
3. Keep the batteries clean.
Clean the battery case with one of the following

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

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

(1 qt) of clean water 3
Thoroughly rinse the battery case with clean water.
Use a fine grade of sandpaper to clean the g01092641

Illustration 51
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT (1) Mounting bolt
(2) Adjusting nuts
remove material excessively. Excessive removal (3) Mounting bolt
of material can cause the clamps to not fit
properly. Coat the clamps and the terminals with 1. Remove the drive belt guard.
SN - 5561 Silicone Lubricant, petroleum jelly or
MPGM grease. 2. Loosen mounting bolt (1), adjusting nuts (2) and
mounting bolt (3).
i02154849
3. Turn adjusting nuts (2) in order to increase or
Belts - Inspect/Adjust/Replace decrease the drive belt tension.
SMCS Code: 1357-025; 1357-040; 1357-510 4. Tighten adjusting nuts (2). Tighten mounting bolt
(3). Tighten mounting bolt (1 ). For the proper
torque, see the Service Manual, "Specifications"
Inspection module.
Inspect the alternator belt and the fan drive belts for 5. Reinstall the drive belt guard.
wear and for cracking. Replace the belts if the belts
are not in good condition. If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation at
Check the belt tension according to the information in
the rated rpm.
the Service Manual, "Specifications".
Slippage of loose belts can reduce the efficiency Adjusting the Fan Drive Belt
of the driven components. Vibration of loose belts
can cause unnecessary wear on the following 1. Loosen the mounting bolt for the pulley.
components:
2. Loosen the adjusting nut for the pulley.
• Belts
3. Move the pulley in order to adjust the belt tension.
• Pulleys
4. Tighten the adjusting nut.
• Bearings
5. Tighten the mounting bolt.
If the belts are too tight, unnecessary stress is placed
on the components. This reduces the service life of
the components.
70
Maintenance Section
Carburetor Air/Fuel Ratio - Check/Adjust
Replacement i02151144
For applications that require multiple drive belts, Cooling System Coolant
replac~ the drive belts in matched sets. Replacing
one dnve belt of a matched set will cause the new
(NGEC) - Change
drive belt to carry more load because the older drive SMCS Code: 1350-044
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail. Clean the cooling system before the recommended
maintenance interval if the following conditions exist:
i01005891
• The engine overheats frequently.
Carburetor Air/Fuel Ratio -
• Foaming is observed.
Check/Adjust
• Engine oil has entered the cooling system and the
SMCS Code: 1266-535; 1266 coolant is contaminated.
An engine failure may occur if the air/fuel ratio is
not appropriate for the fuel and for the operating NOTICE
conditions. The service life of the turbocharger, of the Use of commercially available cooling system clean-
valves, and of the other components may be reduced. ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
Ensure that the carburetor is adjusted properly so proved for Caterpillar engines.
that the air/fuel ratio is correct.
For information on adjusting the carburetor, refer to Drain the Cooling System
the Service Manual, "Systems Operation/Testing
and Adjusting", or refer to the Special Instruction, 1. Stop the engine and allow the engine to cool.
"Installation and Initial Start-Up Procedure". Ensure that the engine will not start when the
cooling system is drained.
i01762721 2. Loosen the cooling system filler cap slowly in

order to relieve any pressure. Remove the cooling
Control Panel - Inspect system filler cap.
SMCS Code: 4490-040; 7451-040
Inspect the condition of the panel. If a component is

damaged, ensure that the component is repaired or
that the component is replaced. If equipped, ensure
that the electronic displays are operating properly.
Inspect the wiring for good condition. Ensure that the

wiring connections are secure.
Record the Data and Review the

2 3
Data
If equipped, check the gauges and check the Illustration 52 g00786868
indicators frequently during normal operation. Record
Locations of the drain plugs
the data in a log. Compare the new data to the data
that was previously recorded. Comparing the new (1) Jacket water pump
(2) Cylinder block
data to the recorded data will establish the normal (3) Auxiliary water pump
~auge readings for the engine. A gauge reading that
1s abnormal may indicate a problem with operation 3. Op~n the cooling system drain valves (if
or with the gauge.
egu1ppe~). If the cooling system is not equipped
with dra_m valves, remove drain plugs (1 ), (2), and
(3). Dram all of the cooling system components:
• Expansion tank or radiator

71
Maintenance Section
Cooling System Coolant (NGEC) - Change
• Water pumps
• Aftercooler
• Thermostatic valve
• Engine block
• All coolant lines
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 Illustration 53
g00786870
Caterpillar to reclaim the used coolant.
Vent plug
The vent line of the ebullient cooled engine will be installed by
For information regarding the disposal and the the customer.
recycling of used coolant, consult your Caterpillar If a customer has not installed the vent lines, loosen the vent
dealer or consult Caterpillar Dealer Service Tools: cap from the tee.
Outside Illinois: 1-800-542-TOOL 3. Remove vent plug (4) for the aftercooler.
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL 4. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 15 L
Clean the Cooling System (4 US gal) of the cooling system capacity. Install
the cooling system filler cap. Install vent plug (4).
1. After the cooling system has been drained, flush
the cooling system with clean water in order to
5. Start the engine. Operate the engine for a
remove any debris.
minimum of 30 minutes with a coolant temperature
of at least 82 °C (180 °F).
2. Close the cooling system drain valves (if
equipped). Clean the drain plugs and install the
6. Stop the engine and allow the engine to cool.
drain plugs.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
NOTICE system filler cap. Open the cooling system drain
Fill the cooling system no faster than 19 L (5 US gal) valves (if equipped) or remove drain plugs (1), (2),
per minute to avoid air locks. and (3). See Illustration 52.
NOTICE NOTICE
If the aftercooler circuit has been drained, the vent Improper or incomplete rinsing of the cooling system
plug must be opened to allow the aftercooler to fill can result in damage to copper and other metal com-
properly. Failure to do this will cause an air lock re- ponents.
sulting in engine damage.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
Note: The cleaner has a smell of ammonia. Continue

to flush the cooling system until the smell is gone.
7. Allow the water to drain. Flush the cooling system

with clean water until the water that drains is
clean. Close the cooling system drain valves (if
equipped). Clean the drain plugs and install the
drain plugs.
72
Maintenance Section
Cooling System Coolant (NGEC) - Change
Cleaning a Cooling System that 7. Flush the cooling system with clean water until
the water that drains is clean. Close the cooling
has Heavy Deposits or Plugging system drain valves (if equipped}. Clean the drain
plugs and install the drain plugs.
Note: For the following procedure to be effective,
there must be an active flow through the cooling
system components. Fill the Cooling System
1. After the cooling system has been drained, flush NOTICE
the cooling system with clean water in order to Fill the cooling system no faster than 19 L (5 US gal}
remove any debris. per minute to avoid air locks.
2. Close the cooling system drain valves (if
equipped}. Clean drain plugs and install drain Note: For information about the proper coolant to
plugs (1 ), (2), and (3). See Illustration 52. use, and for the capacity of the cooling system,
see this Operation and Maintenance Manual, "Refill
NOTICE Capacities and Recommendations" (Maintenance
Fill the cooling system no faster than 19 L (5 US gal) Section).
per minute to avoid air locks.
1. Remove vent plug (4) for the aftercooler. See
Illustration 53.
NOTICE
If the aftercooler circuit has been drained, the vent 2. Fill the cooling system with coolanUantifreeze.
plug must be opened to allow the aftercooler to fill Install vent plug (4). Do not install the cooling
properly. Failure to do this will cause an air lock re- system filler cap.
sulting in engine damage.
3. Start the engine. Operate the engine in order to
purge the air from the cavities of the engine block.
3. Remove vent plug (4) for the aftercooler. See Allow the coolant to warm and allow the coolant
Illustration 53. level to stabilize. Stop the engine.
4. Fill the cooling system with a mixture of clean 4. Check the coolant level. Maintain the coolant to
water and Caterpillar Fast Acting Cooling System the proper level on the sight gauge (if equipped).
Cleaner. Add .5 L (1 pint) of cleaner per 7.5 L If a sight gauge is not equipped, maintain the
(2 US gal) of the cooling system capacity. Install coolant within 13 mm (.5 inch} below the bottom of
the cooling system filler cap. Install vent plug (4). the filler pipe.
5. Start the engine. Operate the engine for a 5. Clean the cooling system filler cap. Inspect the
minimum of 90 minutes with a coolant temperature gaskets of the cooling system filler cap. If the
of at least 82 °C (180 °F). gaskets of the cooling system filler cap are
damaged, discard the old cooling system filler cap
6. Stop the engine and allow the engine to cool. and install a new cooling system filler cap. If the
Loosen the cooling system filler cap slowly in gaskets of the cooling system filler cap are not
order to relieve any pressure. Remove the cooling damaged, use a 9$- 8140 Pressurizing Pump in
system filler cap. Open the cooling system drain order to pressure test the cooling system filler cap.
valves (if equipped) or remove drain plugs (1 ), The correct pressure is stamped on the face of
(2), and (3). See Illustration 52. Allow the water the cooling system filler cap. If the cooling system
to drain. filler cap does not maintain the correct pressure,
install a new cooling system filler cap.
NOTICE
Improper or incomplete rinsing of the cooling system 6. Start the engine. Inspect the cooling system for
can result in damage to copper and other metal com- leaks and for proper operating temperature.
ponents.
To avoid damage to the cooling system, make sure

to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
Note: The cleaner has a smell of ammonia. Continue

to flush the cooling system until the smell is gone.
73
Maintenance Section
Cooling System Coolant Level - Check
i02017615
Cooling System Coolant Level

- Check
SMCS Code: 1350-535-FLV
A WARNING
Climbing equipment may be required to access
this service point. Refer to the Operation and
Maintenance Manual, "Mounting and Dismount-
ing" topic for safety information.
g00103639
Illustration 55
NOTICE Filler cap gaskets
Overfilling the overflow tank (if equipped) will result in
damage to the cooling system. 3. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
If the cooling system has an overflow tank, maintain gaskets are damaged, replace the old cooling
the coolant level in the tank below 1/2 full in order to system filler cap with a new cooling system filler
avoid damage to the cooling system. cap. Install the cooling system filler cap.
4. Start the engine. Inspect the cooling system for

leaks.
i02064894
Cooling System Coolant

Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, ~nd
g00760290
use a separate designated pump for coolant sampling.
Illustration 54 Using the same pump for both types of samples may
Normal position of the coolant in the sight gauge during rated contaminate the samples that are being drawn. This
operation contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
Observe the coolant level in the sight gauge (if dealers and customers.
equipped). When the engine is running at nor~al
operating temperature, the coolant should be m the
upper half of the sight gauge. If the coolant level is For conventional heavy-duty coolanUantifreeze,
low, add the proper coolant mixture. check the concentration of supplemental coolant
additive (SCA) regularly. The concentration of SCA
can be checked with an S·O·S coolant analysis
Add Coolant (Level 1).
Note: For the proper coolant mixture to use, see Obtain the sample of the coolant as close as possible
this Operation and Maintenance Manual, "Refill to the recommended sampling interval. In order
Capacities and Recommendations" topic. to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
1. Stop the engine. Allow the engine to cool. to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
2. Remove the cooling system filler cap slowly in Supplies for collecting samples can be obtained from
order to relieve any pressure. Pour the proper your Caterpillar dealer.
coolant mixture into the filler pipe.
Use the following guidelines for proper sampling of
the coolant:
74
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
• Never collect samples from expansion bottles. For additional information about coolant analysis,
see the Special Publication, SEBU6400, "Caterpillar
• Never collect samples from the drain for a system. Gas Engine Lubricant, Fuel, and Coolant
Recommendations" or consult your Caterpillar dealer.
• Keep the unused sampling bottles stored in plastic
bags.
i02017557
• Keep the lids on empty sampling bottles until you

are ready to collect the sample.
Cooling System Supplemental
Coolant Additive (SCA) -
• Complete the information on the label for the
sampling bottle before you begin to take the
Test/Add
samples.
SMCS Code: 1352-045; 1395-081
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
A WARNING
Cooling system coolant additive contains alkali.
• In order to avoid contamination, immediately place To help prevent personal injury, avoid contact with
the sample in the tube that is provided for mailing. the skin and eyes. Do not drink cooling system
coolant additive.
Submit the sample for Level 1 analysis.
Note: Caterpillar recommends an S·O·S coolant
Note: Level 1 results may indicate a need for
analysis (Level 1).
Level 2 Analysis.
For additional information about coolant analysis, Test the Concentration of the SCA
see the Special Publication, SEBU6400, "Caterpillar
Gas Engine Lubricant, Fuel and Coolant Coolant/Antifreeze and SCA
Recommendations" or consult your Caterpillar dealer.
NOTICE
i02064898 Do not exceed the recommended six percent supple-
mental coolant additive concentration.
Cooling System Coolant
Sample (Level 2) - Obtain Test the concentration of the SCA with the 8T - 5296
Coolant Conditioner Test Kit. Follow the instructions
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 that are provided in the kit.
NOTICE Water and SCA

Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling. NOTICE
Using the same pump for both types of samples may Do not exceed the recommended eight percent sup-
contaminate the samples that are being drawn. This plemental coolant additive concentration.
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers. Test the concentration of the SCA with the BT - 5296
Coolant Conditioner Test Kit. Use the instructions
that follow:
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies 1. Fill the syringe to the "1.0 ml" mark with the
for collecting samples can be obtained from your coolant.
Caterpillar dealer.
2. Dispense the 1.0 ml coolant sample from the
Refer to Operation and Maintenance Manual, syringe into the empty mixing bottle.
"Cooling System Coolant Sample (Level 1) - Obtain"
for the guidelines for proper sampling of the coolant. 3. Add tap water to the mixing bottle in order to bring
the level up to the "10 ml" mark. Place the cap on
Submit the sample for Level 2 analysis. the bottle and shake the bottle.
75
Maintenance Section
Crankcase Blowby - Measure/Record
4. Add 2 to 3 drops of the "NITRITE INDICATOR

SOLUTION B" to the mixing bottle. Move the bottle NOTICE
in a circular motion in order to mix the solution. Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
5. Add 1 drop of "NITRITE TEST SOLUTION A" to faces of the cooling system, reducing the engine's
the mixing bottle. Move the bottle in a circular heat transfer characteristics. Reduced heat transfer
motion in order to mix the solution. could cause cracking of the cylinder head and other
high temperature components.
6. Repeat 5 until the solution changes color from red
to light gray, green, or blue. Record the number of Excessive supplemental coolant additive concentra-
drops of "NITRITE TEST SOLUTION A" that were tion could also result in blockage of the heat exchang-
required to cause the color change. er, overheating, and/or accelerated wear of the water
pump seal.
7. Use Table 21 to interpret the results.
Do not exceed the recommended amount of supple-
Table 21
mental coolant additive concentration.
Number of Concentration Maintenance
Drops of SCA Required
3. Add the proper amount of SCA. The concentration
Less than 25 Less than the Add SCA. of the SCA depends on the type of coolant that
recommended Retest the is used. To determine the proper amount, see
concentration of coolant. this Operation and Maintenance Manual, "Refill
SCA Capacities and Recommendations" topic.
25 to 30 The None
recommended 4. Clean the cooling system filler cap. Install the
concentration of cooling system filler cap.
SCA
More than 30 More than the Remove the i02026805
recommended coolant.
concentration of Replace with Crankcase Blowby -
SCA water only
Retest the Measure/Record
coolant.
SMCS Code: 1317
Add the SCA, If Necessary Note: For a G3500 Engine that is rated at 1500
rpm with 1500 service hours, the crankcase
blowby typically has a range of 259 to 283 Umin
_A WARNING (550 to 600 ft3/hr).
Pressurized System: Hot coolant can cause seri- Measure the crankcase blowby of new engines.
ous burns. To open the cooling system filler cap, Record the data. Continue to periodically measure
stop the engine and wait until the cooling system the blowby. Comparing the recorded data to the new
components are cool. Loosen the cooling system data provides information about the condition of the
pressure cap slowly in order to relieve the pres- engine.
sure.
Note: Crankcase blowby is one of the three factors
1. Remove the cooling system filler cap slowly. that help to determine the in-frame overhaul interval.
For more information, see this Operation and
Note: Always dispose of fluids according to local Maintenance manual, "Overhaul (In-Frame)" topic
regulations. (Maintenance Section).
2. If necessary, drain some coolant in order to allow After a new engine is used for a short time, the
space for the addition of the SCA. blowby can decrease as the piston rings are seated.
The blowby will gradually increase as the following
components show wear:
• piston rings
• cylinder liners
76
Maintenance Section
Crankshaft Vibration Damper - Inspect
Note: A problem with the piston rings causes the The ST - 2B21 Temperature Indicator or the BT - 2B22
oil to deteriorate rapidly. Information regarding the Temperature Indicator are recommended for
condition of the piston rings can be obtained from monitoring the temperature of the damper. Evenly
the measurement of the blowby and the results of space four of the adhesive indicators around the
oil analysis. outer diameter of the damper.
The blowby of a worn engine may exceed the blowby Note: If you use an infrared thermometer to monitor
of a new engine by two times or more. the temperature of the damper, use the thermometer
during operation with similar loads and speeds. Keep
A sudden increase in blowby could indicate a broken a record of the data. If the temperature begins to rise,
piston ring. The following conditions are other reduce the interval for inspecting the damper.
potential sources of blowby:
If the temperature of the damper reaches 110 °C
• Worn valve guides (230 °F), consult your Caterpillar dealer.
• A turbocharger seal that leaks Inspect the damper for evidence of dents, cracks,
and leaks of the fluid.
A rebuilt engine can have a high blowby due to the
following factors: If a fluid leak is found, repair the damper or
replace the damper. The fluid in the damper is
• The piston rings are not seated properly. silicone. Silicone has the following characteristics:
transparent, viscous, smooth, and sticky.
• Worn parts such as valve guides were not replaced.
Inspect the damper and repair or replace the damper
Excessive blowby may indicate the need for an for any of the following reasons.
overhaul. By keeping a record of the results, a
gradual increase in the amount of the blowby will be • The damper is dented, cracked, or leaking.
noted until the amount has become excessive.
• The paint on the damper is discolored from heat.
To measure the blowby, use the BT - 2700 Blowby/Air
Flow Indicator. Refer to Special Instruction, • The engine has had a failure because of a broken
SEHS8712, "Using the ST-2700 Blowby/Airflow crankshaft.
Indicator Group". The instruction is provided with the
tool. • An analysis of the oil has revealed that the front
bearing of the crankshaft is badly worn.
Keep a record of the results.
• There is a large amount of gear train wear that is
For assistance, consult your Caterpillar dealer. not caused by a lack of oil.
i01949731 Removal and Installation

Crankshaft Vibration Damper Refer to the Service Manual, "Disassembly and
- Inspect Assembly" or consult your Caterpillar dealer for
information about damper replacement.
SMCS Code: 1205-040
i01664707
The crankshaft vibration damper limits the torsional
vibration of the crankshaft. The visconic damper has Cylinder Pressure -
a weight that is located inside a fluid filled case.
Measure/Record
Damage to the crankshaft vibration damper or failure
SMCS Code: 1223-082-CC; 1223; 7450-082
of the damper can increase torsional vibrations. This
can result in damage to the crankshaft and to other
Measure the cylinder pressure of new engines.
engine components. A deteriorating damper can
Record the data. Continue to periodically measure
cause excessive gear train noise at variable points
the cylinder pressure. Comparing the recorded data
in the speed range.
to the new data provides information about the
condition of the engine.
A damper that is hot is due to excessive torsional
vibration. Monitor the temperature of the damper
during operation.
77
Maintenance Section
Cylinders - Inspect
Cylinder pressure can be measured during inspection

of the spark plugs. Use the following guidelines for 2136
checking the cylinder pressure:
2067
t'\. \ \
• Remove all of the spark plugs. 1998 ~ .\Y
,,(\' lY
1929
• Fully open the throttle plate.
1860
.i\\\~
• Minimize the cranking time to 3 or 4 revolutions. 1791
L\ \.\Y
This will enable a maximum consistent cranking 1723
l,.(\\ v
speed for the check. Also, the battery power will
1654
J l\ \)i
be conserved.
1585 L\' lV'
y
i'...
A loss of cylinder pressure or a change of pressure

in one or more cylinders may indicate the following
1516
K\\'
/\ t\\Y
""- I" 1
conditions. These conditions may indicate a problem 144 7
with lubrication: 1378
L\\ t\Y
1309 I r\ \ \v
• Excessive deposits
1240
A' l\Y
~\' y
• Guttering of valves 1171
1102
i\.\ y
• A broken valve
1034
,y
v
• A piston ring that sticks 965
10:1 11: 1 12:1 13:1
• A broken piston ring y
g00828960
• Worn piston rings Illustration 56
(Y) Cylinder pressure in kPa
• Worn cylinder liners (X) Compression ratio
(1) Normal range for cylinder pressure
If the cylinder pressure has risen by one or more

compression ratios, the engine needs a top end i00767502
overhaul in order to remove deposits. Failure to
remove the deposits will increase the chance for Cylinders - Inspect
detonation. Severe guttering of the valves will occur.
SMCS Code: 1223-040; 1223
To measure the cylinder pressure, use the 193 - 5859
Cylinder Pressure Gauge Gp. Follow the procedure Use a borescope to inspect the cylinders. The
in the Special Instruction, NEHS0798 that is included inspection will provide information about the internal
with the gauge group. Record the pressure for condition of the engine.
each cylinder. Use the Operation and Maintenance
Manual, "Valve Data Sheet" (Reference Materials A borescope with a lens that can be rotated is
Section). recommended. This type of borescope provides a
clear view of the combustion chamber and of the
Illustration 56 is a graph of typical cylinder pressures bottom deck of the cylinder head. Photographic
for engines with different compression ratios. documentation or video documentation is also
recommended. Consult your Caterpillar dealer for
information on available borescopes.
To perform this procedure, insert the borescope

through the openings for the spark plugs. Use the
borescope to look for the following conditions:
• Valve wear
• Deposits on the valve seat
• Deposits on the valve face

78
Maintenance Section
Driven Equipment - Check
• Polishing of the cylinder walls i01664717
• Scratching of the cylinder walls Engine - Clean

• Deposits on the cylinder walls that are above the SMCS Code: 1000-070
upper limit of the piston stroke
A WARNING
i00449093
Personal injury or death can result from high volt-
Driven Equipment - Check age.
SMCS Code: 3279-535 Moisture could create paths of electrical conduc-

tivity.
To minimize bearing problems and vibration of the
engine crankshaft and the driven equipment, the Make sure the unit is off line (disconnected from
alignment between the engine and driven equipment utility and/or other generators), locked out and
must be maintained properly. tagged "Do Not Operate".
Check the alignment according to the instructions

that are provided by the following manufacturers: NOTICE
Water or condensation can cause damage to gen-
• Caterpillar erator components. Protect all electrical components
from exposure to water.
• OEM of the coupling
NOTICE
• OEM of the driven equipment Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
i00935098 spills whenever a significant quantity accumulates on
the engine.
Driven Equipment -
Inspect/Replace/Lubricate Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
SMCS Code: 3279-040 benefits:
Observe the driven equipment during operation. Look • Easy detection of fluid leaks
for the following items:
• Maximum heat transfer characteristics
• Unusual noise and vibration
• Ease of maintenance
• Loose connections
Note: For more information on cleaning and drying
• Damaged parts electric generators, refer to Special Instruction,
SEHS9124, "Cleaning and Drying of Electric Set
Perform any maintenance that is recommended Generators".
by the OEM of the driven equipment. Refer to the
literature of the OEM of the driven equipment for the
following service instructions.
• Inspection
• Lubricating grease and lubricating oil requirements
• Specifications for adjustment
• Replacement of components
• Requirements for ventilation

79
Maintenance Section
Engine Air Cleaner Element - Replace
i01749609
Engine Air Cleaner Element -

Replace
SMCS Code: 1051-510; 1054-510
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
g00317608
borne debris from entering the air inlet. Illustration 57
Fasteners for the air cleaner cover
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements

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

g00781084
engine. If necessary, use a ladder or a platform to Illustration 58
reach the air cleaner. (1) Cover
(2) Element
• Check the precleaner (if equipped) daily for (3) Air inlet
accumulation of dirt and debris. Remove any dirt
and debris, as needed. 1. Release the fasteners for cover (1 ).
• Operating conditions (dust, dirt and debris) may 2. Remove the cover and element (2).
require more frequent service of the air cleaner
element. 3. Cover air inlet (3) with tape in order to keep dirt
out.
• The air cleaner element may be cleaned up to
six times if the element is properly cleaned and 4. Clean the inside of the cover and the body with
inspected. a clean, dry cloth.
• The air cleaner element should be replaced at least 5. Remove the tape for the air inlet. Install a new
one time per year. This replacement should be element or a clean element.
performed regardless of the number of cleanings.
6. Install the cover.
Replace the dirty paper elements with clean
elements. Before installation, thoroughly inspect the 7. If necessary, reset the air cleaner service indicator.
element for tears and/or holes in the filter material.
Inspect the gasket or the seal of the element for
damage. Maintain a supply of suitable elements for
replacement purposes.
80
Maintenance Section
Engine Air Cleaner Element - Replace
Cleaning the Primary Air Cleaner Note: Refer to "Inspecting the Primary Air Cleaner
Elements".
Elements
The primary air cleaner element can be used up Vacuum Cleaning
to six times if the element is properly cleaned and
inspected. When the element is cleaned, check the Vacuum cleaning is a good method for cleaning
filter material for rips or tears. Replace the element elements which require daily cleaning because of a
at least one time per year regardless of the number dry, dusty environment. Cleaning with pressurized air
of cleanings. is recommended prior to vacuum cleaning. Vacuum
cleaning will not remove deposits of carbon and oil.
Use clean elements while dirty elements are being
cleaned. Note: Refer to "Inspecting the Primary Air Cleaner
Elements".
NOTICE
Do not clean the air cleaner elements by bumping or Inspecting the Primary Air Cleaner
tapping. This could damage the seals. Do not use el- Elements
ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the elements before cleaning. Inspect

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

air and with a vacuum.
Pressurized Air
Pressurized air can be used to clean elements
g00281693
that have not been cleaned more than two times. Illustration 60
Pressurized air will not remove deposits of carbon
and oil. Use filtered, dry air with a maximum pressure Inspect the clean, dry element. Use a 60 watt blue
of 207 kPa (30 psi). light in a dark room or in a similar facility. Place
the blue light in the element. Rotate the element.
Inspect the element for tears and/or holes. Inspect
the element for light that may show through the filter
material. If it is necessary in order to confirm the
result, compare the element to a new element that
has the same part number.
Do not use an element that has any tears and/or

holes in the filter material. Do not use an element with
damaged pleats, gaskets or seals. Discard damaged
elements.
Storing Primary Air Cleaner Elements
g00281692 If an element that passes inspection will not be used

Illustration 59
immediately, store the element for future use.
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.
81
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
g00281694 g00760342
Service indicator
Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. Restricted air flow Some engines may be equipped with a different
may result. To protect against dirt and damage, wrap service indicator.
the elements in Volatile Corrosion Inhibited (VCI)
paper. Observe the service indicator. Clean the air cleaner
element or replace the element when any of the
Place the element into a cardboard box for storage. following conditions occur:
For identification, mark the outside of the container
and mark the element. Include the following • The yellow diaphragm enters the red zone.
information:
• The red piston locks in the visible position.
• Date of cleaning
• The air restriction reaches 3.75 kPa
• Number of cleanings (15 inch of H20).
Store the container in a dry location.
For more detailed information on cleaning the primary

air cleaner element, refer to Special Publication,
SEBF8062, "Procedure to Inspect and Clean Air
Filters". 0
i01665086
Engine Air Cleaner Service

Indicator - Inspect
SMCS Code: 7452-040
g00760341
Illustration 63
A service indicator may be mounted on the air Service indicator on an air cleaner for crankcase ventilation
cleaner element or in a remote location.
Some engines are equipped with an air cleaner for
crankcase ventilation. The air cleaner is mounted
on a camshaft cover. Clean the air cleaner element
or replace the element when any of the following
conditions occur:
• The yellow diaphragm enters the red zone.
• The red piston locks in the visible position.
• The air restriction reaches 0.25 kPa (1 inch of H20).
• The air cleaner is saturated with oil.

82
Maintenance Section
Engine Air Precleaner - Clean
Inspect the service indicator daily for cracks, holes, or i01397717

loose fittings. If any of these conditions are present,
replace the service indicator. Engine Air Precleaner - Clean
SMCS Code: 1055-070
Test the Service Indicator
Service indicators are important instruments.
3
• Apply vacuum (suction) to the service indicator.
2
• Reset the service indicator.
If the yellow core does not latch at the greatest

vacuum, or if service indicator does not reset easily,
obtain a new service indicator. If the new service
indicator will not reset, the fitting for the service
indicator may be plugged.
g00736588
Illustration 65
Typical precleaner
(1) Wing nut
(2) Cover
(3) Body
Remove wing nut (1) and cover (2). Check for an

accumulation of dirt and debris in body (3). Clean the
body, if necessary.
After cleaning the precleaner, install cover (2) and

wing nut (1).
Illustration 64 . g00351792
Note: When the engine is operated in dusty
Porous filter applications, more frequent cleaning is required.
A porous filter is part of the fitting that is used for

i01225429
mounting of the service indicator. Inspect the filter
for cleanliness. Clean the filter, if necessary. Use
compressed air qr a clean, nonflammable solvent.
Engine Crankcase Breather -
Clean
Note: When service indicator is installed, excessive
tightening may crack the top of the service indicator. SMCS Code: 1317-070
Tighten the service indicator to a torque of 2 N·m
(18 lb in). If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become
Replace the service indicator annually regardless of plugged. A plugged crankcase breather will cause
the operating conditions. excessive crankcase pressure that may cause
crankshaft seal leakage.
83
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 66
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".
4 7. Coat 0-ring seals (4) with clean engine oil. Place

the 0-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
Illustration 67
l g00597465
tee. Tighten the clamp to the torque that is listed
in the Service Manual, "Specifications".
i02017664
3. Remove 0-ring seals (4) from the valve covers. Engine Mounts - Check
Inspect the 0-ring seals for good condition. Obtain
new 0-ring seals, if necessary. SMCS Code: 1152-535
·~o~I~~[~·~~~~
0 0 ~
2
g00736591
Illustration 69
(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 can lead to misalignment. Excessive vibration of the
Illustration 68
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
84
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
A WARNING 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.
85
Maintenance Section
Engine Oil Filter (Auxiliary) - Change
i02017678
NOTICE
Engine damage can occur if the crankcase is filled
Engine Oil Filter {Auxiliary) -
above the "FULL" mark on the oil level gauge (dip- Change
stick).
SMCS Code: 1318
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel- Note: An auxiliary oil filter system enables the oil
oped and also force air bubbles into the oil. These capacity of the engine to be increased. Use of the
bubbles (foam) can cause the following problems: re- auxiliary oil filter elements is not recommended.
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the Perform this procedure after the oil has been drained
crankcase breathers, and excessive oil consumption. from the auxiliary oil filter housing.
Excessive oil consumption will cause deposits to form

on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
If the oil level is above the "FULL" mark on the oil level
gauge, drain some of the oil immediately. 2
Note: For the appropriate oil to use, and for

the amount of oil to use, refer to this Operation
and Maintenance Manual, "Refill Capacities and
Recommendations" article (Maintenance Section).
g00787079
Illustration 70
4. Remove the oil filler cap. Fill the crankcase
Auxiliary oil filter housing
through the oil filler tube only. Clean the oil filler
cap. Install the oil filler cap. (1) Vent plug
(2) Drain plug
NOTICE 1. If the engine is equipped with an auxiliary oil filter

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

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

"Starting The Engine" procedure (Operation
Section). Operate the engine at low idle for two
minutes. This will ensure that the lubrication
system and the oil filters are filled with oil. Inspect
the engine for oil leaks. Ensure that the oil level is
between the "ADD" and the "FULL" marks on the
"LOW IDLE" side of the oil level gauge.
7. Stop the engine and allow the oil to drain back into
the sump for a minimum of ten minutes.
8. Remove the oil level gauge and check the oil level.
Maintain the oil level between the "ADD" and the
"FULL" marks on the "ENGINE STOPPED" side of
the oil level gauge.
86
Maintenance Section
Engine Oil Filter - Change
4. Remove bolt (12). Remove washer (13) and

spider (14). Remove plate (15).
5. Remove the oil filter elements if the oil filters have

been installed. Clean the inside of the oil filter
housing.
_,
Inspect the oil filter elements if the oil filters have
-- ------- 8 been installed. For instructions on inspecting
the oil filter elements, refer to the Operation and
Maintenance Manual, "Engine Oil Filter - Change"
0 topic (Maintenance Section).
6. Ensure that plug (5) is tight.
7. Install drain plug (2). Tighten the drain plug to

3 70 ± 14 N·m (50 ± 10 lb ft).
Note: Use of the auxiliary oil filter elements is not

required.
2
i I
8. If the use of auxiliary oil filter elements is desired,
install new elements.
m ~ ,
L _J
9. Install plate (15), spider (14), washer (13), and
bolt (12).
g00787105
10. Install spring (11) on spider (14). Install spring
Illustration 71 retainer (10) and nut (9) on bolt (12).
( 1) Vent plug
(2) Drain plug 11. Tighten nut (9) in order to compress spring (11)
(3) Nut
(4) Washer
until the spring retainer bottoms out on bolt (12).
(5) Plug Do not overtighten the nut.
(6) Bolt
(7) Cover 12. Fill the oil filter housing with oil. For the correct
(8) Cover gasket amount of oil, refer to the Operation and
(9) Nut
(10) Spring retainer Maintenance Manual, "Refill Capacities and
(11) Spring Recommendations" topic (Maintenance Section).
(12) Bolt
(13) Washer 13. Inspect cover gasket (8) for tears, breaks, or other
(14) Spider
(15) Plate
damage. If the cover gasket is damaged, replace
the old cover gasket with a new cover gasket.
1. Remove 12 nuts (3), washers (4), and bolts (6). Install cover gasket (8). Install cover (7).
2. Remove cover (7) and gasket (8). Do not damage 14. Install twelve bolts (6), washers (4), and nuts
the gasket. (3). Tighten nuts sequentially around the cover
until the nuts are snug. Tighten the nuts to
100 ± 15 N·m (75 ± 11 lb ft).
A WARNING
15. Install vent plug (1).
Possible injury can occur during the removal of
the nut, the spring retainer, and the spring. Spring
force will be released when the nut and the spring i02154624
retainer are removed. Be prepared to hold the Engine Oil Filter - Change
spring retainer as the nut is loosened.
SMCS Code: 1308-510; 1308
3. Remove nut (9), spring retainer (10), and spring
(11 ). Hold spring retainer (10) as nut (9) is Replace the engine oil filters when any of the
loosened. following conditions are met:
• Every oil change

87
Maintenance Section
• The engine oil filter differential pressure reaches Note: Some oil will remain in the housing after the oil
100 kPa (15 psi). has been drained. This oil will pour out of the housing
when cover (5) is removed. Prepare to catch the oil
• The engine oil filters have been used for 1500 in a suitable container. Clean up any spilled oil with
operating hours. absorbent pillows or towels. DO NOT use absorbent
particles to clean up the oil.
Service tools are available to aid in the service of oil
filters. Consult your Caterpillar dealer for the part
names and the part numbers. Follow the instructions A WARNING
that are supplied with the service tools. If the service
tools are not used, perform the following appropriate Personal injury can result from parts and/or cov-
procedure. ers under spring pressure.
Spring force will be released when covers are re-

Replacing the Engine Oil Filters moved.
With the Engine Stopped
Be prepared to hold spring loaded covers as the
bolts are loosened.
A WARNING
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact

skin.
Perform the following procedure after the oil has

been drained.
g00760382
Illustration 73
Section view
(4) Bolt
(5) Cover
(6) 0-ring seal
3 (7) Oil filter element
3. Be alert to the spring force. Gradually loosen but

do not remove bolts (4). Before removing bolts (4),
pry cover (5) loose or tap the cover with a rubber
Illustration 72
g01092449 mallet in order to relieve any spring pressure.
(1) Plug
(2) Drain valve 4. Remove bolts (4) and the washers in order to
(3) Drain remove cover (5) and 0-ring seal (6). Remove oil
(4) Bolt filter elements (7).
(5) Cover
5. Clean cover (5), 0-ring seal (6), and the inside
1. Connect a hose to drain (3). Place the other end of the oil filter housing.
of the hose into a suitable container in order to
collect the oil.
NOTICE
2. Open drain valve (2). Remove plug (1 ). Allow the Caterpillar oil filters are built to Caterpillar speci-
oil to drain. Clean the plug and install the plug. fications. Use of an oil filter not recommended by
Close the drain valve. Remove the hose from the Caterpillar could result in severe engine damage to
drain. the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
88
Maintenance Section
6. Ensure that the new oil filter elements are in good If the engine is equipped with duplex oil filters, the
condition. Install the new oil filter elements. engine oil filter elements can be changed while the
engine is operation. This is useful if the oil filter
7. Inspect 0-ring seal (6). Ensure that the surfaces elements require more frequent replacement than
for the 0-ring seal are clean. Install a new the engine oil.
0-ring seal if the old 0-ring seal is damaged or
deteriorated. 1. Move the control valve to the "AUX RUN" position
in order to change the main oil filter elements.
8. Install 0-ring seal (6) and cover (5). Ensure that Move the selector valve to the "MAIN RUN"
the cover's retainer is properly seated. position in order to change the auxiliary oil filter
elements.
9. Close drain valve (2).
2. Allow the oil pressure gauge for the oil filter that
10. Install plug (1). is being changed to reach a "ZERO" pressure
reading.
11. Start the engine. Check for oil leaks.
3. Perform Step 1 through Step 12 of "Replacing the
12. Check the oil level on the "LOW IDLE" side of the Engine Oil Filters With the Engine Stopped".
oil level gauge. Maintain the oil level between the
"ADD" and "FULL" marks on the "LOW IDLE" side 4. Open the "FILL" valve for a minimum of five
of oil level gauge. minutes in order to fill the new oil filter elements.
5. Close the "FILL" valve. Rotate the control valve

Replacing the Engine Oil Filters to the "RUN" position for the oil filter that was
During Engine Operation serviced.
A WARNING Inspect the Used Oil Filter Elements

Filter contains hot pressurized fluid when engine Cut the used oil filter element open with a utility knife.
is running. Cut the filter element free from the end caps. Spread
apart the pleats and inspect the element for metal
Follow instructions on control valve to avoid per- debris. An excessive amount of debris in the element
sonal injury. may indicate early wear or a pending failure.
If rapid air movement exists to blow fluid, Stop the Use a magnet to differentiate between the ferrous
engine to avoid fire. metals and the nonferrous metals that are found
in the element. Ferrous metals may indicate wear
on the steel and the cast iron parts of the engine.
Nonferrous metals may indicate wear on the
· aluminum parts, the brass parts, or the bronze parts
of the engine. Parts that may be affected include the
following components: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Aluminum debris may indicate problems with the

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

to find small amounts of debris in the oil filter element.
If an excessive amount of debris is found in the oil
filter element, consult your Caterpillar dealer in order
to arrange for further oil analysis.
89
Maintenance Section
Engine Oil Level - Check
i02017693 b. If the engine is operating, reduce the engine

speed to low idle. Remove the engine oil level
Engine Oil Level - Check gauge and observe the engine oil level on
"ENGINE AT LOW IDLE WITH WARM OIL"
SMCS Code: 1348-535-FLV side (4).
The most accurate check of the engine oil level is The engine oil level should be between "ADD"
obtained when the engine is stopped. mark (5) and "FULL" mark (6).
NOTICE
Engine damage can occur if the crankcase is filled
above the "FULL" mark on the oil level gauge (dip-
stick).
An overfull crankcase can cause the crankshaft to dip

into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption.
Illustration 75
g00760401 Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
(1) Engine oil level gauge (dipstick)
(2) Filler cap posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
1. Remove filler cap (2) in order to ensure that the under the piston rings, and wear of the cylinder liner.
crankcase pressure is equal to the atmospheric
pressure. If the oil level is above the "FULL" mark on the oil level
gauge, drain some of the oil immediately.
Excess pressure or a slight vacuum will affect
engine oil level that is measured. 3. If necessary, add engine oil. For the correct
engine oil to use, refer to this Operation and
2. Ensure that engine oil level gauge ( 1) is seated. Maintenance Manual, "Refill Capacities and
Recommendations" topic (Maintenance Section).
Do not fill the crankcase above the "FULL" mark
on the engine oil level gauge. Clean the filler cap
3 (2). Install the filler cap.
\
'--~~M=7~'*§lll@==~,~L___,)\~----"''""='"~~~=·~OWJ=TH=OI~l~=·~---ltJ==i 4. Record the amount of engine oil that is added. For
the next engine oil sample and analysis, include
4 5 6 the total amount of engine oil that has been added
\I L. n~ ,. ,=,.,., .,.,., ..,:--.,..=,=wi1"'"'"'=""'""",-'---itJ==i since the previous oil change. This will help to
provide the most accurate analysis.
i01935337
Engine Oil Sample - Obtain

g00735162
Illustration 76
(3) "ENGINE STOPPED WITH OIL COLD" side
SMCS Code: 1348-554-SM
(4) "ENGINE AT LOW IDLE WITH WARM OIL" side
(5) "ADD" mark In addition to a good preventive maintenance
(6) "FULL" mark program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order
a. If the engine is stopped, remove the engine oil to monitor the condition of the engine and the
level gauge. Observe the engine oil level on maintenance requirements of the engine. S·O·S oil
"ENGINE STOPPED WITH OIL COLD" side analysis provides infrared analysis, which is required
(3). for determining nitration and oxidation levels.
90
Maintenance Section
Engine Protective Devices - Check
Obtain the Sample and the Analysis For instructions, see Special Publication, PEHP6001,
"How To Take A Good Oil Sample". Consult your
Caterpillar dealer for complete information and
A, WARNING assistance in establishing an S·O·S program for your
engine.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin. i00626013
Engine Protective Devices -

Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order Check
to help obtain the most accurate analysis, provide
the following information: SMCS Code: 7400-535
• Engine model Alarms and shutoffs must function properly. Alarms

provide timely warning to the operator. Shutoffs help
• Service hours on the engine to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
• The number of hours that have accumulated since in good working order during normal operation.
the last oil change Malfunctions must be simulated in order to test the
engine protective devices.
• The amount of oil that has been added since the
last oil change A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate
To ensure that the sample is representative of the at the setpoints. Ensure that the engine protective
oil in the crankcase, obtain a warm, well mixed oil devices are functioning properly.
sample.
NOTICE
To avoid contamination of the oil samples, the tools During testing, abnormal operating conditions must be
and the supplies that are used for obtaining oil simulated.
samples must be clean.
The tests must be performed correctly in order to pre-
Caterpillar recommends using the sampling valve vent possible damage to the engine.
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling To prevent damage to the engine, only authorized
valve allows oil that is flowing under pressure to be service personnel or your Caterpillar dealer should
obtained during normal engin_e operation. perform the tests.
The 169 - 83 73 Fluid Sampling Bottle is Visual Inspection

recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are Visually check the condition of all gauges, sensors
needed for obtaining oil samples. Instructions are and wiring. Look for wiring and components that
also provided. are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
NOTICE immediately.
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling. i02015492
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This · Engine Speed/Timing Sensor -
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both Clean/Inspect
dealers and customers.
SMCS Code: 1905-040; 1905-070; 1907-040;
1907-070
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is An engine speed/timing sensor is mounted in the
designed to accept sampling bottles. Disposable flywheel housing. The speed/timing sensor provides
tubing must be attached to the pump for insertion information about engine speed and the position of
into the sump. the crankshaft to the ECM.
91
Maintenance Section
Engine Valve Lash and Bridge - Adjust
c. Coat the threads of the sensor with 4C - 5597

Anti-Seize Compound.
Note: The sliphead is designed to contact a tooth

during the first revolution of the speed-timing wheel.
For the maximum allowable clearance between
the sliphead and the tooth, refer to the engine's
Specifications manual.
d. Install the sensor. Tighten the locknut to

40 ± 5 N·m (30 ± 4 lb ft).
i02151241
Illustration 77
g00760464 Engine Valve Lash and Bridge
-Adjust
1. Remove engine speed/timing sensor (1 ). Inspect
the condition of the end of the magnet. Look for SMCS Code: 1102-025; 1102
signs of wear and contaminants.
2. Clean any debris from the face of the magnet. A WARNING

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
g00931748 death may result and the ignition system will be
Illustration 78 damaged if the valve covers are removed during
engine operation. The engine will not operate
3. Check the tension of the sliphead. Gently extend without the valve covers.
sliphead (2) for a minimum of 4 mm (0.16 inch).
Then push back the sliphead.
For procedures on adjusting the valve bridge and the
When the sliphead has the correct tension, at engine valve lash, refer to the following publications:
least 22 N (5 lb) of force is required to push in the
sliphead from the extended position. • Special Instruction, REHS0128, "Using the
147-5482 Indicator Gauge for Valve Lash and
Valve Bridge Adjustment"
NOTICE
The sliphead must be fully extended when the speed/
• The Systems Operation/Testing and Adjusting
timing sensor is installed so that the sensor maintains
manual for the engine
the correct clearance with the speed-timing wheel.
If the correct clearance is not maintained, the signal
• The Specifications manual for the engine
from the sensor will not be generated.
Do not install the sensor between the teeth of the
speed-timing wheel. Damage to the sensor would re-
sult. Before installing the sensor, ensure that a tooth Valve Bridge
of the wheel is visible in the mounting hole for the sen-
sor. Check the valve bridge and adjust the valve bridge,
if necessary. Perform the procedure for both valve
bridges for each cylinder.
4. Install the engine speed/timing sensor.
After the valve bridge for each cylinder is satisfactory,
a. Ensure that a tooth on the speed-timing wheel
measure the valve lash.
is visible in the mounting hole for the sensor.
b. Extend sliphead (2) by a minimum of 4 mm

(0.16 inch).
92
Maintenance Section
Engine Valve Rotators - Inspect
Engine Valve Lash 2. Install the valve covers. See the Service Manual
for the procedure.
NOTICE
3. Start the engine. Operate the engine for 5 minutes.
Only qualified service personnel should perform this
Stop the engine.
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
4. Remove the valve covers. Observe the position of
ment procedure.
the marks that are on the valve rotators.
Operation of Caterpillar engines with improper valve
If a valve fails to rotate, consult your Caterpillar
adjustments can reduce engine efficiency. This re-
dealer.
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 i01505507
catastrophic failure.
Exhaust Bypass - Inspect
If the valve lash is within the tolerance, an adjustment SMCS Code: 1057-040
of the valve lash is NOT necessary.
For instructions on removal and installation, see the
Perform valve lash adjustment if the dimension is not Service Manual, "Disassembly and Assembly".
within the tolerance. The valve bridge adjustment
must be performed before making a valve lash 1. Remove the exhaust bypass valve.
adjustment.
Perform the valve lash setting when the engine is A WARNING

cold. After the engine has been shut down and the
valve covers are removed, the engine is considered The exhaust bypass valve cover is under spring
cold. compression. To prevent personal injury, use cau-
tion when removing the cover.
Before performing maintenance, prevent the entry of
foreign matter into the top of the cylinder head and 2. Disassemble the valve.
the valve mechanism. Thoroughly clean the area
around the valve mechanism covers.
For the valve lash setting, refer to this Operation and

Maintenance Manual, "Specifications" section and/or
the Specifications manual for the engine.
i01765711
Engine Valve Rotators - Inspect

SMCS Code: 1109-040
2
NOTICE
A valve rotator which does not operate properly will g00781274
Illustration 79
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced, Exhaust bypass valve
valve face guttering could result and cause pieces of (1) Diaphragm
the valve to fall into the cylinder. This can cause piston (2) Valve stem
(3) Breather
and cylinder head damage.
3. Inspect diaphragm (1 ). If the diaphragm is worn or
Note: Use of a platform may be necessary to reach cracked, replace the diaphragm.
the engine valve rotators.
4. Inspect valve stem (2) and the valve guide. If the
Perform this procedure after the valve lash has been parts are excessively worn, replace the parts.
set.
5. Clean breather (3).
1. Mark the tops of the valve rotators with a
permanent marker. Note the position of the marks. 6. Assemble the valve.
93
Maintenance Section
Exhaust Piping - Inspect
7. Install the valve. i01505536
Fuel System Fuel Filter

i00721010
Differential Pressure - Check
Exhaust Piping - Inspect
SMCS Code: 1261-535
SMCS Code: 1061-040
A fuel filter differential pressure gauge must be
installed in order to determine when the fuel filter
,A. WARNING requires service. This gauge and the fuel filter are
supplied by the customer.
Hot engine components can cause injury from
burns. Before performing maintenance on the
A fuel filter differential pressure gauge indicates the
engine, allow the engine and the components to difference in fuel pressure between the inlet side
cool. and the outlet side of the fuel filter. The differential
pressure increases as the fuel filter becomes
Inspect the components of the exhaust system. plugged.
Repair the components or replace the components if
any of the following conditions occur: Operate the engine at the rated speed and at the
normal operating temperature. Check the fuel filter
• Damage differential pressure. Service of the fuel filter depends
on the pressure of the fuel system:
• Cracks
• For low pressure gas fuel systems, service the
• Leaks fuel filter when the fuel filter differential pressure
reaches 1. 7 kPa (0.25 psi).
• For high pressure gas fuel systems, service the
Consult your Caterpillar dealer for assistance. fuel filter when the fuel filter differential pressure
reaches 34 kPa (5 psi).
Water Cooled Exhaust Manifolds For instructions, see Special Instruction, SEHS9298,
"Installation and Maintenance of Gaseous Fuel
The water cooled exhaust manifolds do not require Filters". Consult your Caterpillar dealer for assistance.
maintenance unless excessive deposits build up in
the exhaust passages. Buildup of deposits cause
an increase in back pressure that will cause the i01642143
following conditions:
Gas Pressure Regulator -
• Increased fuel consumption Check
• Reduced boost pressure SMCS Code: 1270-535
If excessive deposits build up in the exhaust Check the fuel pressure before the gas pressure
passages, clean the passages in order to remove regulator . Table 22 lists the fuel pressure that is
the deposits. required for the gas pressure regulator.
Table 22
i00796401
Requirements for Fuel Pressure To the Gas
Fuel Filtration System - Service Pressure Regulator
Fuel System Pressure
SMCS Code: 1260
Low pressure gas 10.3 to 34 ± 2 kPa
Engines that use bio-gas require special equipment (1.50 to 5 ± 0.25 psi)
for processing the fuel. Service the fuel filtration
High pressure gas 172 to 207 ±3.5kPa
system according to the instructions that are provided (25 to 30 ± 0.5psi)
Standard Engine
by the OEM of the equipment.
High pressure gas 242 to 275 ± 3.5 kPa
LE Engine (35 to 40 ± 0.5psi)
94
Maintenance Section
Gas Pressure Regulator Condensation - Drain
Fuel Differential Pressure of the

Fuel Supply To the Carburetor
The gas pressure regulator maintains a pressure
differential between the boost and the fuel that
is supplied to the carburetor. After setting, the
gas pressure regulator will maintain the pressure 2
differential in response to changes in the boost
pressure.
Use a water manometer for measuring the pressure

differential. Obtain the measurement when the
engine is operating at high idle rpm. After a load
is applied, the fuel pressure will usually decrease
by approximately 0.1 to 0.25 kPa (0.50 to 1 inches g00829869
Illustration 80
of H20). If the performance of the gas pressure (1) Cap on the drip leg for the balance line
regulator is erratic, the gas pressure regulator may (2) Cap on the drip leg for the gas supply line to the gas pressure
require service. regulator
Natural Gas 1. Close the main gas supply valve.
Set the differential of the fuel supply to a maximum of 2. Remove caps (1) and (2) from the drip legs.
1 to 1.2 kPa (4 to 4.5 inches of H20).
3. Allow the moisture to drain into a suitable
Check the differential pressure in order to maintain container. Inspect the drip legs for debris. Clean
the correct pressure for the fuel that is being burned the drip legs, if necessary.
and the application of the engine. Refer to the
engine's Systems Operation/Testing and Adjusting. 4. Clean the caps. Install the caps.
5. Perform Step 2 through Step 4 for the drip leg on

i01642256 the supply line to the gas shutoff valve.
Gas Pressure Regulator 6. Open the main gas supply valve.
Condensation - Drain
i02121526
SMCS Code: 1270-543
Hoses and Clamps -
To collect condensation, drip legs should be installed
in the following locations: Inspect/Replace
• Supply line for the gas pressure regulator SMCS Code: 7554-040; 7554-510
• Balance line for the gas pressure regulator Inspect all hoses for leaks that are caused by the
following conditions:
• Supply line to the gas shutoff valve
• Cracking
• Softness
• Loose clamps
Replace hoses that are cracked or soft. Tighten any

loose clamps.
95
Maintenance Section
Ignition System Spark Plugs - Check/Adjust/Replace
2. Loosen the cooling system filler cap slowly in

NOTICE order to relieve any pressure. Remove the cooling
Do not bend or strike high pressure lines. Do not in- system filler cap.
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and Note: Drain the coolant into a suitable, clean
hoses. Leaks can cause fires. Inspect all lines, tubes container. The coolant can be reused.
and hoses carefully. Tighten all connections to the rec-
ommended torque. 3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
Check for the following conditions: 4. Remove the hose clamps.
• End fittings that are damaged or leaking 5. Disconnect the old hose.
• Outer covering that is chafed or cut 6. Replace the old hose with a new hose.
• Exposed wire that is used for reinforcement 7. Install the hose clamps with a torque wrench.
• Outer covering that is ballooning locally Note: Refer to the Specifications, SENR3130,
"Torque Specifications" in order to locate the proper
• Flexible part of the hose that is kinked or crushed torques.
• Armoring that is embedded in the outer covering 8. Refill the cooling system.
A constant torque hose clamp can be used in place 9. Clean the cooling system filler cap. Inspect the
of any standard hose clamp. Ensure that the constant cooling system filler cap's gaskets. Replace
torque hose clamp is the same size as the standard the cooling system filler cap if the gaskets are
clamp. damaged. Install the cooling system filler cap.
Due to extreme temperature changes, the hose will 10. Start the engine. Inspect the cooling system for
heat set. Heat setting causes hose clamps to loosen. leaks.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
i01642332
Each installation application can be different. The
differences depend on the following factors:
Ignition System Spark Plugs -
Check/Adjust/Replace
• Type of hose
SMCS Code: 1555-535
• Type of fitting material
• Anticipated expansion and contraction of the hose _.A WARNING

Ignition systems can cause electrical shocks.
• Anticipated expansion and contraction of the
Avoid contacting the ignition system components
fittings
and wiring.
Replace the Hoses and the Clamps Do not attempt to remove the valve covers when
the engine is operating. The transformers are
_.A WARNING death may result and the ignition system will be
damaged if the valve covers are removed during
Pressurized System: Hot coolant can cause seri- engine operation. The engine will not operate
ous burns. To open the cooling system filler cap, without the valve covers.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres- Maintenance of the spark plugs is required in order
sure. to achieve the following benefits:
• Normal fuel consumption

1. Stop the engine. Allow the engine to cool.
• Normal level of emissions
96
Maintenance Section
• Maximum service life of the spark plugs
The service life of the spark plugs is affected by

fouling due to deposits from the oil and by peak
voltage. Maintenance of the ignition system is also
affected by voltage. Higher voltage is required by
higher inlet manifold air pressure and a higher
compression ratio. Higher voltage reduces the
service life of components such as spark plugs,
wires, and transformers.
Removing the Spark Plug
g00787367
Illustration 82
(4) Wiring harness
(5) Transformer
(6) Lip seal
2 (7) Spark plug
2. Disconnect wiring harness (4) from transformer

3 (5). Be careful to completely depress the retainer
clip away from the connector. Remove transformer
(5).
Note: Excessive buildup of oil in the spark plug

well is an indication of a damaged lip seal on the
g00787369 transformer. If this condition is found, clean the
Illustration 81
(1) Bolt surface of the seal groove. Replace the seal.
(2) Valve cover
(3) 0-ring seal 3. Inspect lip seal (6). If the seal is worn or damaged,
discard the seal and use a new seal for assembly.
Note: Do not use an impact wrench to remove the
cover bolts and do not use an impact wrench to install
the cover bolts.
1. Remove bolts (1 ). Remove valve cover (2).

Inspect 0-ring seal (3). If the seal appears to be
worn or damaged, discard the seal and use a new
seal for assembly.
NOTICE
Pulling on the wiring harness may break the wires. Do
not pull on the wiring harness.
(8) 0-ring seal
4. Inspect 0-ring seal (8). If the seal is hard or

cracked, use a new seal for assembly.
A WARNING
Pressurized air can cause personal injury. When
pressurized air is used for cleaning, wear a pro-
tective face shield, protective clothing, and pro-
tective shoes.
97
Maintenance Section
5. Debris may have collected in the spark plug well. Terminal post (1) must not move. If the terminal post
Thoroughly remove any debris. Use compressed can be moved by hand, carefully tighten the post into
air. The maximum air pressure for cleaning the threads of the insulator. If the post cannot be
purposes must be below 207 kPa (30 psi). Ensure tightened, discard the spark plug.
that the area around the spark plug is clean and
free of dirt and debris. Inspect insulator (2) for cracks. If a crack is found,
discard the spark plug.
6. Use a 22.23 mm (0.875 inch), 4C-4601 Spark
Plug Socket and an extension to loosen spark Faint marks may extend from shell (3) onto the
plug (7). After the spark plug has been loosened, insulator. The marks may be a result of corona that
remove the spark plug by hand in order to detect forms at the top of the shell. The conductor will
problems with the threads. After the spark plug develop a corona when a very high voltage potential
has been removed, discard the used spark plug ionizes the air. This is a normal condition. This is not
gasket. an indication of leakage between the shell and the
insulator.
NOTICE
Inspect shell (3) for damage. Cracks can be caused
Do not use a thread tap. A thread tap will remove metal
by overtightening the spark plug. Overtightening can
unnecessarily. The threads could be stripped and the
also loosen the shell. Discard any spark plug that has
cylinder head could be damaged.
a shell that is cracked or loose.
If the spark plug resists removal by hand, apply

penetrating oil to the threads. Use the wrench and
apply steady pressure to the spark plug until the
spark plug is loose.
If the spark plug can not be removed by hand, clean

the threads with 9U- 7511 Spark Plug Seat Cleaner.
This tool scrapes debris from the seat and from the
threads in the cylinder head. Be sure to clean any
debris from the cylinder.
Inspecting the Spark Plug

g00787372
Illustration 85
(6) Precious metal tips on the electrode and the ground strap
Caterpillar spark plugs have precious metal tips (6)

on the electrode and the ground strap. This material
will gradually erode. Use extreme care when you set
the electrode gap. Maintain even spacing and proper
alignment between the two precious metal surfaces.
Replace the spark plug if the precious metal is worn

off. ·
A light brown deposit or a beige deposit around the

g00787368 electrode is produced by normal operation.
Illustration 84
(1) Terminal post Deposits that are gray or black may be caused by
(2) Insulator
the following substances:
(3) Shell
(4) Gasket
(5) Electrode • Excessive oil
Inspect the spark plug closely for damage. The • Use of the wrong oil
condition of the spark plug can indicate the operating
condition of the engine. • A substance that is introduced through the fuel
system or the air system
98
Maintenance Section
A spark plug can operate despite a buildup of ash. Installing the Spark Plug
However, a buildup of ash can cover the electrode
gap. This will cause misfire. Large deposits may Note: Use the 9U - 7516 Spark Plug Gauge to
retain heat which can cause premature fuel ignition. measure the electrode gap. Do not use a flat feeler
This can lead to uncontrollable detonation. gauge for measuring the electrode gap of used spark
plugs. A feeler gauge will incorrectly measure the
actual electrode gap because the used precious
Cleaning the Spark Plug metal tips are curved.
Thoroughly clean the spark plug. Do not use a wire
1. Before installing the spark plug, set the electrode
brush. Glass beads are the preferred method for
gap. The electrode gap depends on the engine's
cleaning.
compression ratio.
Follow these guidelines for using glass beads:
a. For compression ratios that are greater than
9: 1, set the electrode gap to 0.29 ± 0.03 mm
• Always use clean glass beads.
(0.011 ± 0.001 inch).
• Use new glass beads for each set of spark plugs.
b. For compression ratios of 9:1 or less,
set the electrode gap to 0.35 ± 0.03 mm
• Use care in order to clean only the electrode and
(0.014 ± 0.001 inch).
the insulator near the electrode.
Adjust the electrode gap, if necessary. Bend
• Do not use glass beads on the outside of the shell
the ground strap at the existing bend. Then
or on the upper part of the insulator.
bend the strap near the weld in order to achieve
proper alignment and even spacing between
Checking the Spark Plug the two precious metal surfaces. Measure the
electrode gap after the alignment. Correct the
After the spark plug is clean, measure the spark electrode gap, if necessary.
plug's resistance. If the resistance is correct, make
sure that the electrode gap is correct before you Note: Do not use anti-seize compound on spark
install the spark plug. plugs. Most of the heat is transferred through the
threads and the seat area of the spark plug. The
Note: A standard ohmmeter cannot be used for surfaces must be in contact in order to provide the
measuring the resistance of a used spark plug. heat transfer that is required.
Use the 142 - 5055 Insulation Tester Group to 2. Ensure that the spark plug is clean and free of
measure the resistance of the spark plug. Follow dirt and oil.
the warnings and instructions that are provided with
the tool. 3. Always use a new gasket when a spark plug is
installed. If a used spark plug is installed, place a
Connect the red lead of the tester to terminal post new 9Y - 6792 Spark Plug Gasket on the spark
(1 ). Because the ground strap is close to electrode plug. Orient the tabs of the gasket toward the
(5), you will need to connect a smaller lead to the electrode. Otherwise, the gasket may not seat
center electrode. Then connect the black lead of properly. Do not increase the torque on the spark
the tester to the smaller lead. Use the tester's "KO" plug in order to improve the seal. Do not reuse the
scale. The correct resistance depends on the spark gasket. Install a new gasket.
plug that is used:
• For the 146 - 2588 Spark Plug, the correct NOTICE

resistance is approximately 1000 ohms. Do not overtighten the spark plug. The shell can be
cracked and the gasket can be deformed. The met-
• For the 194 - 8518 Spark Plug, the correct al can deform and the gasket can be damaged. The
resistance is approximately 500 ohms. shell can be stretched. This will loosen the seal that is
between the shell and the insulator, allowing combus-
If the resistance is greater than the specification, tion pressure to blow past the seal. Serious damage
discard the spark plug and obtain a new spark plug. to the engine can occur.
Use the proper torque.

99
Maintenance Section
Ignition System Timing - Check/Adjust
4. Install the spark plug by hand until the spark plug • Compression ratio of the engine
bottoms out. Tighten the spark plug to 68 ± 4 N·m
(50 ± 3 lb ft). • Inlet air temperature
5. Ensure that the transformer and the extension are • Methane number of the gas
clean and free from dirt and oil. Lubricate 0-ring
seal (8) (Illustration 83) with one of the following For the proper timing, see the Engine Performance
lubricants: publication for the engine.
• 4C - 9504 Dielectric Grease Adjust the timing according to the Service Manual,
"Systems Operation/Testing and Adjusting" module.
• SN - 5561 Silicone Lubricant Consult your Caterpillar dealer for assistance.
• 8T - 9020 Dielectric Grease

i01113853
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
g00838130 Inspect the following components:

Illustration 86
Retainer on the transformer's connector for the wiring harness
• Piping between the air cleaner and the turbocharger
6. Install the transformer. Orient the transformer • Turbocharger
toward the wiring harness. Carefully align the
socket of the transformer with the wiring harness • Piping between the turbocharger and the
connector. Connect the wiring harness. aftercooler
Note: If the connector's locking tab or the • Aftercooler
transformer's connector are damaged, install a
retainer onto the transformer's connector for the • Connection of the aftercooler to the air plenum
wiring harness. For connectors with a width of
22.3 mm (0.88 inch), use the 178- 0565 Retainer. • Connection of the air plenum to the cylinder head
For connectors with a width of 17.1 mm (0.67 inch),
use the 179 - 1500 Retainer. Ensure that all of the connections are secure. Ensure
that the components are in good condition.
7. Install the valve cover.
Make repairs, if necessary. For information regarding
i01005974 removal and installation of the components, see
the Service Manual, "Disassembly and Assembly"
Ignition System Timing - module. Consult your Caterpillar dealer for
assistance.
Check/Adjust
SMCS Code: 1550-025; 1550-535
After maintenance has been performed on the

ignition system, check the timing of the ignition
system. Adjust the timing, if necessary.
The optimum ignition timing for a gas engine varies

according to several factors:
100
Maintenance Section
Overhaul (In-Frame)
i01950722 Usually, an in-frame overhaul does not require

removal of the engine. Instead, the service is
Overhaul (In-Frame) performed with the engine in place. If the cu~tomer
requires a minimum disruption in the production of
SMCS Code: 1000-020 power, the engine can be replaced with a rebuilt
model of identical specifications.
Scheduling an In-Frame Overhaul
Note: The generator or the driven equipment may
Generally, an in-frame overhaul is performed for also require service when the engine overhaul is
every third top end overhaul. Scheduling an in-frame performed. Refer to the literature that is provided by
overhaul normally depends on the following three the OEM of the driven equipment.
conditions:
·in-Frame Overhaul Information
• An increase of oil consumption
An in-frame overhaul includes all of the work that is
• An increase of crankcase blowby done for a top end overhaul. Additionally, some other
components that wear are replaced. The condition
• A decrease and a variation of cylinder compression of components is inspected. Those components are
replaced, if necessary.
Each individual condition may not indicate a need
for an overhaul. However, evaluating the three Your Caterpillar dealer can provide these services
conditions together is the most accurate method of and components. Your Caterpillar dealer can ensure
determining when an overhaul is necessary. that the components are operating within the
appropriate specifications.
The engine does not require an overhaul if the
engine is operating within acceptable limits for The following definitions explain the terminology for
oil consumption, crankcase blowby, and cylinder the services that are performed during an overhaul:
compression.
Inspect - Inspect the components according to
Periodically measure each of the three conditions. the instructions that are in Caterpillar reusability
The first measurement should occur during the publications. Refer to Guidelines for Reusable
engine commissioning. This establishes a baseline Parts and Salvage Operations, SEBF8029, "Index
for future measurements. Additional measurements of Publications on Reusability or Salvage of Used
are scheduled at regular intervals in order to Parts". The guidelines were developed in order to
determine a schedule for the next in-frame overhaul. help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
The following changes in the three conditions required if the existing parts can still be used,
normally require a scheduled overhaul: reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
• A 300 percent increase in oil consumption Manual, "Specifications" module.
• A 200 percent increase in crankcase blowby Rebuild - The component can be reconditioned in
order to comply with reusability guidelines.
• A 20 percent loss of cylinder compression
Replace - The service life of the part is exhausted.
Note: These indications do not require an engine The part may fail before the next maintenance
to be shut down for service. These indications interval. The part must be replaced with a part that
only mean that an engine should be scheduled for meets functional specifications. The replacement
service in the near future. If the engine operation part may be a new part, a CAT remanufactured part,
is satisfactory, an immediate overhaul is not a a rebuilt part, or a used part. Some worn components
requirement. may be exchanged with your Caterpillar dealer.
Consult your Caterpillar dealer about repair options
Monitor the engine as the engine accumulates for your engine.
service hours. Consult your Caterpillar dealer about
scheduling a major overhaul. If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the
recommendations in Table 23.
101
Maintenance Section
Overhaul (Major)
Table 23 • A decrease and variation of cylinder compression

In-Frame Overhaul
Other factors must also be considered for determining
Clean Oil suction screen a major overhaul:
Clean Aftercooler core
Inspect • The service hours of the engine
Test
• The wear metal analysis of the lube oil
Inspect Compressor bypass valve
Rebuild • An increase in the levels of noise and vibration
Replace Fuel metering valve
Electrohydraulic actuator An increase of wear metals in the lube oil indicates
Hydraulic oil pump that the bearings and the surfaces that wear may
need to be serviced. An increase in the levels of
Oil cooler noise and vibration indicates that rotating parts
Oil pump require service.
Pistons Note: It is possible for oil analysis to indicate a

Transformers
decrease of wear metals in the lube oil. The cylinder
liners may be worn so that polishing of the bore
Rebuild Exhaust bypass occurs. Also, the increased use of lube oil will dilute
the wear metals.
Prelube pump
Starting motor Monitor the engine as the engine accumulates
service hours. Consult your Caterpillar dealer about
Turbochargers
scheduling a major overhaul.
Water pumps
Note: The driven equipment may also require service
Replace Connecting rod bearings
when the engine is overhauled. Refer to the literature
Cylinder head assemblies that is provided by the OEM of the driven equipment.
Cylinder liners
Main bearings
Major Overhaul Information
Oil temperature regulators A major overhaul includes all of the work that is done
for top end overhauls and in-frame overhauls. A
Piston rings major overhaul includes additional parts and labor.
Additional parts and labor are required in order to
Water temperature regulators completely rebuild the engine. In some cases, the
engine is relocated for disassembly.
i01642396 For the major overhaul, all of the bearings,

seals, gaskets, and components that wear are
Overhaul (Major) disassembled. The parts are cleaned and inspected.
If necessary, the parts are replaced. The crankshaft
SMCS Code: 7595-020-MJ is measured for wear. The crankshaft may require
regrinding. Alternatively, the crankshaft may be
Scheduling a Major Overhaul replaced with a Caterpillar replacement part.
Note: For information on estimating operating hours Your Caterpillar dealer can provide these services
before an overhaul, see Maintenance Management and components. Your Caterpillar dealer can ensure
that the components are operating within the
Schedules, SEBU6127.
appropriate specifications.
Generally, a major overhaul is performed at the sixth
top end overhaul. The need for a major overhaul is If you elect to perform an overhaul without the
determined by several factors. Some of those factors services of a Caterpillar dealer, be aware of the
are the same factors that determine the in-frame following recommendations.
overhaul:
Replacing of Components
• An increase of oil consumption
Replace the following components during the major
• An increase of crankcase blowby overhaul.
102
Maintenance Section
Overhaul (Top End)
• 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

i01645114
• 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
• Carburetor Note: For information on estimating operating hours
before an overhaul, see Maintenance Management
Schedules, SEBU6127.
• Crankshaft vibration damper 1.
• Exhaust bypass Top end overhauls are scheduled according t~

the recession of the exhaust valve stems. This
• Gas regulator measurement provides an accurate indication of the
rate of valve wear. This measurement can be used to
• Prelube pump predict when a cylinder head requires replacement.
• Starting motor Measure the projection of the exhaust valve stems

within the first 1000 service hours. This measurement
• Turbochargers · is the baseline. The baseline is a reference for
subsequent measurements. Continue to periodically
• Water pumps measure the projection.
Note: 1. Replace the crankshaft vibration damper if Plan for the top end overhaul as the valve stem
the damper cannot be rebuilt. projection approaches the maximum limit 1.8 mm
(0.07 inch). Perform the top end overhaul when the
valve stem projection has increased by a total of
Inspecting Components 2.3 mm (0.09 inch). Do not allow the projection of the
exhaust valve stems to exceed this limit.
Inspect the following components according to
the instructions that are in Caterpillar reusability Note: Generally, cylinder heads wear out at different
publications. Refer to Guidelines for Reusable rates. In some cases, servicing the cylinder heads at
Parts and Salvage Operations, SEBF8029, "Index different times may be the most economic decision.
of Publications on Reusability or Salvage of Used This depends on the valve stem projection of the
Parts". individual cylinders. However, this decision must
include the costs of additional downtime that is
• Aftercooler caused by this procedure. Perform an economic
analysis in order to determine if cylinder heads should
• Camshafts be serviced as a group or divided into smaller groups.
103
Maintenance Section
Overhaul (Top End)
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
Note: Periodic inspection of the turbocharger is
• Buildup in the cylinders from contamination of the recommended for determining when the turbocharger
fuel will require an overhaul. In a few applications, the
turbocharger may require rebuilding prior to the top
• Plugging of the aftercooler from coolant that is end overhaul. An example is an application with
poorly maintained loads that vary frequently. In these cases, rebuilding
the turbocharger normally occurs separately from
• Plugging of the aftercooler from contamination of rebuilding the cylinder heads. Some applications
the inlet air can operate longer before the turbocharger requires
rebuilding. Only experience can determine the actual
• Degradation of the oil cooler from hydrogen sulfide need.
in the fuel
Inspecting of Components
Inspect the following components according to
the instructions that are in Caterpillar reusability Clean the aftercooler core and the oil cooler
publications. Refer to Guidelines for Reusable core. Pressure test the components. Replace the
Parts and Salvage Operations, SEBF8029, "Index components.
of Publications on Reusability or Salvage of Used
Parts". Note: It is difficult to clean the aftercooler core when
proper maintenance is not performed . The tank that
Your Caterpillar dealer can provide these services is opposite of the inlet port and the outlet port can not
and components. Your Caterpillar dealer can ensure be removed for cleaning.
that the components are operating within the
appropriate specifications. Note: This procedure may be used for cleaning both
the aftercooler core and the oil cooler core.
104
Maintenance Section
Overhaul (Top End)
1. Remove the core. For the procedure, see the For more information on cleaning the cores, consult
Service Manual, "Disassembly and Assembly" your Caterpillar dealer.
module.
Coupling
2. Turn the core upside-down in order to remove
debris. For tandem engine arrangements, inspect the
coupling for the engines according to the information
NOTICE that is provided by the OEM of the coupling. Check
Do not use a high concentration of caustic cleaner to the bolts for proper torque.
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause Governor
leakage. Only use the recommended concentration of
cleaner. Inspect the governor for proper operation. Make any
repairs that are necessary.
3. Back flush the core with cleaner. Transformers
Caterpillar recommends the use of Hydrosolv
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 2

core thoroughly with clean water.
A WARNING
Personal injury can result from air pressure.
Personal injury can result without following prop- g00850303

Illustration 87
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing. The transformers produce a voltage increase. For
good operation, the connections must be clean and
Maximum air pressure at the nozzle must be less secure. Inspect the transformers for the following
than 205 kPa (30 psi) for cleaning purposes. conditions:
6. Dry the core with compressed air. Direct the air in • 1. Damaged connector
the reverse direction of the normal flow.
• 2. Damaged 0-rings
Note: The test pressure for the oil cooler is 790 kPa
• 3. Dirty insulator
(115 psi). The maximum differential pressure of water
for the aftercooler is 44 kPa (6 psi). The maximum
differential pressure of air for the aftercooler is • 4. Loose connections
5.1 kPa (0.74 psi).
• 5. Loose screws in the top ground spring
7. Inspect the core in order to ensure cleanliness.
Pressure test the core. Many shops that service • Moisture
radiators are equipped to perform pressure tests.
If necessary, repair the core. Test the resistance of the transformers according
to the Electronic Troubleshooting, SENR6413,
8. Install the core. For the procedure, see the Service "G3500 Engines". Consult your Caterpillar dealer for
Manual, "Disassembly and Assembly" module. assistance.
105
Maintenance Section
Overhaul Considerations
Oil Suction Screen i01950926
A WARNING
SMCS Code: 7595-043
Hot oil and components can cause personal in-
jury.
Overhaul Information
Do not allow hot oil or components to contact
skin. An overhaul is replacing the major worn components
of the engine. An overhaul is a maintenance interval
that is planned. The engine is rebuilt with certain
Clean the oil suction screen after the oil has been rebuilt parts or new parts that replace the worn parts.
drained.
An overhaul also includes the following maintenance:
• Inspection of all the parts that are visible during

the disassembly
• Replacement of the seals and gaskets that are

removed
• Cleaning of the internal passages of the engine

and the engine block
Most owners will save money by overhauling the

engine at the intervals that are recommended in
the Operation and Maintenance Manual. It is not
g00787412 practical to wait until the engine exhibits symptoms
Illustration 88 of excessive wear or failure. It is not less costly to
(1) Cover wait. A planned overhaul before failure may be the
(2) 0-ring seal best value for the following reasons:
(3) Screen assembly
• Costly unplanned downtime can be avoided.

Note: Approximately 1 L (1 qt) of oil will remain in the
housing after the sump has been completely drained.
• Many original parts can be reused according to the
This oil will pour out of the housing when cover ( 1) is
removed. Prepare to catch the oil in a pan. Clean up guidelines for reusable parts.
any spilled oil with absorbent pillows or towels. DO
• The service life of the engine can be extended
NOT use absorbent particles to clean up the oil.
without the risk of a major catastrophe due to
1. Loosen the bolts from cover (1 ). Remove cover engine failure.
(1) and 0-ring seal (2). Discard the seal. Remove
• Achieve the best cost/value relationship per hour
screen assembly (3).
of extended service life.
2. Wash screen assembly (3) in clean nonflammable
solvent. Allow the screen assembly to dry before Overhaul Intervals
installation.
Top end overhauls are determined by the projection
3. Remove the side covers from the engine block of exhaust valve stems. In-frame overhauls are
and clean the inside of the oil pan. Install the side determined by cylinder compression, crankcase
covers. blowby, and oil consumption. Major overhauls are
determined by the in-frame tests, and by results of
4. Inspect screen assembly (3) for good condition. S·O·S oil analysis.
Obtain a new screen assembly, if necessary.
Install the screen assembly. Install a new 0-ring Some other factors that are important for determining
seal (2). Install cover (1). the overhaul intervals include the following
considerations:
• Performance of preventive maintenance
• Use of recommended lubricants

106
Maintenance Section
• Use of recommended coolants Overhaul Programs

• Use of recommended fuels An economical way to obtain most of the parts
that are needed for overhauls is to use Caterpillar
• Proper installation remanufactured parts. Caterpillar remanufactured
parts are available at a fraction of the cost of new
• Operating conditions parts. These parts have been rebuilt by Caterpillar
and certified for use. The following components are
• Operation within acceptable limits examples of the remanufactured parts:
• Engine load • Alternators
• Engine speed • Connecting rods
Note: To avoid oil problems, engines that are • Crankshafts

turbocharged and aftercooled must be operated at a
minimum of 60 percent of rated load. • Cylinder heads
Generally, engines that are operated at a reduced • Oil Pumps

load and/or speed achieve more service life before
an overhaul. However, this is for engines that are • Starting motors
properly operated and maintained.
• Turbochargers
Overhaul Inspection
• Water pumps
Refer to the Service Manual for the disassembly and
assembly procedures that are necessary in order Consult your Caterpillar dealer for details and for a
to perform the required maintenance on the items list of the remanufactured parts that are available.
that are listed. Consult your Caterpillar dealer for
assistance. Your Caterpillar dealer may be offering a variety of
overhaul options.
To determine the reusability publications that are
needed to inspect the engine, refer to Guidelines for A Flat Rate Overhaul guarantees the maximum price
Reusable Parts and Salvage Operations, SEBF8029, that you will pay for an overhaul. Flat rate prices on
"Index of Publications on Reusability or Salvage of preventive maintenance programs or major repair
Used Parts". options are available from many servicing dealers
for all Caterpillar Engines. Consult your Caterpillar
The Guidelines For Reusable Parts and Salvage dealer in order to schedule a before failure overhaul.
Operations is part of an established Caterpillar
parts reusability program. These guidelines were Overhaul Recommendation
developed in order to assist Caterpillar dealers and
customers reduce costs by avoiding unnecessary Caterpillar recommends a scheduled overhaul in·
expenditures for new parts. If the engine parts comply order to minimize downtime. A scheduled overhaul
with the established inspection specifications, the will provide the lowest cost and the greatest value.
parts can be reused. New parts are not necessary if Schedule an overhaul with your Caterpillar dealer.
the old parts can be reused, repaired, or salvaged.
Overhaul programs vary between dealers. To obtain
If the parts are not within the inspection specifications, specific information about the types of overhaul
the parts should be salvaged, repaired, replaced, programs and services, consult your Caterpillar
or exchanged. The use of out-of-spec parts could dealer.
result in unscheduled downtime and/or costly repairs.
The use of out-of-spec parts can also contribute to
increased fuel consumption and reduction of engine
efficiency.
Your Caterpillar dealer can provide the parts that are

needed to rebuild the engine at the least possible
cost.
107
Maintenance Section
Power Take-Off Clutch - Check/AdjusULubricate
i01506009 i01604510
Power Take-Off Clutch - Radiator - Clean

Check/Adjust/Lubricate SMCS Code: 1353-070
SMCS Code: 3055-036; 3055-086 Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
NOTICE
New power take-offs should have the clutch adjust- Inspect the radiator for these items: damaged fins,
ment checked before being placed into service. The corrosion, dirt, grease, insects, leaves, oil, and other
clutch adjustment should be checked again after the debris. Clean the radiator, if necessary.
first ten hours of operation. New clutch plates have a
"wear in" period, and the clutch may require several
adjustments until the new plates are "worn in". A, WARNING
Personal injury can result from air pressure.
Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.
Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction
of the fan's air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move the
air nozzle in a direction that is parallel with the tubes.
g00781502 This will remove debris that is between the tubes·.
Illustration 89
( 1) Instruction plate
(2) Serial number plate Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
Check the clutch adjustment regularly after "wear in". must be less than 275 kPa (40 psi). Use pressurized
Heavy-duty applications which have engagements water in order to soften mud. Clean the core from
that are frequent and relatively long periods of both sides.
clutch slippage require more frequent adjustment
than light-duty applications. The operating torque Use a degreaser and steam for removal of oil and
should be measured in order to determine if a clutch grease. Clean both sides of the core. Wash the core
adjustment is required. with detergent and hot water. Thoroughly rinse the
core with clean water.
Refer to the OEM information and instruction plate
( 1) for instructions on lubrication, adjustment, and After cleaning, start the engine and accelerate the
other recommendations for service. Perform the engine to high idle rpm. This will help in the removal
. maintenance that is specified on the instruction plate. of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
A, WARNING necessary.
Do not operate the engine with the Instruction Inspect the fins for damage. Bent fins may be opened
Plate cover removed from the clutch. Personal with a "comb". Inspect these items for good condition:
injury may result. welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
If the clutch is damaged to the point of burst fail-
ure, expelled pieces can cause personal injury to For more detailed information on cleaning and
anyone in the immediate area. Proper safeguards inspection, refer to Special Publication, SEBD0518,
must be followed to help prevent accidents. "Know Your Cooling System".
108
Maintenance Section
Speed Sensor - Clean/Inspect
i01631430 i01113939
Speed Sensor - Clean/Inspect Starting Motor - Inspect

SMCS Code: 1907-040; 1907-070 SMCS Code: 1451-040; 1453-040
If the starting motor fails, the engine may not start in

an emergency situation. A scheduled inspection of
the starting motor is recommended.
The starting motor pinion and the flywheel ring gear

must be in good condition in order for the engine
to start properly. The engine will not start if the
starting motor pinion does not engage the flywheel
ring gear. The teeth of the starting motor pinion and
the flywheel ring gear can be damaged because of
irregular engagement.
Inspect the starting motor for proper operation. Listen

for grinding when the engine is started. Inspect the
g00845023
Illustration 90 teeth of the starting motor pinion and the flywheel
(1) Speed sensor for the governor ring gear. Look for patterns of wear on the teeth. Look
(2) Speed sensor for the service meter for teeth that are broken or chipped. If damaged teeth
are found, the starting motor pinion and the flywheel
1. Remove the speed sensors from the flywheel ring gear must be replaced.
housing. Inspect the condition of the ends
of the sensors. Check for signs of wear and
contaminants. Electric Starting Motor
2. Clean the metal shavings and other debris from Note: Problems with the electric starting motor can
the faces of the sensors. be caused by the following conditions: malfunction of
the solenoid and malfunction of the electric starting
system.
Inspect the electrical system for the following

conditions:
g00318744 • Corrosion
Illustration 91
Speed sensor • Wires that are worn or frayed
3. Install the speed sensor in the flywheel housing. • Cleanliness
Turn the sensor clockwise until the sensor
contacts the teeth of the flywheel ring gear. Make repairs, if necessary.
4. Turn the sensor 1/2 of a turn (180 degrees)
counterclockwise. Maintain a clearance of
0.56 mm (.022 inch) to 0.84 mm (.033 inch)
between the sensor and the teeth of the flywheel
ring gear. Tighten the locknut to 45 ± 7 N·m
(33 ± 5 lb ft).
109
Maintenance Section
Turbocharger - Inspect
Air Starting Motor

NOTICE
Turbocharger bearing failures can cause large quan-
A WARNING tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
Personal injury or death can result from improp-
damage.
erly checking for a leak.
Minor leakage of a turbocharger housing under ex-
Always use a board or cardboard when checking
tended low idle operation should not cause problems
for a leak. Escaping air or fluid under pressure,
as long as a turbocharger bearing failure has not oc-
even a pin-hole size leak, can penetrate body tis-
curred.
sue causing serious injury, and possible death.
When a turbocharger bearing failure is accompanied
If fluid is injected into your skin, it must be treated
by a significant engine performance loss (exhaust
immediately by a doctor familiar with this type of
smoke or engine rpm up at no load), do not continue
injury. engine operation until the turbocharger is repaired or
replaced.
Inspect all of the components in the air circuit for
the starting motor. Inspect all of the air lines and
An inspection of the turbocharger can minimize
connections for leaks.
unscheduled downtime. Also, the chance for potential
damage to other engine parts is reduced.
If the teeth of the starting motor pinion and/or the
flywheel ring gear are damaged, the air circuit for
Note: Turbocharger components require clearances
the starting motor must be examined in order to
that are precise. The turbocharger cartridge must be
determine the cause of the problem.
balanced due to high rpm.
Removal and Installation of the The following conditions can cause the turbocharger
to be out-of-balance:
Starting Motor
Refer to the Service Manual, "Disassembly and • The buildup of deposits
Assembly" module for information on removing the
• Chipping and/or flaking of deposits
starting motor and installing the starting motor.
If the turbocharger must be removed for inspection,
use caution. Do not break deposits from the turbine
wheel. Do not attempt to clean the turbine wheel. For
i01454354 options regarding removal, installation, repair and
replacement, see the Service Manual or consult your
Turbocharger - Inspect Caterpillar dealer.
SMCS Code: 1052-040 1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
Periodic inspection and cleaning is recommended for inspect the piping for the presence of oil.
the turbocharger. Fouling of the turbine wheels can
contribute to loss of engine power and overall loss 2. Turn the compressor wheel and the turbine wheel
of engine efficiency. by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
If the turbocharger fails during engine operation, contact with the turbocharger housing. There
damage to the turbocharger compressor wheel should not be any visible signs of contact between
and/or to the engine may occur. Damage to the the turbine wheel or compressor wheel and the
turbocharger compressor wheel could allow parts turbocharger housing. If there is any indication of
from the compressor wheel to enter an engine contact between the rotating turbine wheel or the
cylinder. This can cause additional damage to the compressor wheel and the turbocharger housing,
pistons, the valves, and the cylinder head. the turbocharger should be reconditioned.
3. Check the compressor wheel for cleanliness.

If only the inlet side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
oil seal.
110
Maintenance Section
Valve Stem Projection - Measure/Record
The presence of oil may be the result of extended Measure the projection of the exhaust valve rotators
engine operation at low idle. The presence of oil with a 155 - 1536 Valve Recession Tool Group.
may also result from restriction of the inlet air Follow the instructions that are provided with the tool
(plugged air filters). This causes oil to leak past group.
the seal for the turbocharger compressor.
Record the measurements on the Operation and
If oil is found on the compressor wheel and/or Maintenance Manual, "Valve Data Sheet" (Reference
at the air inlet, the source of the oil is the fuel Materials Section).
compressor or the PCV system.
• Measure the projection of the exhaust valve
Note: Deposits of ash and silicone can accumulate rotators after 250 service hours. This measurement
on the turbine wheel. Turbine wheel will become is the baseline. The baseline is a reference for
unbalanced when the deposits flake off. The subsequent measurements.
turbocharger cartridge must be replaced when this
occurs. However, remove deposits from the housing. • Measure the projection of the exhaust valve
This will prevent wear on the blades of the new rotators at the first 1000 service hours. Illustration
turbine wheel. 92 shows schedules for determining subsequent
intervals.
4. Inspect the turbine wheel and the nozzle for
deposits of ash and silicone. If deposits of 1.6 mm • After 70 percent of the maximum limit has been
(0.06 inch) thickness are found or if the turbine is reached, measure the projection of the exhaust
in contact with the housing, the turbocharger must valve rotators at every 1000 hours of operation.
be disassembled and cleaned. Removal of the The 70 percent is 1.60 mm (0.063 inch).
deposits can be difficult.
• Plan for the top end overhaul as the projection of
5. Inspect the bore of the turbine housing for the valve rotator approaches the maximum limit.
corrosion and deposits. Perform the top end overhaul when the projection
of the valve rotator has increased by a total of
6. Clean the turbocharger compressor housing with 2.3 mm (0.09 inch). Do not allow the recession
standard shop solvents and a soft bristle brush. of the exhaust valves to exceed this limit. The
valve head can break. This will cause severe
7. Fasten the air inlet piping and the exhaust outlet damage in the combustion chamber.
piping to the turbocharger housing.
i01966163
Valve Stem Projection -

Measure/Record
SMCS Code: 1105-082
Valve Recession - The valves and the valve seats

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

greatest wear. The top end overhaul is scheduled
according to the recession of the exhaust valves.
It is difficult to measure the actual valve recession

in the cylinder head. A simpler method is used to
determine the valve recession:
• Measure the projection of the valve rotator above

the cylinder head. It is not necessary to remove the
rocker arms in order to obtain this measurement.
111
Maintenance Section
Walk-Around Inspection
A B c
2 .286
(0 .090)
\.
\~ v ,,,,'~/ '"'-
~
"' ~
2.032
(0 .080)
1. 778
(0 .070)
l.J
U""'
/
, ;
J
,, /
,
,
[/~
_,I
/
,. -~/
1. 524 _V ,,
;
/
v
;
(0 .060)
,,,,,,," v
/ , ,. /
1. 270
,. ...
.V ,• ,
(0. 050) v
, ~
1. 016
v
~
(0. 040) ,/
0. 762 / ,/ /
v·
(0. 030) '/ ;
0. 508 ~
,/
/ i.." "'
(0. 020)
o. 254 /,/ ' /
(0. 010) <~ v
y I~
2 1000 2000 3000 4000 5000 6000 7000 9000 11.000 13,000 15,000
3 x.~~~~~~~~~~~~~~~~~~~~~~~-
g00792504
Illustration 92
(A) Schedule (X) Hours of operation
(B) Schedule (1) 0.254 mm (0.0100 inch)
(C) Schedule (2) 0.218 mm (0.0086 inch)
(Y) Valve recession in millimeters (inches) (3) 0.152 mm (0.0060 inch)
To determine intervals, use the point on the graph in i01492446

Illustration 92 that is closest to the measurement for
each cylinder. Walk-Around Inspection
For example, suppose that the measurement that SMCS Code: 1000-040
was obtained at the initial 1000 hours shows a valve
recession of approximately 0.152 mm (0.0060 inch). Inspect the Engine for Leaks and
According to Schedule (C), the next interval for
measuring that cylinder is at 5000 service hours. for Loose Connections
Another cylinder may have a valve recession of
approximately 0.254 mm (0.0100 inch). According A walk-around inspection should only take a few
minutes. When the time is taken to perform these
to Schedule (A), the next interval for measuring that
checks, costly repairs and accidents can be avoided.
cylinder is at 3000 service hours.
Consult your Caterpillar dealer for assistance. For maximum engine service life, thoroughly inspect
the engine room before starting the engine. Look for
items such as leaks, loose bolts, loose connections
and trash buildup. Make repairs, as needed.
• The guards must be in the proper place. Repair

damaged guards or replace missing guards.
• Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system
contamination.
112
Maintenance Section
Water Pump - Inspect
• Inspect the exhaust system for leaks. If a leak is

NOTICE found, make repairs.
For any type of leak, clean up the fluid. If leaking is ob-
served, find the source and correct the leak. If leaking
i00524084
is suspected, check the fluid levels more often than
recommended until the leak is found or fixed, or until Water Pump - Inspect
the suspicion of a leak is proved to be unwarranted.
SMCS Code: 1361-040
NOTICE A failed water pump might cause severe engine
Accumulated grease and/or oil on an engine or deck is overheating problems that could result in cracks in
a fire hazard. Remove this debris with steam cleaning the cylinder head, a piston seizure or other potential
or high pressure water. damage to the engine.
• Ensure that cooling lines are properly clamped. Visually inspect the water pump for leaks. If leaking
Check for leaks. Check the condition of all pipes. of the water pump seals is observed, replace all of
the water pump seals. Refer to the Service Manual
• Inspect the water pumps for coolant leaks. for the disassembly and assembly procedure.
Note: The water pump seal is lubricated by coolant Inspect the water pump for wear, cracks, pin holes
in the cooling system. It is normal for a small amount and proper operation. Refer to the Service Manual or
of leakage to occur when the engine cools and the consult your Caterpillar dealer if repair is needed or
parts contract. replacement is needed.
Excessive coolant leakage may indicate the need i01665404

to replace the water pump seal. For instructions
on removal and installation of water pumps and/or Water Temperature Regulator -
seals, refer to the Service Manual, "Disassembly and
Assembly" module for the engine or consult your Replace
Caterpillar dealer.
SMCS Code: 1355-510
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil Replace the Water Temperature
pan, the oil filters and the valve covers.
Regulators in the Water
Temperature Regulator Housing
A WARNING
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 Illustration 93 g00787738
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.
113
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
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.
114
Reference Information Section
Customer Service
Reference Information Latin America, Mexico, Carribean

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

i02097871
Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000; 4450 CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
USA and Canada Fax: 22-849-4544
When a problem arises concerning the operation of Far East

an engine or concerning the service of an engine, Caterpillar Asia Pte. Ltd.
the problem will normally be managed by the dealer 7 Tractor Road
in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level without additional assistance, use the phone Hong Kong
number that is listed below to talk with a Field Phone: 852-2848-0333
Service Coordinator: Fax: 852-2848-0440
1-800-447-4986 Japan
Shin Caterpillar Mitsubishi Ltd.
The normal hours are from 8:00 to 4:30 Monday SBS Tower
through Friday Central Standard Time. 10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
3. If your needs have not been met still, submit the Japan
matter in writing to the following address: Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Caterpillar Inc.
Manager, Customer Service, Engine Division Japan
Mossville Bldg AC Caterpillar Power Systems, Inc.
P.O. Box 610 SBS Tower (14th floor)
Mossville, Illinois 61552-0610 4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Please keep in mind: probably, your problem will. Phone: 81-3-5797-4300
ultimately be solved at the dealership, using the Fax: 81-3-5797-4359
dealership's facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a Australia and New Zealand
problem is experienced. Caterpillar of Australia Ltd.
1 Caterpillar Drive
Outside of the USA and of Canada Private Mail Bag 4
Tullamarine, Victoria 3043
If a problem arises outside the USA and outside Australia
Canada, and if the problem cannot be resolved at the Phone: 03-9953-9333
dealer level, consult the appropriate Caterpillar office. Fax: 03-9335-3366
115
Customer Service
i01028392
Ordering Replacement Parts

SMCS Code: 4450; 7567
A WARNING
When replacement parts are required for this
product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

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

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

information:
• Part number
• Part name
• Quantity
If there is a question concerning the part number,

please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance

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

dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
116
Reference Materials
Reference Materials • Maintenance log
i00912149
Maintenance Records
SMCS Code: 1000; 4450
Caterpillar Inc. recommends the retention of accurate

maintenance records. Accurate maintenance records
can be used for the following purposes:
• Determine operating costs.
• Establish maintenance schedules for other engines

that are operated in the same environment.
• Show compliance with the required maintenance

practices and maintenance intervals.
Maintenance records can be used for a variety of

other business decisions that are related to engine
maintenance.
Maintenance records are a key element of a

maintenance program that is well managed. Accurate
maintenance records can help your Caterpillar dealer
to fine tune the recommended maintenance intervals
in order to meet the specific operating situation. This
should result in a lower engine operating cost.
Records should be kept for the following items:
Fuel Consumption - A record of fuel consumption

is essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul
intervals.
Service Hours - A record of service hours is

essential to determine when the speed sensitive
components should be inspected or repaired.
Documents - These items should be easy to

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

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
• Dealer work orders and itemized bills
• Owner's repair costs
• Owner's receipts
117
Reference Materials
i01176304
Maintenance Log
SMCS Code: 1000; 4450
Table 24
Engine Model Customer Identifier

Serial Number Arrangement Number
Service Quantity
Service Item Date Authorization
Hours Of Fuel
118
Reference Materials
i00769479
Valve Data Sheet

SMCS Code: 1000
Table 25
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
119
Reference Materials
i02097940 Miscellaneous
Reference Material • Application and Installation Guide, LEKQ7250, "Air
Intake"
SMCS Code: 1000; 4450
• Application and Installation Guide, LEKQ7260,
The following literature can be obtained through any "Low BTU Engines"
Caterpillar dealer.
• Engine Performance, LEBQ6117, "G3500
Lubricants Industrial"
• Data Sheet, PEHP0002, "Multipurpose Lithium • Engine Performance, LEBQ6169, "G3500

Complex Grease with Molybdenum (MPGM)" Generator Set"
• Data Sheet, PEHP0003, "Multipurpose Lithium • Electronic Troubleshooting, SENR6413, "G3500

Complex Grease (MPG)" Engines"
• Data Sheet, PEHP0017, "Special Purpose Grease • Disassembly and Assembly, SENR6419, "G3500
(SPG) Bearing Lubricant" Engines"
• Special Publication, PEDP7036, "S·O·S Fluid • Electronic Troubleshooting , SENR6517, "G3500

Analysis" Air/Fuel Ratio Control"
• Special Publication, PEHP6001, "How To Take A • Service Manual, REG1139F, "Service Manual
Good Oil Sample" Contents Microfiche"
• Special Publication, SEBU6400, "Caterpillar • Software Program, LEKQ6378, "Methane Number

Gas Engine Lubricant, Fuel, and Coolant Program"
Recommendations"
• Special Publication, PECP9067, "One Safe
Source" English language for use in NACD, CACO,
Fuels and APO
• Application and Installation Guide, LEKQ7256, • Special Publication, PECP9068, "One Safe
"Fuels, Fuel Systems" Source" English language for use in EAME
• Application and Installation Guide, LEKQ7260, • Specifications, SENR3130, "Torque Specifications"
"Low Energy Fuels"
• Specifications, SENR6411, "G3500 Engines"
• Special Publication, SEBU6400, "Caterpillar
Gas Engine Lubricant, Fuel, and Coolant • Specifications, SENR6417, "G3500 Engine
Recommendations" Attachments"
Coolants • Special Instruction, GMG00694, "Analyzing

Cylinder Condition By Measuring Air Flow"
• Data Sheet, PEHP7057, "Coolant Analysis"
• Special Instruction, REHS0128, "Using the
• Special Publication, PEDP7036, "S·O·S Fluid 147-5482 Indicator Gauge For Valve Lash and
Analysis" Valve Bridge Adjustment"
• Special Publication, SEBD0518, "Know Your • Special Instruction, SEHS7332, "Do Not Operate
Cooling System" Tag"
• Special Publication, SEBD0970, "Coolant and Your • Special Instruction, SEHS7633, "Battery Test
Engine" Procedure"
• Special Publication, SEBU6400, "Caterpillar • Special Instruction, SEHS8622, "Using the FT-
Gas Engine Lubricant, Fuel, and Coolant 1984 Air-To-Air Aftercooler Leak Test Group"
Recommendations"
• Special Instruction, SEHS8712, "Using the
8T-2700 Blowby/Airflow Indicator Group"
120
Reference Materials
• Special Instruction, SEHS9031, "Storage The "American Petroleum Institute Publication No.
Procedure for Caterpillar Products" 1509" can be obtained from the following locations:
local technological society, local library, and local
• Special Instruction, SEHS9298, "Installation and college. If necessary, consult API at the following
Maintenance of Gaseous Fuel Filters" address:
• Special Instruction, SEHS9769, "Installation and American Petroleum Institute

Initial Start-Up Procedure for G3500 Engines" 1220 L St. N.W.
Washington, DC, USA 20005
• Special Publication, NEHS0526, "Service Telephone: (202) 682-8000
Technician Application Guide"
The International Organization for Standardization
• Special Publication, NENG2500, "Caterpillar Tools (ISO) offers information and customer service
and Shop Products Guide" regarding international standards and standardizing
activities. ISO can also supply information on the
• Special Publication, SEBF8029, "Index to following subjects that are not controlled by ISO:
Guidelines for Reusable Parts and Salvage national standards, local standards, regulations,
Operations" certification, and related activities. Consult the
member of ISO in your country.
• Special Publication, SEBF8062, "Procedure to
Inspect and Clean Air Filters" International Organization for Standardization
(ISO)
• Systems Operation/Testing and Adjusting, 1, rue de Varembe
SENR6412, "G3500 Engines" Case postale 56
CH-1211 Geneve 20
• Systems Operation/Testing and Adjusting, Switzerland
SENR6418, "G3500 Engine Attachments" Telephone: +41 22 749 01 11
Facsimile: +41 22 733 34 30
• Systems Operation/Testing and Adjusting, E-mail: central@iso.ch
SENR6420, "Remote Control Panel (Status)" Web site: http://www.iso.ch
European classifications are established by the

Additional Reference Material Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
The "Engine Fluids Data Book" can be obtained from
Engines).
the following locations: local technological society,
local library, and local college. If necessary, consult
EMA at the following address: CIMAC Central Secretariat
Lyoner Strasse 18
Engine Manufacturers Association 60528 Frankfurt
Two North LaSalle Street, Suite 2200 Germany
Chicago, Illinois, USA 60602 Telephone: +49 69 6603 1567
E-mail: ema@enginemanufacturers.org Facsimile: +49 69 6603 1566
(312) 827-8700
Facsimile: (312) 827-8737 i00382622
The "Society of Automotive Engineers (SAE) Warranty Information

Specifications" can be found in your SAE handbook.
This publication can also be obtained from the SMCS Code: 1000
following locations: local technological society, local
library, and local college. If necessary, consult SAE
at the following address:
Engine Protection Plans
SAE International Extended Warranties and Service

400 Commonwealth Drive Contracts
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841 A wide variety of protection plans are available for
Caterpillar Engines. Consult your Caterpillar dealer
for detailed information on the specific programs and
coverages that are available.
121
Reference Materials
Consult your Caterpillar dealer for information on a

plan that is tailored in order to fit your requirements.
122
Index Section
Index
A Cooling System Coolant (NGEC) - Change .......... 70
Clean the Cooling System ................................. 71
Actuator Control Linkage - Lubricate ..................... 64 Cleaning a Cooling System that has Heavy
After Starting Engine ............................................. 52 Deposits or Plugging ........................................ 72
Engaging the Driven Equipment ........................ 52 Drain the Cooling System .................................. 70
After Stopping Engine ............................................ 56 Fill the Cooling System ...................................... 72
Aftercooler Condensation - Drain .......................... 64 Cooling System Coolant Level - Check ................. 73
Air Starting Motor Lubricator Bowl - Clean ............ 64 Add Coolant ....................................................... 73
Air Starting Motor Lubricator Oil Level - Check ..... 65 Cooling System Coolant Sample (Level 1) -
Adjust the Lubricator .......................................... 65 Obtain .................................................................. 73
Air Tank Moisture and Sediment - Drain ................ 66 Cooling System Coolant Sample (Level 2) -
Alarms and Shutoffs .............................................. 36 Obtain .................................................................. 74
Setpoints for Alarms and Shutoffs ..................... 37 Cooling System Supplemental Coolant Additive
Testing Alarms and Shutoffs .............................. 36 (SCA) - Test/Add .................................................. 74
Alternator - Inspect ................................................ 66 Add the SCA, If Necessary ................................ 75
Test the Concentration of the SCA..................... 7 4
Crankcase Blowby - Measure/Record ................... 75
B Crankshaft Vibration Damper - Inspect ................. 76
Removal and Installation .................................... 76
Battery - Replace ............................................. 66-67 Crushing Prevention and Cutting Prevention ........ 14
Battery Charger - Check ........................................ 67 Customer Assistance ............................................ 114
Checking After Stopping .................................... 68 Outside of the USA and of Canada ................... 114
Checking Before Start-Up .................................. 67 USA and Canada .............................................. 114
Battery Electrolyte Level - Check .......................... 68 Customer Service ................................................. 114
Before Starting Engine .................................... 15, 48 Cylinder Pressure - Measure/Record .................... 76
Air Inlet System .................................................. 48 Cylinders - Inspect... .............................................. 77
Cooling System .................................................. 48
Driven Equipment .............................................. 48
Electrical System ....................... ............ ............ 48 D
Fuel System ....................................................... 48
Lubrication System ............................................ 49 Driven Equipment - Check ..................................... 78
Starting System .................................................. 49 Driven Equipment - Inspect/Replace/Lubricate ..... 78
Walk-Around Inspection ..................................... 48
Belts - Inspect/Adjust/Replace ............................... 69
Adjusting the Alternator Belt .............................. 69 E
Adjusting the Fan Drive Belt .............................. 69
Inspection ........................................................... 69 Electrical System................................................... 16
Replacement. ..................................................... 70 Grounding Practices .... ........ .. .. .... .. ..... ... .... ........ 16
Burn Prevention..................................................... 13 Emergency Stopping ............................................. 54
Batteries ............................................................. 13 Emergency Stop Button ..................................... 54
Coolant. .............................................................. 13 Engine - Clean ....................................................... 78
Oils ..................................................................... 13 Engine Air Cleaner Element - Replace .................. 79
Cleaning the Primary Air Cleaner Elements ...... 80
Servicing the Air Cleaner Elements ................... 79
c Engine Air Cleaner Service Indicator- Inspect... ... 81
Test the Service Indicator................................... 82
Carburetor Air/Fuel Ratio - Check/Adjust.. ............ 70 Engine Air Precleaner - Clean ............................... 82
Cold Weather Starting ........................................... 49 Engine Crankcase Breather - Clean ...................... 82
Control Panel......................................................... 38 Engine Mounts - Check ......................................... 83
Alarm Module ..................................................... 46 Engine Oil - Change .............................................. 84
Electronic Modular Control Panel II (EMCP 11) ... 42 Engine Oil Filter - Change ..................................... 86
Generator Set Control (GSC) ............................. 43 Inspect the Used Oil Filter Elements.................. 88
Remote Control Panel (Status) .......................... 38 Replacing the Engine Oil Filters During Engine
Synchronizing Lights Module ............................. 47 Operation ......................................................... 88
Control Panel - Inspect.. ........................................ 70 Replacing the Engine Oil Filters With the Engine
Record the Data and Review the Data ........ ...... 70 Stopped ............................................................ 87
Engine Oil Filter (Auxiliary) - Change .................... 85
Engine Oil Level - Check ....................................... 89
123
Index Section
Engine Oil Sample - Obtain ................................... 89

Obtain the Sample and the Analysis .................. 90
Engine Operation ................................................... 53 Ignition System Spark Plugs - Check/Adjust/
Operating the Engine and the Driven Replace ................................................................ 95
Equipment ........................................................ 53 Checking the Spark Plug ................................... 98
Partial Load Operation ....................................... 53 Cleaning the Spark Plug .................................... 98
Engine Protective Devices - Check ....................... 90 Inspecting the Spark Plug .................................. 97
Visual Inspection................................................ 90 Installing the Spark Plug .................................... 98
Engine Speed/Timing Sensor - Clean/Inspect... .... 90 Removing the Spark Plug .................................. 96
Engine Starting ................................................ 15, 48 Ignition System Timing - Check/Adjust.. ................ 99
Engine Stopping .............................................. 16, 54 Ignition Systems .................................................... 15
Engine Valve Lash and Bridge - Adjust ................. 91 Important Safety Information ................................... 2
Engine Valve Lash ............................................. 92 Inlet Air System - Inspect... .................................... 99
Valve Bridge ....................................................... 91
Engine Valve Rotators - Inspect ............................ 92
Exhaust Bypass - Inspect.. .................................... 92 L
Exhaust Piping - Inspect... ..................................... 93
Water Cooled Exhaust Manifolds ....................... 93 Lifting and Storage ................................................ 25
F M
Features and Controls ........................................... 30 Maintenance Interval Schedule (Bio-Gas) ............. 62

Fire Prevention and Explosion Prevention ............ 14 Maintenance Interval Schedule (Naturally
Fire Extinguisher................................................ 14 Aspirated) ............................................................ 63
Foreword ................................................................. 5 Maintenance Interval Schedule (Standby) ............. 61
California Proposition 65 Warning ....................... 4 Maintenance Interval Schedule (Turbocharged
Literature Information ........................................... 4 Aftercooled) ............. ............ ................................ 60
Maintenance ........................................................ 4 Maintenance Log .................................................. 117
Maintenance Intervals .......................................... 4 Maintenance Records ........................................... 116
Operation ... .......................................................... 4 Maintenance Section ............................................. 57
Overhaul .............................................................. 5 Manual Stop Procedure ......................................... 55
Safety ................................................................... 4 Model View Illustrations ......................................... 17
Fuel Filtration System - Service ............................. 93 Model Views and Specifications............................ 17
Fuel System Fuel Filter Differential Pressure - Mounting and Dismounting .................................... 15
Check................................................................... 93
0
G
Operation Section.................................................. 25
Gas Pressure Regulator - Check ........................... 93 Ordering Replacement Parts ................................ 115
Fuel Differential Pressure of the Fuel Supply To the Overhaul (In-Frame) ............................................ 100
Carburetor ........................................................ 94 In-Frame Overhaul Information ........................ 100
Gas Pressure Regulator Condensation - Drain ..... 94 Scheduling an In-Frame Overhaul. .................. 100
Gauges and Indicators .......................................... 27 Overhaul (Major) .................................................. 101
Optional Gauges ................................................ 28 Major Overhaul Information ............................. 101
General Hazard Information ................................... 11 Scheduling a Major Overhaul.. ......................... 101
Asbestos Information ......................................... 12 Overhaul (Top End) ... ... .. .............. .. .. ... .. .. ... .. .... ... 102
Containing Fluid Spillage................................... 12 Scheduling a Top End Overhaul ... ... .. .. .. .. .. ... .. . 102
Dispose of Waste Properly .... .. .. ... .. ... .. .. ... .. ... .... 13 Top End Overhaul Information ......................... 103
Fluid Penetration................................................ 12 Overhaul Considerations ..................................... 105
Pressure Air and Water...................................... 12 Overhaul Information ....................................... 105
Softwrap ................................ ~ ............................ 13
Hoses and Clamps - Inspect/Replace ................... 94

Replace the Hoses and the Clamps .................. 95
124
Index Section
p Starting Motor - Inspect.. ..................................... 108

Air Starting Motor............................................. 109
Performance Parameters ...................................... 30 Electric Starting Motor...................................... 108
Air/Fuel Ratio ..................................................... 30 Removal and Installation of the Starting
Angle of the Throttle Plate ................................. 31 Motor .............................................................. 109
Oil Consumption ................................................ 31 Starting the Engine ................................................ 50
Optional Air/Fuel Ratio Control .......................... 31 Automatic Starting .............................................. 50
Setting of the Exhaust Bypass (Wastegate) ...... 31 Manual Starting .................................................. 50
Plate Locations and Film Locations ....................... 23 Operation of the Generator Set Control Panel. .. 50
Engine Identification ........................................... 23 Purging Unburned Gas ...................................... 50
Information Plate ................................................ 23 Starting with Jump Start Cables ............................ 51
Serial Number Plate ........................................... 23
Power Take-Off Clutch - Check/Adjust/
Lubricate ............................................................ 107 T
Product Description .......... ... .. ..... ..... .. ........ ..... ... ... . 18
Cooling System .................................................. 19 Table of Contents..................................................... 3
Engine Service Life ............................................ 20 Turbocharger - Inspect ........................................ 109
Fuel System....................................................... 18
Ignition System .................................................. 19
Lubrication System .. ... .. ... .. .. ... .... ......... .. .. ... ..... .. 19 v
Product Identification Information .......................... 23
Product Information Section .................................. 17 Valve Data Sheet.. ................................................ 118
Product Lifting ........................................................ 25 Valve Stem Projection - Measure/Record ............. 110
Engine Lifting with a Generator. ......................... 25
Product Storage ..................................................... 26
Generator Storage ............................................. 26 w
R Inspect the Engine for Leaks and for Loose
Connections .................................................... 111
Radiator - Clean .................................................. 107 Warranty Information ........................................... 120
Reference Information ........................................... 24 Engine Protection Plans ................................... 120
Reference Information Section ............................. 114 Water Pump - Inspect ........................................... 112
Reference Material ............................................... 119 Water Temperature Regulator - Replace .............. 112
Additional Reference Material. ......................... 120 Replace the Water Temperature Regulators in the
Coolants ............................................................ 119 Water Temperature Regulator Housing and in the
Fuels ................................................................. 119 Thermostatic Valve .......................................... 112
Lubricants ......................................................... 119
Miscellaneous ................................................... 119
Reference Materials ............................................. 116
Refill Capacities ..................................................... 57
Refill Capacities and Recommendations ............... 57
Cooling System .................................................. 58
Fuel .................................................................... 57
Lubrication System ............................................ 57
s
Safety Messages ..................................................... 6
Safety Section ......................................................... 6
Sensors and Electrical Components ..................... 32
Electronic Ignition System (EIS) ........................ 32
Junction Box ...................................................... 33
Sensors .............................................................. 34
Specifications ........................................................ 20
Crankshaft Positions for Valve Lash Setting ...... 22
General Engine Specifications ........................... 20
Speed Sensor - Clean/Inspect... .......................... 108
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 Numbe~----------------------------
Engine Serial N u m b e r : - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Transmission Serial N u m b e r : - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Generator Serial N u m b e r : - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Attachment Serial N u m b e r s : - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Attachment I n f o r m a t i o n : - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Customer Equipment N u m b e r : - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Dealer Equipment N u m b e r : - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Dealer Information
Name: Branch: _ _ _ _ _ _ _ _ _ _ _ _ __
Address:
Dealer Contact Phone Number
Sales:
Parts:
Service:
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C•TERPILLAR® SEBU6711-10

Important Safety Information

The meaning of this safety alert symbol is as follows:

Failure to heed this warning can lead to prema-

Table of Contents Maintenance Interval Schedule (Naturally

Foreword ................................................................. 4 Reference Information Section

Safety Section Customer Service ................................................ 114

Safety Messages ... ............... .................................. 6 Reference Materials ............................................. 116

General Hazard Information .................................. 11 Index Section

Fire Prevention and Explosion Prevention ............ 14

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

Mounting and Dismounting .. .. ... .. .. .... .. ... .. ..... .. ...... 15

Ignition Systems ................................................... 15

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

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

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

Product Information Section

Product Identification Information ........................ 23

Gauges and Indicators .......................................... 27

Features and Controls .......................................... 30

Engine Starting ..................................................... 48

Engine Operation .................................................. 53

Engine Stopping ................................................... 54

Maintenance Interval Schedule (Turbocharged

Maintenance Interval Schedule (Standby) ............ 61

Maintenance Interval Schedule (Bio-Gas) ............ 62

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.

Replace any safety message that is damaged or Electrical Shock (2)

The safety message for engine lifting is located on

If improper equipment is used to lift the engine, injury

Read the Manual Before Operating Hot Pressurized Fluid (4)

The safety message for read the manual before

A WARNING The safety message for hot pressurized fluid is

Coupling (5) Jumper Cable Connections (6)

BATTERIES NAY B6 LOCATED IN SEPA-

1. Align and couple the equipment. BATTERIES MAY BE LOCATED IN SEPARATE

Flash Fire (7) Prelube Pump (8)

Motor has an automatic reset thermal protector. If

After motor cools sufficiently, thermal protector

To service motor, disconnect power source from

General Hazard Information

• Wear a hard hat, protective glasses, and other

Engine exhaust contains products of combustion • Report all necessary repairs.

Pressure Air and Water Asbestos Information

When pressure air and/or pressure water is used for

The maximum air pressure for cleaning purposes

Use caution. Avoid inhaling dust that might be

Containing Fluid Spillage • Avoid grinding materials that contain asbestos.

• Tools that are suitable for containing fluids and

Obey all local regulations for the disposal of liquids.

• Comply with applicable rules and regulations i02088921

If the application has a makeup tank, remove the cap

Do not smoke while checking the battery electrolyte

i01027886 Do not allow flammable materials to accumulate on

Do not smoke while the engine is refueled. Do not Fire Extinguisher

Do not smoke in areas that contain flammable i01359666

Keep objects away from moving fan blades. The fan

i01372247 Ensure that the engine is equipped with a lighting