g3516e Service Manual (Gas)

SENR3130-12 KENR5271-04 KENR6833-02 KENR6834-03

G3516E Generator set

s/n GAS1-Up

Media Number -SENR3130-12

Service manual Torque Specifications General Information Introduction to Torque Torque-Turn Torque Sequence Metric (ISO) Fasteners Metric (ISO) Nuts and Bolts Metric (ISO) Taperlock Studs Metric (ISO) Machine Screws Hex Button Head Screw and Set Screws English (SAE) Fasteners English (SAE) Nuts and Bolts English (SAE) Taperlock Studs English (SAE) Machine Screws Hex Button Head Screw and Set Screws Ground Engaging Tool (G.E.T.) Fasteners Installation of Fittings Installation of Split Flange Couplings Installation of Adjustable STOR Fittings Straight Thread O-Ring Fittings Plugs Straight Thread O-Ring Plugs (Hex Drive) Straight Thread O-Ring Plugs (Socket Drive) Drain Plugs with Straight Threads Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies) O-Ring Face Seal Fittings Bulkhead Nuts Flare Fittings 37 Degree Flare Fittings 45 Degree Flare and 45 Degree Inverted Flare Fittings Air Conditioning Fittings Air Brake Fittings Tapered Pipe Thread Fittings Miscellaneous Fittings Hi Duty Tube Fittings (Shear Sleeve) SAE Flareless Fittings Installing a New Flareless Fitting Installing a Used Flareless Fitting Flex Fittings Hose Clamps Worm Drive Band Type Clamps Constant Torque Hose Clamps

INDEX 001

002

003

004 005

006 007

008 009 010

011 012 013 014

015

TORQUE SPECIFICATIONS

001

Service manual

Media Number -SENR3130-12

General Information

Mismatched or incorrect fasteners can result in damage or malfunction, or personal injury. Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners.

Introduction to Torque "Torque" is measured in terms of force and distance. Force is the amount of pushing or pulling applied at the end of the lever. Distance is the length of the lever that is being used. Torque values are given in the following units: NEWTON meters (N·m), pound inches (lb in) and pound feet (lb ft) This manual is intended to provide the operator with a reference. This manual will provide the standard torque settings for the following: bolts, nuts, plugs, fittings and clamps. Exceptions to these torques are given in the Service Manual, if necessary. Be sure to use a torque wrench that has the proper range. Torque wrenches must be used properly in order to ensure that the correct torque is applied. Always use a smooth pull for torque wrenches. Do not jerk a torque wrench. Do not use adapters that change the length of the torque wrench. For the correct use of your torque wrench, refer to the instructions that were packaged with your torque wrench. For more information on the correct use of torque wrenches, refer to Special Publication, SEBV0516, "An Introduction to Torque". Prior to installation of any hardware, ensure that components are in near new condition. Bolts and threads must not be worn or damaged. Threads must not have burrs or nicks. Hardware must be free of rust and corrosion. Clean reused fasteners with a noncorrosive cleaner. Lightly lubricate the threads of reused fasteners. Lightly lubricate the mating surface of the head of reused fasteners. Other applications for lubricating fasteners may also be specified in the Service Manual. The Service Manual may also specify the use of sealants and compounds. Note: Do not use sealants that are not specified in the Service Manual. Do not use compounds that are not specified in the Service Manual. Clean old compound from the bolt and from the hole before installation.

Torque-Turn The torque-turn method is used when precise control over clamping force is required. There is an initial torque and an additional turn. The initial torque is required to bring all parts of the joint into contact. The additional turn provides the desired clamping force. Ensure that all fasteners have been torqued before you perform the additional turns. Turn the fastener according to the specified amount. The specified amount will normally be equal to or greater than 90°. The specified amount will normally be in 30° increments. Turns of 120° or 180° are preferred. Turns of 120° or 180° are easily measured by the points of the hex head of the fastener. Lubrication may be specified in order to reduce the effort that is required for the final turn. The use of the torque-turn method will allow the following: l l

Increase the life of the fastener. Maximize the potential clamping force of a fastener.

Typical applications are the following: l l l l l

Track bolts Sprocket bolts Connecting rod bolts Engine Cylinder Heads Drive Shaft bolts

Note: Too much tension on the bolt will cause the bolt to be stretched beyond the point of yield. The bolt will be permanently stretched. The bolt will loosen the grip on the parts that are being fastened. If the bolt is tightened again, the bolt will break. Do not reuse bolts that have been permanently stretched.

Torque Sequence Unless the bolt tightening sequence is specified by the Service Manual, the fasteners should be tightened in a cross pattern. Use Step 1 through Step 5 unless the tightening sequence is specified: 1. Hand tighten all fasteners. Larger fasteners may require the use of a small hand wrench. 2. Torque all fasteners to 40% of full torque. 3. Torque all fasteners to 70% of full torque. 4. Torque all fasteners to full torque by using a cross pattern. Large flanges may require additional passes. 5. Apply at least one final full torque to all fasteners in a clockwise direction until all torque is uniform. Large flanges may require additional passes. Note: Final torque may be a turn.

TORQUE SPECIFICATIONS

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Metric (ISO) Fasteners Metric (ISO) Nuts and Bolts

Illustration 1

g00909614

Note: The following table has the recommended standard torque values for metric nuts and bolts for use on all Caterpillar equipment and Mitsubishi engines. Table 1 Thread Size Torque mm M6 M8 M10 M12 M14 M16 M20 M24 M30 M36

12 ± 3 N·m (105 ± 27 lb in) 28 ± 7 N·m (250 ± 62 lb in) 55 ± 10 N·m (41 ± 7 lb ft) 100 ± 20 N·m (75 ± 15 lb ft) 160 ± 30 N·m (120 ± 22 lb ft) 240 ± 40 N·m (175 ± 30 lb ft) 460 ± 60 N·m (340 ± 44 lb ft) 800 ± 100 N·m (590 ± 75 lb ft) 1600 ± 200 N·m (1180 ± 150 lb ft)

2800 ± 350 N·m (2060 ± 260 lb ft) Note: The following table has the recommended standard torque values for metric nuts and bolts for use on Perkins engines. Table 2 Thread Size Torque mm M6 M8 M10 M12 M14 M16 M18 M20 M24

5 N·m (44 lb in) 22 N·m (195 lb in) 44 N·m (32 lb ft) 78 N·m (60 lb ft) 124 N·m (90 lb ft) 177 N·m (130 lb ft) 200 N·m (150 lb ft) 400 N·m (300 lb ft) 790 N·m (580 lb ft)

Note: The difference between Caterpillar standard torque values and Perkins standard torque values are due to different classes of fasteners. Caterpillar uses class 10.9 fasteners. Perkins uses class 8.8 fasteners. The different class of fasteners have different tensile strengths.

Metric (ISO) Taperlock Studs Note: The following table has the recommended standard torque values for metric taperlock studs for use on all Caterpillar equipment and Mitsubishi engines. Table 3 Thread Size Torque mm M6 M8

8 ± 3 N·m (71 ± 27 lb in) 17 ± 5 N·m (150 ± 44 lb in)

M10 M12 M16 M20 M24 M30 M36

35 ± 5 N·m (26 ± 4 lb ft) 65 ± 10 N·m (48 ± 7 lb ft) 110 ± 20 N·m (80 ± 15 lb ft) 170 ± 30 N·m (125 ± 22 lb ft) 400 ± 60 N·m (300 ± 44 lb ft) 750 ± 80 N·m (550 ± 60 lb ft) 1200 ± 150 N·m (880 ± 110 lb ft)

Note: The following table has the recommended standard torque values for Metric taperlock studs for use on Perkins engines. Table 4 Thread Size Torque mm M6 M8 M10 M12

5 N·m (44 lb in) 11 N·m (97 lb in) 18 N·m (160 lb in) 25 N·m (220 lb in)

Metric (ISO) Machine Screws

Illustration 2

g00908932

Table 5 Thread Size Torque mm M1.6 M2 M2.5 M3 M4 M5

0.10 ± 0.01 N·m (0.9 ± 0.1 lb in) 0.15 ± 0.01 N·m (1.3 ± 0.1 lb in) 0.35 ± 0.05 N·m (3.1 ± 0.4 lb in) 0.50 ± 0.05 N·m (4.4 ± 0.4 lb in) 1.70 ± 0.25 N·m (15.0 ± 2.2 lb in) 2.25 ± 0.25 N·m (19.9 ± 2.2 lb in)

Hex Button Head Screw and Set Screws

Illustration 3

g01186742

Table 6 Thread Size Torque mm M3 M4 M5 M6

.6 ± .1 N·m (5 ± 0.9 lb in) 2 ± .3 N·m (18 ± 3 lb in) 4 ± .5 N·m (35 ± 4 lb in) 6 ± 1 N·m (55 ± 9 lb in)

M8 M10 M12 M14 M16 M20 M24 M30 M36

15 ± 2 N·m (135 ± 18 lb in) 30 ± 7 N·m (265 ± 62 lb in) 50 ± 10 N·m (37 ± 7 lb ft) 80 ± 15 N·m (60 ± 11 lb ft) 125 ± 20 N·m (90 ± 15 lb ft) 250 ± 40 N·m (185 ± 30 lb ft) 425 ± 50 N·m (310 ± 37 lb ft) 850 ± 100 N·m (620 ± 75 lb ft) 1500 ± 200 N·m (1100 ± 150 lb ft)

TORQUE SPECIFICATIONS

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Media Number -SENR3130-12

English (SAE) Fasteners English (SAE) Nuts and Bolts

Illustration 1

g00908911

Table 1 Thread Size Torque Inch 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

12 ± 3 N·m (105 ± 27 lb in) 25 ± 6 N·m (220 ± 53 lb in) 47 ± 9 N·m (35 ± 7 lb ft) 70 ± 15 N·m (50 ± 11 lb ft) 105 ± 20 N·m (75 ± 15 lb ft) 160 ± 30 N·m (120 ± 22 lb ft) 215 ± 40 N·m (160 ± 30 lb ft) 370 ± 50 N·m (275 ± 37 lb ft) 620 ± 80 N·m (460 ± 60 lb ft) 900 ± 100 N·m (660 ± 75 lb ft)

1 1/8 1 1/4 1 3/8 1 1/2

1300 ± 150 N·m (960 ± 110 lb ft) 1800 ± 200 N·m (1320 ± 150 lb ft) 2400 ± 300 N·m (1780 ± 220 lb ft) 3100 ± 350 N·m (2280 ± 260 lb ft)

English (SAE) Taperlock Studs Table 2 Thread Size Standard Torque Inch 1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2

8 ± 3 N·m (70 ± 27 lb in) 17 ± 5 N·m (150 ± 44 lb in) 35 ± 5 N·m (26 ± 4 lb ft) 45 ± 10 N·m (33 ± 7 lb ft) 65 ± 10 N·m (48 ± 7 lb ft) 110 ± 20 N·m (80 ± 15 lb ft) 170 ± 30 N·m (125 ± 22 lb ft) 260 ± 40 N·m (190 ± 30 lb ft) 400 ± 60 N·m (300 ± 44 lb ft) 525 ± 60 N·m (390 ± 44 lb ft) 750 ± 80 N·m (550 ± 60 lb ft) 950 ± 125 N·m (700 ± 90 lb ft) 1200 ± 150 N·m (880 ± 110 lb ft)

English (SAE) Machine Screws

Illustration 2

g00908932

Table 3 Thread Size Torque No. 0-80 1-64 2-56 3-48 4-40 5-40 6-32 8-32 10-24 12-24

0.10 ± 0.01 N·m (0.9 ± 0.1 lb in) 0.15 ± 0.01 N·m (1.3 ± 0.1 lb in) 0.25 ± 0.02 N·m (2.2 ± 0.2 lb in) 0.35 ± 0.05 N·m (3.1 ± 0.4 lb in) 0.50 ± 0.05 N·m (4.4 ± 0.4 lb in) 0.70 ± 0.10 N·m (6.2 ± 0.9 lb in) 0.90 ± 0.10 N·m (8.0 ± 0.9 lb in) 1.70 ± 0.25 N·m (15.0 ± 2.2 lb in) 2.25 ± 0.25 N·m (19.9 ± 2.2 lb in) 3.40 ± 0.60 N·m (30.1 ± 5.3 lb in)

Hex Button Head Screw and Set Screws

Illustration 3

g01186972

Table 4 Thread Size Torque inch # 4 & #5 #6 & #8 #10 & #12 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8

.6 ± .1 N·m (5 ± 0.9 lb in) 2 ± .3 N·m (18 ± 3 lb in) 4 ± .5 N·m (35 ± 4 lb in) 6 ± 1 N·m (55 ± 9 lb in) 13 ± 3 N·m (115 ± 27 lb in) 25 ± 6 N·m (220 ± 53 lb in) 40 ± 8 N·m (20 ± 6 lb ft) 60 ± 12 N·m (44 ± 9 lb ft) 85 ± 15 N·m (65 ± 11 lb ft) 115 ± 20 N·m (85 ± 15 lb ft) 200 ± 40 N·m (150 ± 30 lb ft) 325 ± 40 N·m (240 ± 30 lb ft) 500 ± 65 N·m (370 ± 48 lb ft) 700 ± 90 N·m (520 ± 65 lb ft)

1 1/4 1 3/8 1 1/2

1000 ± 125 N·m (740 ± 90 lb ft) 1300 ± 150 N·m (960 ± 110 lb ft) 1700 ± 200 N·m (1260 ± 150 lb ft)

TORQUE SPECIFICATIONS

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Service manual

Media Number -SENR3130-12

Ground Engaging Tool (G.E.T.) Fasteners Ground Engaging Tools (G.E.T.) are secured by many types of bolts. Refer to Table 1 for the correct torque for the following combinations of fasteners for G.E.T.: l l

Plow bolts and nuts Hex head bolts and nuts

Table 1 Torque (1)

Thread Size Inch

N·m

lb ft

5/8 inch

270 ± 40

200 ± 30

3/4 inch

475 ± 60

350 ± 45

7/8 inch

750 ± 90

550 ± 65

1 inch

1150 ± 150

850 ± 110

1 1/4 inch

2300 ± 300

1700 ± 220

(1)

These values are only for Caterpillar bolts for cutting edges.

Personal injury can result when installing plow bolts. The appropriate safety equipment must be worn when striking the plow bolts. To avoid injury to your eyes and ears, wear protective glasses and hearing protection during this procedure.

Illustration 1

g00909058

View of a typical plow bolt

Plow bolts must be installed properly. Refer to the following procedure for the correct installation of plow

bolts. 1. Clean all surfaces that contact the bolt. Remove all occurrences of the following conditions:rust, paint, nicks and burrs 2. Tighten the nut to the correct torque. Refer to Table 1 for the correct torque. 3. Use a hammer to strike the head of the bolt. The bolt must be struck with significant force. Note: The head of the bolt may be recessed below the mounting surface. Use a suitable punch in order to transfer the hammer blow to the bolt head. 4. Tighten the nut to the correct torque. Refer to Table 1 for the correct torque.

TORQUE SPECIFICATIONS

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Media Number -SENR3130-12

Installation of Fittings Note: The tightening sequence of the fasteners that attach a tube assembly or hose assembly to the machine is very critical to the proper function of the machine. The sealing surfaces of the tube assembly or hose assembly should be secured squarely. The sealing surfaces of the tube assembly or hose assembly should be tightened to the serviced component (control valve, cylinder, hydraulic motor, etc). Perform this procedure prior to the final tightening of any clamps or clips that are used in order to fasten the tube assembly or the hose assembly to the machine. Fittings have different connections. Fittings may have two completely different ends. Be sure to use the proper torque for the end of the fitting that is used. The following list contains some common types of fittings. l l l l l l l l

Straight Thread O-Ring (STOR) Adjustable Straight Thread O-Ring (STOR) O-Ring Face Seal (ORFS) Tapered Pipe Thread (NPT and NPTF) 37 Degree Flare Fitting 45 Degree Flare Fitting 45 Degree Inverted Flare Fitting Split Flange Coupling

Installation of Split Flange Couplings 1. For a metal tube to hose installation, install the tube and tighten all bolts finger tight at the rigid end. 2. Install the hose and tighten all bolts finger tight. 3. Put the hose in a position so that the hose does not make contact with the machine or with another hose.

Illustration 1

g00906528

4. Position the split flange parallel over the port. Tighten the bolts on both connections to the proper torque. Follow the prescribed torque sequence for split flange connections. Refer to Illustration 1. Add the measurement of gap (A) to the measurement of gap (B) . The total must not exceed 4.0 mm (0.16 inch). 5. Start the engine. 6. Move the implement control levers to all of the positions. 7. Look at the hose during movement of the implement. Ensure that the hose is not in contact with the machine or with other hoses. Note: For hoses that cross an articulation hitch, check for contact during articulation. For hoses that connect to the steering system, check for contact during steering. 8. Shut off the engine. 9. If the hose contacts other hoses or the machine during the test, loosen the bolts and reposition the hose. Repeat steps 3 through 8 until there is no contact.

Installation of Adjustable STOR Fittings This type of fitting is used in many applications. One end of the fitting will be an adjustable STOR fitting. The other end will be different. Always use the same installation procedure for the STOR end. Adjustable STOR fittings can be positioned before tightening.

Illustration 2 Elbow body assembly (1) End that connects to the tube or hose (2) Fitting body (3) Locknut (4) Backup washer (5) O-ring seal (6) End that is assembled to the mating part

g01848653

1. Put locknut (3) , backup washer (4) and O-ring seal (5) as far away from the threads as possible. Hold these components in this position. Turn the fitting into the mating part. Turn the fitting until backup washer (4) contacts the surface of the mating part. Note: Excessive use of the wrench will distort the washer. Distortion of the washer will prevent proper sealing. 2. Put the fitting assembly in the correct position. loosen fitting (2) until the correct assembly position is achieved. Do not loosen the fitting more than 360 degrees. Install the tube or hose hand tight in order to verify the orientation of the fitting. Tighten the fitting (2) to the torque that is shown in the correct chart for the fitting that is used. Tighten locknut (3) to the torque that is shown in the correct chart for the fitting that is used. Use a backup wrench, when the locknut is tightened. Note: Torque the fitting prior to the locknut. Note: If the fitting is not adjustable, the hex on the body replaces the locknut. To install this type of fitting, tighten the hex against the face of the mating part. Excessive tightening of the connectors can cause failure. Connectors that are under tightened can also cause failures. The following failures occur: l

l l

Excessive tightening can expand a loose ferrule into the nut. This will cause the ferrule to lock up in the nut and the nut will not function properly. Excessive tightening can split the nut on the end of the tube or can split the ferrule. Excessive tightening can gall or excessive tightening can strip the threads of the nut.

Note: If the above conditions occur due to excessive tightening, the damaged fluid connector must be scrapped and the fluid connectors must be replaced.

TORQUE SPECIFICATIONS

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Media Number -SENR3130-12

Straight Thread O-Ring Fittings

Illustration 1

g00911924

Note: For torques for plugs, refer to Specifications, "Plugs". Note: Straight Thread O-Ring fittings for medium pressure usage will have shorter threaded ends than high pressure fittings. The torque value for medium pressure Straight Thread O-Ring fittings will be lower than the torque values that are required for Straight Thread O-Ring fittings for high pressure fittings. Table 1 Ferrous Straight Thread O-Ring Fitting Torques for Mating with Ferrous Materials Medium Pressure use with 37° Flare Fittings Thread Size Nominal Outer Diameter of the Tube Inch 3.18 mm (.125 inch) 4.76 mm (.188 inch) 6.35 mm (.250 inch) 7.94 mm (.312 inch) 9.52 mm (.375 inch) 12.70 mm (.500 inch) 15.88 mm (.625 inch) 19.05 mm (.750 inch)

5/16 - 24 3/8 - 24 7/16 - 20 1/2 - 20 9/16 - 18 3/4 - 16 7/8 - 14 1 1/16 - 12

Standard Torque Tolerance (+10% − 0%)

8 + 1 N·m (70 + 9 lb in) 13 + 2 N·m (115 + 18 lb in) 17 + 2 N·m (150 + 18 lb in) 28 + 3 N·m (250 + 27 lb in) 35 + 4 N·m (26 + 3 lb ft) 55 + 6 N·m (41 + 4 lb ft) 80 + 8 N·m (60 + 6 lb ft) 100 + 10 N·m (75 + 7 lb ft)

22.22 mm (.875 inch) 25.40 mm (1.000 inch) 31.75 mm (1.250 inch) 38.10 mm (1.500 inch) 50.80 mm (2.000 inch)

1 3/16 - 12 1 5/16 - 12 1 5/8 - 12 1 7/8 - 12 2 1/2 - 12

135 + 14 N·m (100 + 10 lb ft) 150 + 15 N·m (110 + 11 lb ft) 290 + 29 N·m (215 + 21 lb ft) 325 + 33 N·m (240 + 24 lb ft) 420 + 43 N·m (310 + 32 lb ft)

Note: Use 50 percent of the torque values from Table 1 when the fitting or the port material is nonferrous. Note: Straight Thread O-Ring fittings for high pressure usage will have longer threaded ends than medium pressure fittings. The torque value for high pressure Straight Thread O-Ring fittings will be higher than the torque values that are required for Straight Thread O-Ring fittings for medium pressure fittings. Table 2 Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials High Pressure use with O-Ring Face Seal Fittings Thread Size Nominal Outer Diameter of the Tube Inch 4.76 mm (0.188 inch) 6.35 mm (0.250 inch) 7.94 mm (0.312 inch) 9.52 mm (0.375 inch) 12.7 mm (0.500 inch) 15.88 mm (0.625 inch) 19.05 mm (0.750 inch) 22.22 mm (0.875 inch) 25.40 mm (1.000 inch) 31.75 mm (1.250 inch)

3/8 - 24 7/16 - 20 1/2 - 20 9/16 - 18 3/4 - 16 7/8 - 14 1 1/16 - 12 1 3/16 - 12 1 5/16 - 12 1 5/8 -12

Standard Torque Tolerance (+10% − 0%)

12 + 2 N·m (105 + 18 lb in) 22 + 3 N·m (195 + 27 lb in) 30 + 3 N·m (265 + 27 lb in) 48 + 5 N·m (35 + 4 lb ft) 82 + 9 N·m (60 + 7 lb ft) 140 + 14 N·m (105 + 10 lb ft) 190 + 19 N·m (140 + 14 lb ft) 250 + 25 N·m (185 + 18 lb ft) 300 + 30 N·m (220 + 22 lb ft) 350 + 36 N·m (260 + 27 lb ft)

38.10 mm (1.500 inch) 63.50 mm (2.500 inch)

1 7/8 - 12 21/2 - 12

415 + 42 N·m (305 + 31 lb ft) 510 + 51 N·m (375 + 38 lb ft)

Note: Use 50 percent of the torque values from Table 2 when the fitting or the port material is nonferrous. Table 3 Metric Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials

Ref Nominal Outer Diameter of the Tube

Thread Size

4 mm

M8 X 1

5 mm

M10 X 1

6 mm

M12 X 1.5

8 mm

M14 X 1.5

10 mm

M16 X 1.5

12 mm

M18 X 1.5

16 mm

M22 X 1.5

20 mm

M27 X 2

22 mm

M30 X 2

25 mm

M33 X 2

30 mm

M42 X 2

38 mm

M48 X 2

50 mm

M60 X 2

Standard Torque Tolerance (+10% -0%) 11 + 2 N·m (95 + 18 lb in) 21 + 3 N·m (185 + 27 lb in) 37 + 4 N·m (27 + 3 lb ft) 47 + 5 N·m (35 + 4 lb ft) 58 + 6 N·m (43 + 4 lb ft) 75 + 8 N·m (55 + 6 lb ft) 105 + 11 N·m (75 + 8 lb ft) 180 + 18 N·m (130 + 13 lb ft) 225 + 23 N·m (165 + 17 lb ft) 325 + 33 N·m (240 + 24 lb ft) 350 + 36 N·m (260 + 27 lb ft) 440 + 45 N·m (325 + 33 lb ft) 525 + 53 N·m (390 + 39 lb ft)

Note: Use 50 percent of the torque values from 3 when the fitting or the port material is nonferrous.

TORQUE SPECIFICATIONS

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Media Number -SENR3130-12

Plugs Straight Thread O-Ring Plugs (Hex Drive)

Illustration 1

g00911999

Table 1 Thread Size Inch 5/16 3/8 7/16 1/2 9/16 3/4 7/8 1 1/16 1 3/16 1 5/16

Torque Tolerance (+10% − 0%)

9 + 1 N·m (80 + 9 lb in) 17 + 2 N·m (150 + 18 lb in) 23 + 3 N·m (205 + 27 lb in) 28 + 3 N·m (250 + 27 lb in) 34 + 4 N·m (25 + 3 lb ft) 60 + 6 N·m (44 + 4 lb ft) 115 + 12 N·m (85 + 9 lb ft) 140 + 14 N·m (105 + 10 lb ft) 190 + 19 N·m (140 + 14 lb ft) 210 + 21 N·m (155 + 15 lb ft)

1 5/8 1 7/8 2 1/2

290 + 29 N·m (215 + 21 lb ft) 325 + 33 N·m (240 + 24 lb ft) 420 + 43 N·m (310 + 32 lb ft)

Note: Use 50 percent of the torque values from Table 1 when the fitting or the port material is nonferrous.

Straight Thread O-Ring Plugs (Socket Drive)

Illustration 2

g00912006

Note: The socket may be hexagonal or a square recessed drive. Table 2 Thread Size Inch 5/16 3/8 7/16 1/2 9/16 3/4 7/8 1 1/16

Torque Tolerance (+10% − 0%)

5 + 1 N·m (44 + 9 lb in) 11 + 2 N·m (100 + 18 lb in) 16 + 2 N·m (140 + 18 lb in) 20 + 2 N·m (180 + 18 lb in) 35 + 4 N·m (26 + 3 lb ft) 70 + 7 N·m (50 + 5 lb ft) 100 + 10 N·m (75 + 7 lb ft) 170 + 17 N·m (125 + 13 lb ft)

1 3/16 1 5/16 1 5/8 1 7/8 2 1/2

215 + 22 N·m (160 + 16 lb ft) 270 + 27 N·m (200 + 20 lb ft) 285 + 29 N·m (210 + 21 lb ft) 370 + 37 N·m (270 + 27 lb ft) 415 + 42 N·m (305 + 31 lb ft)

Drain Plugs with Straight Threads

Illustration 3

g01848045

Note: Plug (A), plug (B) and plug (C) are used with a gasket. Conical seal plug (D) does not use a gasket. Table 3 Thread Size Type of Plug Inch 1/2 - 13 5/8 - 11

Torque Tolerance (+10% − 0%)

20 + 5 N·m (175 + 44 lb in) 35 + 5 N·m (26 + 4 lb ft)

A 3/4 - 12 3/4 - 16

50 + 5 N·m (37 + 4 lb ft)

7/8 - 14 1 1/8 - 12

70 + 15 N·m (52 + 11 lb ft)

1 5/16 - 12 1 1/2 - 12

90 + 15 N·m (66 + 11 lb ft)

B 2 - 12

125 + 15 N·m (92 + 11 lb ft)

1 1/8 - 12

70 + 15 N·m (52 + 11 lb ft)

C 1 5/16 - 12 1/2 - 20

90 + 15 N·m (66 + 11 lb ft) 11 + 4 N·m (97 + 35 lb in)

7/8 -14

55 + 7 N·m (41 + 5 lb ft)

D 1 3/8 -13 1 1/2 - 12

90 + 15 N·m (66 + 11 lb ft) 110 + 15 N·m (81 + 11 lb ft)

Note: Use 50% of the values in Table 3 when either the plug or the port material is nonferrous.

Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies)

Illustration 4

g00912010

Note: When you tighten the plug, the torque must not be transmitted to the joint between the tube and the elbow. Table 4 Thread Size Torque Inch 7/8

150 ± 25 N·m (110 ± 18 lb ft)

1 1/16 1 3/16 1 1/4 1 5/16 1 5/8 1 7/8 2 1/2

200 ± 25 N·m (150 ± 18 lb ft) 275 ± 35 N·m (200 ± 26 lb ft) 275 ± 35 N·m (200 ± 26 lb ft) 300 ± 40 N·m (220 ± 30 lb ft) 450 ± 50 N·m (330 ± 37 lb ft) 575 ± 75 N·m (425 ± 55 lb ft) 1000 ± 100 N·m (740 ± 74 lb ft)

TORQUE SPECIFICATIONS

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Media Number -SENR3130-12

O-Ring Face Seal Fittings

Illustration 1

g01848710

O-ring face seal fitting (ORFS fitting) (1) O-ring face seal connector (1A) O-ring groove (2) O-ring seal (3) Nut for the O-ring face seal

Table 1 Ferrous ORFS Fitting Thread Size Inch 9/16 - 18 11/16 - 16 13/16 - 16 1 - 14 1 13/16 - 12 1 7/16 - 12

Standard Torque for Nut (3)

26 ± 3 N·m (230 ± 27 lb in) 43 ± 5 N·m (30 ± 4 lb ft) 65 ± 7 N·m (50 ± 5 lb ft) 109 ± 11 N·m (80 ± 8 lb ft) 144 ± 15 N·m (105 ± 11 lb ft) 216 ± 22 N·m (160 ± 16 lb ft)

1 11/16 - 12 2 - 12

304 ± 31 N·m (220 ± 23 lb ft) 360 ± 36 N·m (270 ± 27 lb ft)

TORQUE SPECIFICATIONS

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Service manual

Media Number -SENR3130-12

Bulkhead Nuts

Illustration 1

g01848733

(1) Bulkhead connector (1A) Bulkhead nut

Note: The bulkhead connector may have different connections. The type of fluid connection does not affect the torque for nut (1A) . Note: When you assemble the fluid connection, do not use the bulkhead nut (1A) as leverage for a backup wrench. Use the hex on the body (1) of the connector for leverage. Table 1 Thread Size Torque Inch 5/16 3/8 7/16 1/2 9/16 11/16

8 ± 1 N·m (70 ± 9 lb in) 10 ± 1 N·m (90 ± 9 lb in) 17 ± 1 N·m (150 ± 9 lb in) 21 ± 2 N·m (185 ± 18 lb in) 27 ± 2 N·m (240 ± 18 lb in)

36 ± 2 N·m (27 ± 1.5 lb ft) 3/4 13/16 7/8 1 1 1/16 1 3/16 1 5/16 1 7/16 1 5/8 1 11/16 1 7/8 2 2 1/2 Note:

45 ± 3 N·m (33 ± 2 lb ft) 48 ± 3 N·m (35 ± 2 lb ft) 53 ± 3 N·m (39 ± 2 lb ft) 72 ± 4 N·m (55 ± 3 lb ft) 84 ± 5 N·m (60 ± 4 lb ft) 108 ± 6 N·m (80 ± 4 lb ft) 137 ± 7 N·m (100 ± 5 lb ft) 149 ± 8 N·m (110 ± 6 lb ft) 179 ± 9 N·m (130 ± 7 lb ft) 179 ± 9 N·m (130 ± 7 lb ft) 185 ± 10 N·m (135 ± 7 lb ft) 203 ± 11 N·m (150 ± 8 lb ft) 262 ± 14 N·m (195 ± 10 lb ft)

TORQUE SPECIFICATIONS

010

Service manual

Media Number -SENR3130-12

Flare Fittings The torques in Table 1 are for 37 degree flare fittings. The torques in Table 2 are for 45 degree flare fittings and 45 degree inverted flare fittings.

37 Degree Flare Fittings

Illustration 1

g01848048

(1) 37 degree flare fitting. (2) Swivel nuts.

Table 1 Nuts for 37 Degree Flare Fittings Thread Size Nominal Outer Diameter of the Tube Inch 3.18 mm (.125 inch) 4.76 mm (.188 inch) 6.35 mm (.250 inch) 7.94 mm (.312 inch)

5/16 3/8 7/16 1/2

Standard Torque Tolerance (+ 10% − 0%)

5 ± 1 N·m (45 ± 9 lb in) 11 ± 2 N·m (100 ± 18 lb in) 16 ± 2 N·m (140 ± 18 lb in) 20 ± 2 N·m (180 ± 18 lb in)

9.52 mm (.375 inch) 12.70 mm (.500 inch) 15.88 mm (.625 inch) 19.05 mm (.750 inch) 22.22 mm (.875 inch) 25.40 mm (1.000 inch) 31.75 mm (1.250 inch) 38.10 mm (1.500 inch) 50.80 mm (2.000 inch)

9/16 3/4 7/8 1 1/16 1 3/16 1 5/16 1 5/8 1 7/8 2 1/2

27 ± 3 N·m (240 ± 25 lb in) 58 + 6 N·m (43 + 4 lb ft) 74 ± 8 N·m (55 ± 6 lb ft) 108 ± 11 N·m (80 ± 8 lb ft) 135 ± 14 N·m (100 ± 10 lb ft) 156 ± 16 N·m (115 ± 12 lb ft) 217 ± 22 N·m (160 ± 16 lb ft) 251 ± 26 N·m (185 ± 19 lb ft) 339 ± 34 N·m (250 ± 25 lb ft)

Note: Use 50 percent of the torque values from Table 1 when the fitting or the port material is nonferrous.

45 Degree Flare and 45 Degree Inverted Flare Fittings

Illustration 2

g01848049

(1) 45 Degree Inverted Flare Fittings. (2) 45 Degree Flare Fittings.

Table 2

45 Degree Flare Fittings and 45 Degree Inverted Flare Fittings Thread Size Nominal Outer Diameter of the Tube

Standard Torque Inch

3.18 mm (.125 inch) 4.76 mm (.188 inch) 6.35 mm (.250 inch) 7.94 mm (.312 inch) 9.52 mm (.375 inch) 11.11 mm (.438 inch) 12.70 mm (.500 inch) 15.88 mm (.625 inch) 19.05 mm (.750 inch) 22.22 mm (.875 inch)

5/16 3/8 7/16 1/2 5/8 11/16 3/4 7/8 1 1/16 1 1/4

5 ± 1 N·m (45 ± 9 lb in) 8 ± 1 N·m (70 ± 9 lb in) 11 ± 1 N·m (100 ± 9 lb in) 17 ± 1 N·m (150 ± 9 lb in) 30 ± 2 N·m (265 ± 18 lb in) 30 ± 2 N·m (265 ± 18 lb in) 38 ± 2 N·m (28 ± 2 lb ft) 50 ± 3 N·m (37 ± 2 lb ft) 90 ± 5 N·m (65 ± 4 lb ft) 100 ± 6 N·m (75 ± 5 lb ft)

TORQUE SPECIFICATIONS

011

Service manual

Media Number -SENR3130-12

Air Conditioning Fittings

Illustration 1

g01848052

(1) O-ring seal. (2) 45 degree flare fitting.

Table 1 Air Conditioning Fittings Thread Size Inch

O-Ring Fitting End Torque

45 Degree Flare Fitting End Torque for Steel Tubes

5/8 - 18

14 ± 4 N·m (125 ± 35 lb in)

30 ± 3 N·m (265 ± 27 lb in)

3/4 - 16

27 ± 4 N·m (240 ± 35 lb in)

52 ± 5 N·m (38 ± 4 lb ft)

40 ± 4 N·m (30 ± 3 lb ft)

60 ± 7 N·m (44 ± 5 lb ft)

45 ± 5 N·m (33 ± 4 lb ft)

75 ± 8 N·m (55 ± 6 lb ft)

7/8 - 14 1 - 14 1 1/16 - 14

Table 2

Torque for Aluminum Tubes

23 ± 3 N·m (205 ± 27 lb in)

33 ± 4 N·m (290 ± 35 lb in)

38 ± 4 N·m (335 ± 35 lb in)

50 ± 5 N·m (37 ± 4 lb ft)

Quick Disconnect Air Conditioning Fittings Thread Size Inch 7/8 - 20 1 1/4 - 18

Torque

49 ± 3 N·m (36 ± 2 lb ft) 62 ± 3 N·m (46 ± 2 lb ft)

TORQUE SPECIFICATIONS

012

Service manual

Media Number -SENR3130-12

Air Brake Fittings

Illustration 1

g01848737

Put nut (1) and sleeve (2) over the tube. Push the tube into the counterbore of the fitting body as far as possible. There are two methods that may be used to tighten the nut. Tighten the nut with one of two methods. l l

Tighten nut (1) to the torque that is specified in Table 1. Tighten nut (1) by the number of turns that is specified in Table 1. The number of turns is for the turns after the nut is finger tight.

Table 1 Turn Tightening Nominal Outer Diameter of the Tube

Torque

Nonmetallic Tubing

Copper Tubing

6.35 mm (0.250 inch)

11 ± 3 N·m (97 ± 27 lb in)

3

2

9.53 mm (0.375 inch)

20 ± 3 N·m (175 ± 27 lb in)

4

2

35 ± 6 N·m (26 ± 4 lb ft)

4

2

40 ± 6 N·m (30 ± 4 lb ft)

3 1/2

3

50 ± 6 N·m (37 ± 4 lb ft)

3 1/2

3

12.70 mm (0.500 inch)

15.88 mm (0.625 inch)

19.05 mm (0.750 inch)

Note: Clean the connectors and the seals and lubricate the connectors and seals by using Refrigerant Mineral Oil. This is a special oil that is compatible with R−134a.

013

TORQUE SPECIFICATIONS

Service manual

Media Number -SENR3130-12

Tapered Pipe Thread Fittings Torque is based on the diameter of the thread. The torque values are identical for coarse threads and fine threads. Note: The following table has the recommended standard torque value for tapered pipe thread fitting for use on all Caterpillar equipment and Mitsubishi engines. Use Table 1 as a general recommendation only. Actual values may vary due to variations in the material of the connector. Actual values may vary due to variations in the characteristics of the threads. Table 1 Tapered Pipe Thread Fittings Standard Torque Diameter of the Pipe Thread (Inch)

1/16 1/8 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2

Threads with 5P-3413 Pipe Sealant

Threads without Pipe Sealant

10 N·m (90 lb in)

10 N·m (90 lb in)

16 N·m (140 lb in)

16 N·m (140 lb in)

20 N·m (175 lb in)

25 N·m (220 lb in)

35 N·m (26 lb ft)

45 N·m (33 lb ft)

45 N·m (33 lb ft)

60 N·m (44 lb ft)

60 N·m (44 lb ft)

75 N·m (55 lb ft)

75 N·m (55 lb ft)

90 N·m (65 lb ft)

95 N·m (70 lb ft)

110 N·m (80 lb ft)

110 N·m (80 lb ft)

130 N·m (95 lb ft)

130 N·m (95 lb ft)

160 N·m (120 lb ft)

Note: Use 50 percent of the torque values from Table 1 when the fitting, the plug, or the port material is nonferrous. Note: Use 50 percent of the torque values from Table 1 when a tapered thread is mated with a straight thread.

TORQUE SPECIFICATIONS

014

Service manual

Media Number -SENR3130-12

Miscellaneous Fittings Hi Duty Tube Fittings (Shear Sleeve)

Illustration 1

g00909648

Put nut (1) over the tube and push the tube into the counterbore of the fitting body as far as possible. Turn the nut with a wrench until a small decrease in torque is felt. The small decrease in torque indicates that the sleeve (1A) has been broken off of the nut. Hold the tube in order to prevent the tube from turning. Tighten the nut for an additional 1 1/2 turns.

SAE Flareless Fittings

Illustration 2

g00909647

Installing a New Flareless Fitting Put nut (1) and sleeve (2) over the tube. The head end of the sleeve should be next to the nut. The head end has a shoulder. The nut will be seated against this shoulder when the nut is tightened. Push the tube into the counterbore of the fitting body as far as possible. Turn nut (1) clockwise until the sleeve grips the tube. The sleeve must prevent all movement of the tube. Tighten the nut for an additional 1 1/4 turns. The sleeve should be seated and the sleeve should give a locking action.

Installing a Used Flareless Fitting

Less turns are required for a used fitting. Put nut (1) and sleeve (2) over the tube. The head of the sleeve should be next to the nut. Push the tube into the counterbore of the fitting body as far as possible. Tighten the nut until a sudden increase in torque is felt. Next, tighten the fitting for an additional 1/6 to 1/3 turn in order to seat the sleeve.

Flex Fittings

Illustration 3

g00909645

Put nut (1) and sleeve (2) over the tube and push the tube into the counterbore of the fitting body as far as possible. Tighten the nut until the nut is against the hex part of the fitting body.

TORQUE SPECIFICATIONS

015

Service manual

Media Number -SENR3130-12

Hose Clamps Worm Drive Band Type Clamps

Illustration 1

g00910017

Table 1 Width (A) of Clamp 7.9 mm (0.31 inch)

Torque for New Hose 1.4 ± 0.3 N·m (12 ± 3 lb in)

13.5 mm (0.53 inch)

4.5 ± 0.7 N·m (40 ± 6 lb in)

15.9 mm (0.63 inch)

7.5 ± 1 N·m (66 ± 9 lb in)

Width (A) of Clamp

Torque for Reused Hose (1)

7.9 mm (0.31 inch)

0.8 ± 0.3 N·m (7 ± 3 lb in)

13.5 mm (0.53 inch)

3.0 ± 0.5 N·m (27 ± 4 lb in)

15.9 mm (0.63 inch)

4.5 ± 0.7 N·m (40 ± 6 lb in)

(1)

Use this value when the hose is reused. The clamp may be new or reused.

Constant Torque Hose Clamps Use a constant torque hose clamp in place of any worm drive band type clamp. Ensure that the constant torque hose clamp is the same size as the worm drive band type clamp. Due to extreme temperature changes, the hose will heat set. Heat setting can cause worm drive band type clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures that have been caused by worm drive band type clamps that have loosened. The constant torque hose clamp will help prevent these failures.

Illustration 2

g01848056

(1) Constant Torque Hose Clamp (Belleville Washer) (2) Constant Torque Hose Clamp (Tee bolt and Spring)

Use a torque wrench for proper installation of all constant torque hose clamps. There are two types of constant torque hose clamps: Belleville washer (1) and Tee bolt and spring (2) When the constant torque hose clamp (Belleville washer) (1) is assembled correctly, the Belleville washers (1A) are nearly collapsed flat. The proper torque for screw (1B) is based on the diameter (B) of the clamp. Refer to the following table for the correct torque. Table 2 Diameter (B)

Standard Torque

Up to 50.8 mm (2 inch)

7.5 ± 1 N·m (65 ± 10 lb in)

Greater than 50.8 mm (2 inch)

11 ± 1 N·m (95 ± 10 lb in)

The correct torque for the constant torque hose clamp (tee bolt and spring) (2) is 7.5 ± 1 N·m (65 ± 10 lb in).

Media Number -KENR5271-04

G3516E Service manual (GAS) Disassembly and Assembly Electronic Control Module - Remove and Install Removal Procedure Installation Procedure Fuel Control Valve - Remove and Install Removal Procedure Installation Procedure Throttle Control Valve - Remove Removal Procedure Throttle Control Valve - Install Installation Procedure Spark Plug - Remove and Install Removal Procedure Installation Procedure Exhaust Elbow - Remove and Install Removal Procedure Installation Procedure Exhaust Manifold - Remove Removal Procedure Exhaust Manifold - Install Installation Procedure Aftercooler - Remove Removal Procedure Aftercooler - Install Installation Procedure Air Inlet Manifold - Remove and Install Removal Procedure Installation Procedure Turbocharger - Remove Removal Procedure Turbocharger - Disassemble - Dual Turbochargers Disassembly Procedure Turbocharger - Assemble - Dual Turbochargers Assembly Procedure Turbocharger - Install Installation Procedure Actuator Bypass Valve (Variable) - Remove Removal Procedure Actuator Bypass Valve (Variable) - Install Installation Procedure Water Temperature Regulators - Remove Removal Procedure Water Temperature Regulators - Install Installation Procedure Thermostatic Valve - Remove Removal Procedure Thermostatic Valve - Disassemble Disassembly Procedure Thermostatic Valve - Assemble Assembly Procedure Thermostatic Valve - Install Installation Procedure

INDEX 001

002

003 004 005

006

007 008 009 010 011

012 013 014 015 016 017 018 019 020 021 022 023

Water Pump - Remove Removal Procedure Water Pump - Disassemble Disassembly Procedure Water Pump - Assemble Assembly Procedure Water Pump - Install Installation Procedure Auxiliary Water Pump - Remove Removal Procedure Auxiliary Water Pump - Disassemble Disassembly Procedure Auxiliary Water Pump - Assemble Assembly Procedure Auxiliary Water Pump - Install Installation Procedure Engine Oil Pump - Remove Removal Procedure Engine Oil Pump - Disassemble Disassembly Procedure Engine Oil Pump - Assemble Assembly Procedure Engine Oil Pump - Install Installation Procedure Engine Oil Cooler - Remove Removal Procedure Engine Oil Cooler - Install Installation Procedure Engine Oil Filter Base - Remove Removal Procedure Engine Oil Filter Base - Disassemble Disassembly Procedure Engine Oil Filter Base - Assemble Assembly Procedure Engine Oil Filter Base - Install Installation Procedure Engine Oil and Water Pump Drive - Remove Removal Procedure Engine Oil and Water Pump Drive - Disassemble Disassembly Procedure Engine Oil and Water Pump Drive - Assemble Assembly Procedure Engine Oil and Water Pump Drive - Install Installation Procedure Engine Oil Pan - Remove Removal Procedure Engine Oil Pan - Disassemble Disassembly Procedure Engine Oil Pan - Assemble Assembly Procedure Engine Oil Pan - Install Installation Procedure Engine Oil Sequence Valves - Remove and Install Removal Procedure Installation Procedure Drive Housing (Front) - Remove and Install

024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050

051

Removal Procedure Installation Procedure Vibration Damper - Remove and Install Removal Procedure Installation Procedure Flywheel - Remove and Install Removal Procedure Installation Procedure Flywheel Housing - Remove Removal Procedure Flywheel Housing - Install Installation Procedure Crankshaft Front Seal and Wear Sleeve - Remove Removal Procedure Crankshaft Front Seal and Wear Sleeve - Install Installation Procedure Crankshaft Rear Seal and Wear Sleeve - Remove Removal Procedure Crankshaft Rear Seal and Wear Sleeve - Install Installation Procedure Accessory Drive (Front) - Remove Removal Procedure Accessory Drive (Front) - Disassemble Disassembly Procedure Accessory Drive (Front) - Assemble Assembly Procedure Accessory Drive (Front) - Install Installation Procedure Gear Group (Rear) - Remove Removal Procedure Gear Group (Rear) - Install Installation Procedure Crankcase Breather - Remove and Install Removal Procedure Installation Procedure Valve Cover - Remove and Install Removal Procedure Installation Procedure Rocker Shaft and Push Rod - Remove Removal Procedure Rocker Shaft - Disassemble Disassembly Procedure Rocker Shaft - Assemble Assembly Procedure Rocker Shaft and Push Rod - Install Installation Procedure Cylinder Head - Remove Removal Procedure Cylinder Head - Disassemble Disassembly Procedure Cylinder Head - Assemble Assembly Procedure Cylinder Head - Install Installation Procedure Piston Cooling Jets - Remove and Install Removal Procedure

052

053

054 055 056 057 058 059 060 061 062 063 064 065 066

067

068 069 070 071 072 073 074 075 076

Installation Procedure Bearing Clearance - Check Measurement Procedure Connecting Rod Bearings - Remove and Install Removal Procedure Installation Procedure Piston and Connecting Rods - Remove Removal Procedure Piston and Connecting Rods - Install Installation Procedure Cylinder Liner - Remove Removal Procedure Cylinder Liner - Install Installation Procedure Cylinder Liner Projection Install the Cylinder Liner Camshaft - Remove Removal Procedure Camshaft - Install Installation Procedure Camshaft Bearings - Remove Removal Procedure Camshaft Bearings - Install Installation Procedure Crankshaft Main Bearings - Remove Removal Procedure Crankshaft Main Bearings - Install Installation Procedure Crankshaft - Remove Removal Procedure Crankshaft - Install Installation Procedure

077 078

079 080 081 082

083 084 085 086 087 088 089 090

DISASSEMBLY AND ASSEMBLY

001

G3516E Service manual (GAS)

Media Number -KENR5271-04

Electronic Control Module - Remove and Install Removal Procedure

Illustration 1

1. Remove cover (1) .

g01000193

Illustration 2

g01047147

2. Disconnect harness assemblies (2) from electronic control modules (4) . 3. Remove bolts (3) . 4. Remove electronic control modules (4) .

Installation Procedure

Illustration 3

1. Position electronic control modules (4) . 2. Install bolts (3) . 3. Connect harness assemblies (2) to electronic control modules (4) .

g01047147

Illustration 4

g01000193

4. Install cover (1) . Note: If the master ECM is replaced, a timing calibration will need to be preformed. If the master ECM is replaced, you will need to verify the customer's programmable parameters. Refer to Testing and Adjusting, "General Information (Electronic Control System)".

DISASSEMBLY AND ASSEMBLY

002

G3516E Service manual (GAS)

Media Number -KENR5271-04

Fuel Control Valve - Remove and Install S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Removal Procedure 1. Disconnect the harness assembly from the fuel control valve.

Illustration 1

2. Remove bolts (2) and disconnect tube assembly (1) .

g01071320

Illustration 2

g01071321

3. Remove bolts (4) and (8). Remove tube assembly (5) . 4. Remove bracket (3) . 5. Remove bolts (6) and tube assembly (7) . 6. Remove bolts (9) . 7. Use two technicians in order to remove fuel control valve (10). Remove fuel control valve (10). The weight of the fuel control valve is approximately 45 kg (100 lb).

Installation Procedure

Illustration 3

g01071321

1. Use two technicians in order to position fuel control valve (10). Position fuel control valve (10). The weight of the fuel control valve is approximately 45 kg (100 lb). 2. Install bolts (9) . 3. Install tube assembly (7) and bolts (6) . 4. Install bracket (3) . 5. Position tube assembly (5). Install bolts (4) and (8) .

Illustration 4

6. Connect tube assembly (1) and install bolts (2) . 7. Connect the harness assembly to the fuel control valve.

g01071320

DISASSEMBLY AND ASSEMBLY

003

G3516E Service manual (GAS)

Media Number -KENR5271-04

Throttle Control Valve - Remove S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

4

ZZ

9U-7091

Tapered Cap/Plug

1

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN. 1. Turn off the gas supply.

Illustration 1

2. Disconnect harness assembly (1) .

g01070966

Illustration 2

3. Remove bolts (2) and (3) . 4. Remove bolts (4) from the bracket.

g01070961

Illustration 3

g01070970

Note: Use Tooling (A) and a suitable lifting device in order to support elbow (6) . 5. Attach Tooling (A) and a suitable lifting device to elbow (6) and throttle (7) . 6. Remove bolts (5) . 7. Remove throttle (7) and the gasket. The weight of the throttle is approximately 54 kg (120 lb).

DISASSEMBLY AND ASSEMBLY

004

G3516E Service manual (GAS)

Media Number -KENR5271-04

Throttle Control Valve - Install S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Installation Procedure Table 1 Required Tools Tool A

Part Number

Part Description

138-7573

Link Bracket

Qty 4

Illustration 1

g01070970

Note: Use Tooling (A) and a suitable lifting device in order to support elbow (6) . 1. Attach Tooling (A) and a suitable lifting device to elbow (6) and throttle (7) . 2. Position elbow (6), throttle (7), and the gasket. The weight of the throttle is approximately 54 kg (120 lb). 3. Install bolts (5) .

Illustration 2

4. Install bolts (2) and (3) . 5. Install bolts (4) .

g01070961

Illustration 3

6. Connect harness assembly (1) . 7. Turn on the gas supply.

g01070966

DISASSEMBLY AND ASSEMBLY

005

G3516E Service manual (GAS)

Media Number -KENR5271-04

Spark Plug - Remove and Install Removal Procedure

Illustration 1

1. Remove bolts (1) . 2. Remove cover (2) .

g00998234

Illustration 2

3. Disconnect harness assembly (3) . 4. Remove bolts (5) . 5. Remove transformer (4) .

g01009731

Illustration 3

6. Remove extension assembly (6) from transformer (4) .

g01009732

Illustration 4

7. Remove spark plug (7) .

Installation Procedure

g01009734

Illustration 5

g01009734

1. Install spark plug (7). Tighten spark plug (7) to a torque of 50 ± 4 N·m (37 ± 3 lb ft).

Illustration 6

2. Install extension assembly (6) onto transformer (4) .

g01009732

Illustration 7

3. Install transformer (4) . 4. Install bolts (5) . 5. Connect harness assembly (3) .

g01009731

Illustration 8

6. Position cover (2) . 7. Install bolts (1) .

g00998234

DISASSEMBLY AND ASSEMBLY

006

G3516E Service manual (GAS)

Media Number -KENR5271-04

Exhaust Elbow - Remove and Install S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Removal Procedure Table 1 Required Tools Tool A

Part Number

Part Description

138-7575

Link Bracket

Qty 4

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 1

1. Remove bolts (1) .

g01063842

Illustration 2

g01064186

2. Attach Tooling (A) and a suitable lifting device to exhaust elbow (2) and the turbochargers. 3. Remove bolts (3) and (4) . 4. Remove exhaust elbow (2). Continue to support the turbochargers when exhaust elbow (2) is removed. The weight of the exhaust elbow is approximately 60 kg (132 lb).

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

A

138-7575

Link Bracket

4

B

4C-5599

Anti-Seize Compound

1

Illustration 3

g01064186

1. Attach Tooling (A) and a suitable lifting device to exhaust elbow (2) . 2. Position exhaust elbow (2). The weight of the exhaust elbow is approximately 60 kg (132 lb). 3. Apply Tooling (B) to the washers and the threads of bolts (3) and (4) . 4. Install bolts (3) and (4). Tighten bolts (3) to a torque of 20 ± 2 N·m (15 ± 1 lb ft).

Illustration 4

g01063842

5. Apply Tooling (B) to the washers and the threads of bolts (1). Install bolts (1) .

DISASSEMBLY AND ASSEMBLY

007

G3516E Service manual (GAS)

Media Number -KENR5271-04

Exhaust Manifold - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

1U-9200

Lever Puller Hoist

1

Shackle

1

A 189-0412

Illustration 1

1. Remove plates (1) and shield assemblies (2) . 2. Remove shield assembly (3) .

g00998146

Illustration 2

g00998147

Illustration 3

g00998149

3. Disconnect harness assemblies (4) . 4. If necessary, remove the thermocouples from exhaust manifold (6) . 5. Attach Tooling (A) and a suitable lifting device to exhaust manifold (6) . The weight of exhaust manifold (6) is approximately 136 kg (300 lb). 6. Remove bolt (7) . Position clamp (8) out of the way. 7. Remove bolts (5) in order to remove exhaust manifold (6) and the seals.

DISASSEMBLY AND ASSEMBLY

008

G3516E Service manual (GAS)

Media Number -KENR5271-04

Exhaust Manifold - Install Installation Procedure Table 1 Required Tools Tool

Part Number 1U-9200

Part Description

Qty

Lever Puller Hoist

1

189-0412

Shackle

1

B

5P-3931

Anti-Seize Compound

-

C

- (1)

Nickel based anti-seize compound

-

A

(1)

Refer to Technical Information Bulletin, TIBU 5269 for Manufacturer Part Numbers.

Illustration 1

g00998149

1. Attach Tooling (A) and a suitable lifting device to exhaust manifold (6) . The weight of exhaust manifold (6) is approximately 136 kg (300 lb).

Illustration 2

g00998147

2. Position exhaust manifold (6) and the seals. 3. Apply Tooling (B) to bolts (5) and the washers. 4. Install bolts (5) . Tighten bolts (5) to a torque of 55 ± 5 N·m (41 ± 4 lb ft). 5. Apply Tooling (B) to clamp (8) . 6. Position clamp (8) . 7. Apply Tooling (B) to bolt (7) . 8. Install bolt (7) . Tighten bolt (7) to a torque of 25 ± 6 N·m (18 ± 4 lb ft). 9. If necessary, install the thermocouples on exhaust manifold (6) . Apply Tooling (C) to the thermocouples prior to installation. If the thermocouples are straight, tighten the nuts to a torque of 25 ± 5 N·m (18 ± 4 lb ft). If the thermocouples have a 90 degree bend, tighten the nuts to a torque of 12 ± 3 N·m (105 ± 27 lb in). 10. Connect harness assemblies (4) .

Illustration 3

11. Install shield assembly (3) . 12. Install shield assemblies (2) and plates (1) .

g00998146

DISASSEMBLY AND ASSEMBLY

009

G3516E Service manual (GAS)

Media Number -KENR5271-04

Aftercooler - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7575

Link Bracket

4

B

138-7574

Link Bracket

2

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

1. Shut off the gas supply. 2. Drain the cooling system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations". 3. Drain the auxiliary cooling system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

Illustration 1

g00993587

4. Remove bolts (1) in order to disconnect throttle assembly (3) and the gasket from cover (2) .

Illustration 2

5. Remove tube assemblies (5) from aftercooler (4) . 6. Remove tube assemblies (6) from aftercooler (7) .

g00993588

Illustration 3

g00993589

7. Attach Tooling (A) to cover (2) and a suitable lifting device. 8. Remove bolts (8) . 9. Remove cover (2), aftercooler (4), aftercooler (7), and the O-ring seal. The weight of cover (2), aftercooler (4), and aftercooler (7) is approximately 590 kg (1300 lb).

Illustration 4

g00993591

10. Remove bolts (9) in order to remove cover (2), aftercooler (4), and the O-ring seal from aftercooler (7). The weight of cover (2) and aftercooler (4) is approximately 340 kg (750 lb). 11. Remove Tooling (A) .

Illustration 5

g00993592

12. Install Tooling (B) and a suitable lifting device to cover (2) . 13. Remove bolts (10) in order to remove cover (2) from aftercooler (4) . 14. Remove cover (2) and the O-ring seal. The weight of the cover is approximately 91 kg (200 lb).

DISASSEMBLY AND ASSEMBLY

010

G3516E Service manual (GAS)

Media Number -KENR5271-04

Aftercooler - Install Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7575

Link Bracket

4

B

138-7574

Link Bracket

2

Illustration 1

g00993592

1. Install Tooling (B) and a suitable lifting device to cover (2) . 2. Position cover (2) and the O-ring seal on aftercooler (4). The weight of the cover is approximately 91 kg (200 lb). 3. Install bolts (10) .

Illustration 2

g00993591

4. Install Tooling (A) . 5. Position cover (2), aftercooler (4), and the O-ring seal onto aftercooler (7). The weight of cover (2) and aftercooler (4) is approximately 340 kg (750 lb). 6. Install bolts (9) .

Illustration 3

g00993589

7. Position cover (2), aftercooler (4), aftercooler (7), and the O-ring seal. The weight of cover (2), aftercooler (4), and aftercooler (7) is approximately 590 kg (1300 lb). 8. Install bolts (8) . 9. Remove Tooling (A) .

Illustration 4

10. Install tube assemblies (6) onto aftercooler (7) . 11. Install tube assemblies (5) onto aftercooler (4) .

g00993588

Illustration 5

g00993587

12. Position throttle assembly (3) and the gasket onto cover (2). Install bolts (1) . 13. Fill the auxiliary cooling system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations". 14. Fill the cooling system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations". 15. Turn on the gas supply.

011

DISASSEMBLY AND ASSEMBLY

G3516E Service manual (GAS)

Media Number -KENR5271-04

Air Inlet Manifold - Remove and Install Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7575

Link Bracket

5

B

1U-9200

Lever Puller Hoist

1

Start By: A. Remove the fuel control valve. Refer to Disassembly and Assembly, "Fuel Control Valve - Remove and Install". B. Remove the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove".

Illustration 1

g01002143

1. Cut cable straps (1) . 2. Position harness assemblies (2) out of the way. 3. Repeat Step 1 for the opposite side.

Illustration 2

g01002144

4. Disconnect harness assembly (5) . 5. Remove adapter (4) and the O-ring seal from air inlet manifold (3) .

Illustration 3

6. Remove plug (6) from air inlet manifold (3) .

g01002145

Illustration 4

7. Remove bolts (7) . 8. Position flanges (8) away from air inlet manifold (3) .

g01002146

Illustration 5

9. Remove bolts (9) from air inlet manifold (3) .

g01002153

Illustration 6

g01047793

10. Attach Tooling (A) and a suitable lifting device to air inlet manifold (3) . 11. Attach Tooling (B) to Tooling (A) and the suitable lifting device. 12. Do not put tension on Tooling (B) . 13. Lift the air inlet manifold partially away from the engine. The weight of the air inlet manifold is approximately 295 kg (650 lb). 14. Use Tooling (B) in order to assist the removal of air inlet manifold (3) .

Illustration 7

g01002155

15. Remove O-ring seals (10) from flanges (8) .

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

A

138-7575

Link Bracket

5

B

1U-9200

Lever Puller Hoist

1

Illustration 8

1. Install O-ring seals (10) onto flanges (8) .

g01002155

Illustration 9

g01047793

2. Attach Tooling (A) and a suitable lifting device to air inlet manifold (3) . 3. Attach Tooling (B) to Tooling (A) and the suitable lifting device. 4. Position air inlet manifold (3) .

Illustration 10

5. Install bolts (9) into air inlet manifold (3) .

g01002153

Illustration 11

6. Position flanges (8) onto air inlet manifold (3) . 7. Install bolts (7) .

g01002146

Illustration 12

8. Install adapter (4) and the O-ring seal onto air inlet manifold (3) . 9. Connect harness assembly (5) .

g01002144

Illustration 13

g01002145

10. Install plug (6) into air inlet manifold (3) .

Illustration 14

g01002143

11. Position harness assemblies (2). Install cable straps (1) . 12. Repeat Step 11 for the opposite side. End By: a. Install the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Install". b. Install the fuel control valve. Refer to Disassembly and Assembly, "Fuel Control Valve - Remove and Install".

DISASSEMBLY AND ASSEMBLY

012

G3516E Service manual (GAS)

Media Number -KENR5271-04

Turbocharger - Remove S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7575

Link Bracket

2

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. 1. Drain the coolant system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

Illustration 1

2. Disconnect tube assemblies (1) and (4) . 3. Disconnect tube assemblies (2) and (3) . 4. Remove bolts (5) .

g01063415

Illustration 2

g01063422

5. Attach Tooling (A) and a suitable lifting device to turbocharger (9) and the air inlet elbow. 6. Remove bolts (6) . 7. Remove clamp (7) . 8. Remove bolts (8) . 9. Remove turbocharger (9). The weight of the turbocharger is approximately 100 kg (220 lb).

DISASSEMBLY AND ASSEMBLY

013

G3516E Service manual (GAS)

Media Number -KENR5271-04

Turbocharger - Disassemble - Dual Turbochargers S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Disassembly Procedure Start By: A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g01063565

1. Mark the three turbocharger housings for alignment upon assembly. 2. Remove bolts (2) . 3. Remove compressor housing (1) and diffuser (3) from cartridge assembly (4) . The weight of the compressor housing is approximately 25 kg (55 lb). 4. Remove bolts (6) . 5. Remove turbine housing (7) and nozzle ring (5) from cartridge assembly (4) . The weight of the turbine housing is approximately 40 kg (90 lb). The weight of the cartridge assembly is approximately 30 kg (70 lb).

DISASSEMBLY AND ASSEMBLY

014

G3516E Service manual (GAS)

Media Number -KENR5271-04

Turbocharger - Assemble - Dual Turbochargers S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Assembly Procedure

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Obtain new seals for assembly. Thoroughly clean all of the parts. Unless other instructions are provided, coat the parts of the cartridge with clean engine oil.

Illustration 1

g01063565

1. Ensure that the following parts are aligned correctly upon assembly: turbine housing (7) , cartridge assembly (4) and compressor housing (1) .

2. Use two technicians in order to install nozzle ring (5) and turbine housing (7) on cartridge assembly (4) . The weight of the cartridge assembly is approximately 30 kg (70 lb). The weight of the turbine housing is approximately 40 kg (90 lb). 3. Install diffuser (3) and compressor housing (1) . The weight of the compressor housing is approximately 25 kg (55 lb). 4. Install bolts (2) and (6) . Tighten bolts (2) to a torque of 65 ± 5 N·m (48 ± 4 lb ft). Tighten bolts (6) to a torque of 40 ± 5 N·m (30 ± 4 lb ft). End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".

DISASSEMBLY AND ASSEMBLY

015

G3516E Service manual (GAS)

Media Number -KENR5271-04

Turbocharger - Install S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7575

Link Bracket

2

B

4C-5599

Anti-Seize Compound

1

Illustration 1

g01063422

1. Attach Tooling (A) and a suitable lifting device to turbocharger (9) and the air inlet elbow. 2. Position turbocharger (9) on the engine. The weight of the turbocharger is approximately 100 kg (220 lb).

3. Apply Tooling (B) to bolts (8). Install bolts (8) and tighten to a torque of 20 ± 2 N·m (15 ± 1 lb ft). 4. Apply Tooling (B) to bolts (6). Install bolts (6) and tighten to a torque of 50 ± 10 N·m (37 ± 7 lb ft). 5. Remove Tooling (A) and a suitable lifting device from turbocharger (9) and the air inlet elbow.

Illustration 2

g01063415

6. Apply Tooling (B) to bolts (5). Install bolts (5) and tighten to a torque of 50 ± 10 N·m (37 ± 7 lb ft). 7. Connect tube assemblies (2) and (3) . 8. Connect tube assemblies (1) and (4) . 9. Fill the coolant system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

DISASSEMBLY AND ASSEMBLY

016

G3516E Service manual (GAS)

Media Number -KENR5271-04

Actuator Bypass Valve (Variable) - Remove S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1-UP , S/N - TJC1-UP , S/N - TJD1-UP

Removal Procedure 1. Shut off the gas supply.

Illustration 1

2. Remove clamps (3) . 3. Remove valve assembly (2) from coupling (1) .

g01071292

Illustration 2

g01018584

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 4. Remove valve assembly (2) . Note: Note the position of pin (5) and plate (10) . 5. Remove the assembly of the following items: shaft assembly (7), tube assembly (8), torsion spring (6) and torsion spring (9). Disassemble shaft assembly (7), tube assembly (8), and torsion springs (6) and (9) . 6. Remove coupling (1) from shaft assembly (4) .

DISASSEMBLY AND ASSEMBLY

017

G3516E Service manual (GAS)

Media Number -KENR5271-04

Actuator Bypass Valve (Variable) - Install S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1-UP , S/N - TJC1-UP , S/N - TJD1-UP

Installation Procedure Note: Verify that the actuator bypass valve is in the correct orientation prior to installation.

Illustration 1

g01018584

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 1. Rotate shaft assembly (4) clockwise until the shaft contacts the internal stop. 2. Orient pin (5) parallel with valve assembly (2) in order to close plate (10) . 3. Assemble shaft assembly (7) , tube assembly (8) , and torsion springs (6) and (9) . Attach the assemblies to coupling (1) .

Note: Use new capscrews when a new coupling is used. 4. Before you tighten the coupling assembly, make sure that shaft assembly (4) is in the fully clockwise position and make sure that pin (5) is parallel with the valve assembly. Tighten the capscrews in the coupling to a torque of 15 ± 1 N·m (135 ± 9 lb in).

Illustration 2

5. Position valve assembly (2) onto coupling (1) . 6. Install clamps (3) . 7. Turn on the gas supply.

g01071292

DISASSEMBLY AND ASSEMBLY

018

G3516E Service manual (GAS)

Media Number -KENR5271-04

Water Temperature Regulators - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

4

B

189-0410

Shackle As

2

1. Drain the cooling system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

Illustration 1

g00999534

2. Remove bolts (1) and bolts (6) in order to remove elbow (2) and the gasket. 3. Remove bolts (4) in order to remove adapter (5) from regulator housing assembly (3) .

Illustration 2

g00999535

4. Attach Tooling (A) and Tooling (B) to cover (7). Use a chain in order to secure cover (7) in place.

Illustration 3

g00999536

5. Attach Tooling (A) and a suitable lifting device to regulator housing assembly (3) . 6. Remove bolts (8) . 7. Remove bolts (10) in order to remove bracket (9) . 8. Remove bolts (11) in order to remove regulator housing assembly (3) from housing (12) .

Illustration 4

9. Remove seal (13) from housing (12) .

g00999537

Illustration 5

g00999538

10. Remove water temperature regulators (14) from regulator housing assembly (3). The weight of the water regulator housing is approximately 40 kg (90 lb). 11. Remove seals (15) from regulator housing assembly (3) .

DISASSEMBLY AND ASSEMBLY

019

G3516E Service manual (GAS)

Media Number -KENR5271-04

Water Temperature Regulators - Install Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

A

138-7573

Link Bracket

4

B

189-0410

Shackle As

2

C

221-8647

Installer

1

Illustration 1

Qty

g00999540

Illustration 2

g00999539

Illustration 3

g00999538

1. Use Tooling (C) in order to install seals (15) into regulator housing assembly (3) . 2. Install water temperature regulators (14) into regulator housing assembly (3). The weight of the water regulator housing is approximately 40 kg (90 lb).

Illustration 4

3. Position seal (13) onto housing (12) .

g00999537

Illustration 5

g00999536

4. Attach Tooling (A) and a suitable lifting device to regulator housing assembly (3) . 5. Position regulator housing assembly (3) onto housing (12) . 6. Install bolts (11) . 7. Position bracket (9) . 8. Install bolts (10) . 9. Install bolts (8) .

Illustration 6

10. Remove Tooling (A) and Tooling (B) from cover (7) .

g00999535

Illustration 7

g00999534

11. Install bolts (4) in order to secure adapter (5) onto regulator housing assembly (3) . 12. Position elbow (2) and the gasket. 13. Install bolts (1) and bolts (6) . 14. Refill the cooling system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

DISASSEMBLY AND ASSEMBLY

020

G3516E Service manual (GAS)

Media Number -KENR5271-04

Thermostatic Valve - Remove Removal Procedure

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

1. Turn off the auxiliary water supply. 2. Drain the water to a level below the thermostatic valve.

Illustration 1

g00997800

3. Remove bolts (4) in order to disconnect tee (3) and the gasket from thermostatic valve (2) . 4. Remove bolts (6) in order to disconnect elbow (7) from thermostatic valve (2) . 5. Remove bolts (1) in order to remove thermostatic valve (2) from elbow (5) .

DISASSEMBLY AND ASSEMBLY

021

G3516E Service manual (GAS)

Media Number -KENR5271-04

Thermostatic Valve - Disassemble Disassembly Procedure Start By: A. Remove the thermostatic valve. Refer to Disassembly and Assembly, "Thermostatic Valve - Remove".

Illustration 1

1. Remove bolts (7) in order to remove lower housing (9) from upper housing (1) . 2. Remove regulator assemblies (8) from upper housing (1) . 3. Remove O-ring seals (6) from upper housing (1) . 4. Remove sleeves (4) and O-ring seals (5) from upper housing (1) . 5. Remove bolts (3) in order to remove seats (2) from upper housing (1) .

g00997739

DISASSEMBLY AND ASSEMBLY

022

G3516E Service manual (GAS)

Media Number -KENR5271-04

Thermostatic Valve - Assemble Assembly Procedure

Illustration 1

g00997739

1. Install bolts (3) in order to install seats (2) to upper housing (1). Tighten bolts (3) to a torque of 20 ± 2 N·m (15 ± 2 lb ft). 2. Install sleeves (4) and O-ring seals (5) onto upper housing (1) . 3. Install O-ring seals (6) onto upper housing (1) . 4. Install regulator assemblies (8) onto upper housing (1) . 5. Install bolts (7) in order to install lower housing (9) to upper housing (1). End By: Install the thermostatic valve. Refer to Disassembly and Assembly, "Thermostatic Valve - Install".

DISASSEMBLY AND ASSEMBLY

023

G3516E Service manual (GAS)

Media Number -KENR5271-04

Thermostatic Valve - Install Installation Procedure

Illustration 1

g00997800

1. Position thermostatic valve (2) onto elbow (5) . 2. Install bolts (1) . 3. Install bolts (6) in order to connect elbow (7) to thermostatic valve (2) . 4. Install bolts (4) in order to connect tee (3) and the gasket to thermostatic valve (2) . 5. Refill with coolant.

DISASSEMBLY AND ASSEMBLY

024

G3516E Service manual (GAS)

Media Number -KENR5271-04

Water Pump - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

9U-7089

Tapered Cap/Plug

1

9U-7095

Tapered Cap/Plug

1

ZZ

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

1. Drain the cooling system coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change".

Illustration 1

g01127935

2. Disconnect hose assembly (1) . 3. Disconnect adapter (2) and the gasket from water pump (3) . 4. Disconnect tube assembly (6) from adapter (5) . 5. Remove bolts (4) in order to remove adapter (5) and the O-ring seal from water pump (3) . 6. Remove bolts (7) in order to remove guard assembly (8) from the engine.

Illustration 2

g01127942

7. Remove bolts (9) in order to remove water pump (3) from the engine. Use two people in order to remove water pump (3) from the engine. The weight of water pump (3) is approximately 34 kg (75 lb).

DISASSEMBLY AND ASSEMBLY

025

G3516E Service manual (GAS)

Media Number -KENR5271-04

Water Pump - Disassemble Disassembly Procedure Table 1 Required Tools Tool

Part Number

A

1P-0510

B

-

C

Part Description

Qty

Driver Gp

1

1 inch by 4 inch steel plate

2

248-3311

Holding Fixture

1

D

248-3310

Locknut Wrench

1

E

8H-0663

Bearing Puller Gp

1

Start By: A. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g01036014

1. Remove plug (1) and plug (2) from bearing housing (3). Remove plug (6) from housing (5). Remove the O-ring seals from the plugs. 2. Remove water pump filter (4) from bearing housing (3) .

Illustration 2

g01035264

3. Remove bolts (7) and washers. Remove bearing housing (3) from housing (5). Remove O-ring seal (8) from bearing housing (3) .

Illustration 3

g01035285

4. Install Tooling (B) under impeller (9). Use a suitable press and Tooling (A) to remove the impeller. Note: Do not allow bearing housing (3) to fall to the floor when the impeller is removed from the pump shaft.

Illustration 4

g01035309

5. Remove socket head bolts (10). Remove retainer (11) and pump shaft (12) from bearing housing (3) . Note: Spring (14) and ceramic seal (13) will be removed from the shaft assembly when the pump shaft is removed from the bearing housing.

Illustration 5

g01035407

6. Install pump shaft (12) in Tooling (C). Loosen set screws (15). Use Tooling (D) to remove bearing locknut (16) from the pump shaft. Note: The splined end of the pump shaft is marked in order to indicate either RH threads or LH threads on the pump shaft.

Illustration 6

g01035429

7. Use Tooling (E) to remove bearing assembly (17) from pump shaft (12) .

Illustration 7

g01035437

8. Remove ceramic seal (18) and lip seal (19) from bearing housing (3) .

DISASSEMBLY AND ASSEMBLY

026

G3516E Service manual (GAS)

Media Number -KENR5271-04

Water Pump - Assemble Assembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

1P-0510

Driver Gp

1

C

248-3311

Holding Fixture

1

D

248-3310

Locknut Wrench

1

E

8H-0663

Bearing Puller Gp

1

F

1U-6396

O-Ring Assembly Compound

-

G

7N-8268

Installation Tool

1

H

8H-8581

Feeler Gauge

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g01040290

1. Use Tooling (E) and a suitable press to install bearing assembly (17) on pump shaft (12) . 2. Install bearing cone (23) on the pump shaft. 3. Install spacer (22) and bearing cups (21) on the pump shaft. 4. Install bearing cone (20) on the pump shaft.

Illustration 2

g01035607

5. The splined end of the pump shaft is marked in order to indicate either RH threads or LH threads on the pump shaft. Install bearing locknut (16). Use Tooling (D) on the bearing locknut. Tighten the bearing locknut to a torque of 300 ± 30 N·m (221 ± 22 lb ft). Note: The torque wrench must be 90 degrees to Tooling (D) . 6. Install set screws (15) and tighten to a torque of 4 ± 1 N·m (35 ± 9 lb in).

Illustration 3

g01035690

Note: Do not damage the wear surfaces of the carbon ring or the ceramic ring. Do not touch the wear surfaces of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal. 7. Apply Tooling (F) to the outside diameter of ceramic seal (18). Use Tooling (G) and hand pressure to install ceramic seal (18) in bearing housing (3) .

Illustration 4

g01035699

8. Use Tooling (A) and a suitable press to install lip seal (19) in bearing housing (3). Ensure that the lip is toward the outside. Note: Install the lip seal dry. Install the lip seal within two minutes of removal from the shipping sleeve.

Illustration 5

g01035809

9. Lubricate pump shaft (12) with clean engine oil. Install the pump shaft in bearing housing (3). Install retainer (11). Install socket head bolts (10) and tighten to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

Illustration 6

g01035829

Note: Do not damage the wear surfaces of the carbon ring or the ceramic ring. Do not touch the wear surfaces of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal. 10. Remove spring (14) from ceramic seal (13) . 11. Apply Tooling (F) to the inside diameter of ceramic seal (13). Use hand pressure and the tool that is supplied with the water pump seal group to install the ceramic seal. The face of ceramic seal (13) should make light contact with ceramic seal (18) . 12. Install spring (14) . 13. Lubricate pump shaft (12) on bearing housing (3) with clean engine oil. Position impeller (9) on the pump shaft.

Illustration 7

g01035846

14. Place bearing housing (3) on impeller (9). Use a suitable press and press pump shaft (12) into the impeller. Install the impeller so the dimension between the impeller and the pump shaft is 0.000 ± 0.076 mm (0.0000 ± 0.0030 inch).

Illustration 8

g01035264

15. Install O-ring seal (8) on bearing housing (3). Lubricate the O-ring seal with clean engine oil. 16. Position bearing housing (3) in housing (5). Install washers and bolts (7) finger tight.

Illustration 9

g01036084

17. Tighten the bolts in a numerical sequence to a torque of 50 ± 9 N·m (35 ± 7 lb ft). 18. Use Tooling (H) and measure the gap between the impeller and the pump housing. The minimum

gap between the impeller and the pump housing is 0.20 mm (0.008 inch).

Illustration 10

g01036014

19. Install the O-ring seal on plug (6). Install the plug in housing (5). Tighten the plug to a torque of 177 ± 7 N·m (131 ± 6 lb ft). 20. Install the O-ring seal on plug (2). Install the plug in bearing housing (3). Tighten the plug to a torque of 8 ± 1 N·m (6 ± 1 lb ft). 21. Install the O-ring seal on plug (1). Install the plug in bearing housing (3). Tighten the plug to a torque of 17 ± 1 N·m (12 ± 1 lb ft). 22. Install water pump filter (4) in bearing housing (3) . End By: Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".

DISASSEMBLY AND ASSEMBLY

027

G3516E Service manual (GAS)

Media Number -KENR5271-04

Water Pump - Install Installation Procedure

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g01127942

1. Use two people in order to position water pump (3) onto the engine. The weight of water pump (3) is approximately 34 kg (75 lb). 2. Install bolts (9) in order to secure water pump (3) to the engine.

Illustration 2

g01127935

3. Install bolts (7) in order to attach guard assembly (8) to the engine. 4. Install bolts (4) in order to attach adapter (5) and the O-ring seal to water pump (3) . 5. Connect tube assembly (6) to adapter (5) . 6. Connect adapter (2) and the gasket to water pump (3) . 7. Connect hose assembly (1) . 8. Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change".

DISASSEMBLY AND ASSEMBLY

028

G3516E Service manual (GAS)

Media Number -KENR5271-04

Auxiliary Water Pump - Remove Removal Procedure 1. Drain the auxiliary coolant system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change".

Illustration 1

g01128898

Illustration 2

g01128899

2. Disconnect hose assembly (1) . 3. Disconnect elbow (8). Remove the gasket from thermostatic valve (9) . 4. Loosen bolts (10) . 5. Disconnect tube assembly (2). Remove the gasket. 6. Remove bolts (5) and bolts (7) in order to remove adapter (6). Remove the gasket. 7. Remove bolts (3) . 8. Use two people in order to remove auxiliary water pump (4) and the O-ring seals. The weight of auxiliary water pump (4) is approximately 41 kg (90 lb).

DISASSEMBLY AND ASSEMBLY

029

G3516E Service manual (GAS)

Media Number -KENR5271-04

Auxiliary Water Pump - Disassemble Disassembly Procedure Table 1 Required Tools Tool

Part Number

A

1P-0510

B

-

C

Part Description

Qty

Driver Gp

1

1 inch by 4 inch steel plate

2

248-3311

Holding Fixture

1

D

248-3310

Locknut Wrench

1

E

8H-0663

Bearing Puller Gp

1

Start By: A. Remove the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water Pump Remove".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g01036014

1. Remove plug (1) and plug (2) from bearing housing (3). Remove plug (6) from housing (5). Remove the O-ring seals from the plugs. 2. Remove water pump filter (4) from bearing housing (3) .

Illustration 2

g01035264

3. Remove bolts (7) and washers. Remove bearing housing (3) from housing (5). Remove O-ring seal (8) from bearing housing (3) .

Illustration 3

g01035285

4. Install Tooling (B) under impeller (9). Use a suitable press and Tooling (A) to remove the impeller. Note: Do not allow bearing housing (3) to fall to the floor when the impeller is removed from the pump shaft.

Illustration 4

g01035309

5. Remove socket head bolts (10). Remove retainer (11) and pump shaft (12) from bearing housing (3) . Note: Spring (14) and ceramic seal (13) will be removed from the shaft assembly when the pump shaft is removed from the bearing housing.

Illustration 5

g01035407

6. Install pump shaft (12) in Tooling (C). Loosen set screws (15). Use Tooling (D) to remove bearing locknut (16) from the pump shaft. Note: The splined end of the pump shaft is marked in order to indicate either RH threads or LH threads on the pump shaft.

Illustration 6

g01035429

7. Use Tooling (E) to remove bearing assembly (17) from pump shaft (12) .

Illustration 7

g01035437

8. Remove ceramic seal (18) and lip seal (19) from bearing housing (3) .

DISASSEMBLY AND ASSEMBLY

030

G3516E Service manual (GAS)

Media Number -KENR5271-04

Auxiliary Water Pump - Assemble Assembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

1P-0510

Driver Gp

1

C

248-3311

Holding Fixture

1

D

248-3310

Locknut Wrench

1

E

8H-0663

Bearing Puller Gp

1

F

1U-6396

O-Ring Assembly Compound

-

G

7N-8268

Installation Tool

1

H

8H-8581

Feeler Gauge

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g01040290

1. Use Tooling (E) and a suitable press to install bearing assembly (17) on pump shaft (12) . 2. Install bearing cone (23) on the pump shaft. 3. Install spacer (22) and bearing cups (21) on the pump shaft. 4. Install bearing cone (20) on the pump shaft.

Illustration 2

g01035607

5. The splined end of the pump shaft is marked in order to indicate either RH threads or LH threads on the pump shaft. Install bearing locknut (16). Use Tooling (D) on the bearing locknut. Tighten the bearing locknut to a torque of 300 ± 30 N·m (221 ± 22 lb ft). Note: The torque wrench must be 90 degrees to Tooling (D) . 6. Install set screws (15) and tighten to a torque of 4 ± 1 N·m (35 ± 9 lb in).

Illustration 3

g01035690

Note: Do not damage the wear surfaces of the carbon ring or the ceramic ring. Do not touch the wear surfaces of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal. 7. Apply Tooling (F) to the outside diameter of ceramic seal (18). Use Tooling (G) and hand pressure to install ceramic seal (18) in bearing housing (3) .

Illustration 4

g01035699

8. Use Tooling (A) and a suitable press to install lip seal (19) in bearing housing (3). Ensure that the lip is toward the outside. Note: Install the lip seal dry. Install the lip seal within two minutes of removal from the shipping sleeve.

Illustration 5

g01035809

9. Lubricate pump shaft (12) with clean engine oil. Install the pump shaft in bearing housing (3). Install retainer (11). Install socket head bolts (10) and tighten to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

Illustration 6

g01035829

Note: Do not damage the wear surfaces of the carbon ring or the ceramic ring. Do not touch the wear surfaces of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal. 10. Remove spring (14) from ceramic seal (13) . 11. Apply Tooling (F) to the inside diameter of ceramic seal (13). Use hand pressure and the tool that is supplied with the water pump seal group to install the ceramic seal. The face of ceramic seal (13) should make light contact with ceramic seal (18) . 12. Install spring (14) . 13. Lubricate pump shaft (12) on bearing housing (3) with clean engine oil. Position impeller (9) on the pump shaft.

Illustration 7

g01035846

14. Place bearing housing (3) on impeller (9). Use a suitable press and press pump shaft (12) into the impeller. Install the impeller so the dimension between the impeller and the pump shaft is 0.000 ± 0.076 mm (0.0000 ± 0.0030 inch).

Illustration 8

g01035264

15. Install O-ring seal (8) on bearing housing (3). Lubricate the O-ring seal with clean engine oil. 16. Position bearing housing (3) in housing (5). Install washers and bolts (7) finger tight.

Illustration 9

g01036084

17. Tighten the bolts in a numerical sequence to a torque of 50 ± 9 N·m (35 ± 7 lb ft). 18. Use Tooling (H) and measure the gap between the impeller and the pump housing. The minimum

gap between the impeller and the pump housing is 0.20 mm (0.008 inch).

Illustration 10

g01036014

19. Install the O-ring seal on plug (6). Install the plug in housing (5). Tighten the plug to a torque of 177 ± 7 N·m (131 ± 6 lb ft). 20. Install the O-ring seal on plug (2). Install the plug in bearing housing (3). Tighten the plug to a torque of 8 ± 1 N·m (6 ± 1 lb ft). 21. Install the O-ring seal on plug (1). Install the plug in bearing housing (3). Tighten the plug to a torque of 17 ± 1 N·m (12 ± 1 lb ft). 22. Install water pump filter (4) in bearing housing (3) . End By: Install the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water Pump Install".

DISASSEMBLY AND ASSEMBLY

031

G3516E Service manual (GAS)

Media Number -KENR5271-04

Auxiliary Water Pump - Install Installation Procedure

Illustration 1

g01128898

Illustration 2

g01128899

1. Use two people in order to position auxiliary water pump (4) and the O-ring seals. The weight of auxiliary water pump (4) is approximately 41 kg (90 lb). 2. Install bolts (3) . 3. Position the gasket and adapter (6) . 4. Install bolts (5) and bolts (7) . 5. Position the gasket and connect tube assembly (2) . 6. Tighten bolts (10) . 7. Position the gasket onto thermostatic valve (9) . 8. Connect elbow (8) . 9. Connect hose assembly (1) . 10. Fill the auxiliary coolant system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change".

DISASSEMBLY AND ASSEMBLY

032

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Pump - Remove Removal Procedure Table 1 Required Tools Tool A

Part Number

Part Description

138-7573

Link Bracket

Qty 1

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

Illustration 1

2. Remove bolts (1) and bolts (2) . 3. Remove adapter (3) and the gaskets. 4. Remove bolts (4) and bracket (5) .

g00990333

Illustration 2

5. Remove bolts (6) in order to disconnect adapter (7) . 6. Disconnect tube assembly (9) from bonnet (8) .

g00990334

Illustration 3

g00990336

7. Remove bolts (10) . 8. Remove elbow (11) and the O-ring seal from engine oil pump (12) .

Illustration 4

9. Remove bolts (13) . 10. Remove collar (14) from engine oil pump (12) .

g00990337

Illustration 5

g00990338

11. Attach Tooling (A) and a suitable lifting device to engine oil pump (12) . 12. Remove bolts (15) . 13. Remove engine oil pump (12). The weight of the engine oil pump is approximately 36 kg (80 lb).

DISASSEMBLY AND ASSEMBLY

033

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Pump - Disassemble Disassembly Procedure Start By: A. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove". Note: Cleanliness is an important factor. Before you begin the disassembly procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform disassembly procedures on a clean work surface. Keep components covered and protected at all times.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00905006

Illustration 2

g00905007

Illustration 3

g00905008

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 1. Remove bolts (2) and cover (3) from body (1) . 2. Remove spring (4) and spool (5) from body (1) .

Illustration 4

g00905011

Illustration 5

g00905012

3. Remove bolts (6) from cover (7) . 4. Remove cover (7) from body (1) .

Illustration 6

g00905016

5. Remove gasket (8) from cover (7) .

Illustration 7

g00905020

Illustration 8

g00905023

6. Remove bolts (9) from cover (10) . 7. Remove cover (10) from body (1) .

Illustration 9

8. Remove bearings (11) from cover (10) .

g00905024

Illustration 10

g00905027

9. Remove shaft (12), shaft (13), and shaft (14) from body (1) .

Illustration 11

g00905029

10. Remove bearings (15) from body (1) .

DISASSEMBLY AND ASSEMBLY

034

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Pump - Assemble Assembly Procedure Note: Cleanliness is an important factor. Before you begin the assembly procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00905029

1. Install bearings (15) into body (1) .

Illustration 2

g00905027

2. Install shaft (12), shaft (13), and shaft (14) into body (1) .

Illustration 3

g00905024

3. Install bearings (11) into cover (10) .

Illustration 4

g00905023

Illustration 5

g00905020

4. Install cover (10) onto body (1) . 5. Install bolts (9) into cover (10) .

Illustration 6

6. Install gasket (8) into cover (7) .

g00905016

Illustration 7

g00905012

Illustration 8

g00905011

7. Install cover (7) onto body (1) . 8. Install bolts (6) into cover (7) .

Illustration 9

g00905008

Illustration 10

g00905007

Illustration 11

g00905006

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 9. Install spool (5) and spring (4) into body (1) . 10. Install cover (3) and bolts (2) into body (1) . End By: Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".

DISASSEMBLY AND ASSEMBLY

035

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Pump - Install Installation Procedure Table 1 Required Tools Tool A

Part Number

Part Description

138-7573

Link Bracket

Illustration 1

Qty 1

g00990338

1. Attach Tooling (A) and a suitable lifting device to engine oil pump (12) . 2. Position engine oil pump (12). The weight of the engine oil pump is approximately 36 kg (80 lb). 3. Install bolts (15) .

Illustration 2

4. Position collar (14) onto engine oil pump (12) . 5. Install bolts (13) .

g00990337

Illustration 3

g00990336

6. Position the O-ring seal onto engine oil pump (12) and elbow (11) . 7. Install bolts (10) .

Illustration 4

8. Position tube assembly (9) onto bonnet (8) . 9. Position adapter (7) . 10. Install bolts (6) .

g00990334

Illustration 5

g00990333

11. Position bracket (5). Install bolts (4) . 12. Position the gaskets and adapter (3) . 13. Install bolts (1) and bolts (2) . 14. Fill the coolant system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

DISASSEMBLY AND ASSEMBLY

036

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Cooler - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

6V-7496

Tapered Cap/Plug

2

9U-7090

Tapered Cap/Plug

1

9U-7092

Tapered Cap/Plug

3

9U-7094

Tapered Cap/Plug

2

ZZ

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN. 1. Drain the cooling system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

Illustration 1

2. Remove plates (1) and shield assemblies (2) .

g00999933

Illustration 2

3. Remove tube assembly (4) and joint assembly (3) . 4. Remove tube assembly (5) .

g00999934

Illustration 3

5. Remove bolts (6) and bolts (8) . 6. Disconnect elbow (7) .

g01060632

Illustration 4

7. Disconnect tube assembly (9) from bonnet (10) .

g00999936

Illustration 5

8. Attach a suitable lifting device to engine oil cooler (11) .

g00999937

Illustration 6

g00999938

Illustration 7

g00999939

9. Remove bolts (12) and bolts (15) . 10. Move bonnet (13) and cooler bypass elbow (17) away from tube assembly (14) and tube assembly (16) . 11. Remove engine oil cooler (11). The weight of the engine oil cooler is approximately 104 kg (230 lb).

Illustration 8

g00999940

12. Remove bolts (19) . 13. Remove tube assembly (18) . 14. Remove bolts (20) in order to remove bonnet (10) and the gasket from engine oil cooler (11) .

Illustration 9

15. Remove bolts (21) . 16. Remove bonnet (13) and the gasket from engine oil cooler (11) . 17. Remove bolts (22) . 18. Remove cooler bypass elbow (17) from engine oil cooler (11) .

g00999941

Illustration 10

g00999942

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 19. Remove plug (27) . 20. Remove bolts (26) . 21. Remove cover (28) and O-ring seal (25) from cooler bypass elbow (17) . 22. Remove spring (24) and bypass valve (23) from cooler bypass elbow (17) .

DISASSEMBLY AND ASSEMBLY

037

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Cooler - Install Installation Procedure

Illustration 1

g00999942

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 1. Install bypass valve (23) and spring (24) into cooler bypass elbow (17) . 2. Install cover (28) and O-ring seal (25) onto cooler bypass elbow (17) . 3. Install bolts (26) . 4. Install plug (27) .

Illustration 2

g00999941

5. Attach a suitable lifting device to engine oil cooler (11) . 6. Install cooler bypass elbow (17) onto engine oil cooler (11) . 7. Install bolts (22) . 8. Install bonnet (13) and the gasket on engine oil cooler (11). Install bolts (21) .

Illustration 3

g00999940

9. Position the gasket and bonnet (10) onto engine oil cooler (11). Install bolts (20) . 10. Install tube assembly (18) . 11. Install bolts (19) .

Illustration 4

g00999938

Illustration 5

g00999939

12. Position engine oil cooler (11). The weight of the engine oil cooler is approximately 104 kg (230 lb). 13. Position bonnet (13) and cooler bypass elbow (17) onto tube assembly (14) and tube assembly (16) . 14. Install bolts (12) and bolts (15) .

Illustration 6

15. Connect tube assembly (9) to bonnet (10) .

g00999936

Illustration 7

16. Connect elbow (7) . 17. Install bolts (6) and bolts (8) .

g01060632

Illustration 8

18. Install tube assembly (5) . 19. Install tube assembly (4) and joint assembly (3) .

g00999934

Illustration 9

g00999933

20. Install plates (1) and shield assemblies (2) . 21. Refill the cooling system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

DISASSEMBLY AND ASSEMBLY

038

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Filter Base - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

2

B

185-3630

Filter Wrench Assembly

1

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 1

g01000488

1. Remove plates (1) and shield assemblies (2) . 2. Disconnect harness assemblies (3) from base assembly (4) . 3. Use Tooling (B) to remove engine oil filter assemblies (5) from base assembly (4) .

Illustration 2

4. Remove bolts (7) and bolts (8) in order to remove bracket (6) .

g01000489

Illustration 3

g01000490

Illustration 4

g01000491

5. Attach Tooling (A) and a suitable lifting device to base assembly (4) . 6. Remove bolts (9) in order to disconnect base adapter (10) and the gasket from base assembly (4) .

Illustration 5

g01000492

7. Remove bolts (11) in order to remove base assembly (4) . The weight of the base assembly is approximately 41 kg (90 lb).

DISASSEMBLY AND ASSEMBLY

039

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Filter Base - Disassemble Disassembly Procedure Start By: A. Remove the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base Remove".

Illustration 1

g01001687

1. Remove bolts (1) in order to remove bracket (2) from base assembly (3) .

Illustration 2

g01001688

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 2. Remove bolts (5) in order to remove covers (4) and the gasket from base assembly (3) . 3. Remove springs (7) and plungers (6) from base assembly (3) .

DISASSEMBLY AND ASSEMBLY

040

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Filter Base - Assemble Assembly Procedure

Illustration 1

g01001688

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 1. Install springs (7) and plungers (6) into base assembly (3) . 2. Position covers (4) and the gasket onto base assembly (3) . 3. Install bolts (5) .

Illustration 2

g01001687

4. Position bracket (2) onto base assembly (3) . 5. Install bolts (1) . End By: Install the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base Install".

DISASSEMBLY AND ASSEMBLY

041

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Filter Base - Install Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

2

B

185-3630

Filter Wrench Assembly

1

Illustration 1

g01000492

1. Attach Tooling (A) and a suitable lifting device to base assembly (4) . 2. Position base assembly (4) . The weight of the base assembly is approximately 41 kg (90 lb). 3. Install bolts (11) .

Illustration 2

g01000491

Illustration 3

g01000490

4. Position base adapter (10) and the gasket in order to connect base assembly (4) . 5. Install bolts (9) . 6. Remove Tooling (A) .

Illustration 4

7. Position bracket (6) . 8. Install bolts (8) and bolts (7) .

g01000489

Illustration 5

g01000488

9. Use Tooling (B) to install engine oil filter assemblies (5) onto base assembly (4) . 10. Connect harness assemblies (3) onto base assembly (4) . 11. Install shield assemblies (2) and plates (1) .

DISASSEMBLY AND ASSEMBLY

042

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil and Water Pump Drive - Remove Removal Procedure Start By: A. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove". B. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".

Illustration 1

1. Remove bolts (2) . 2. Remove adapter assembly (1) and the O-ring seal.

g00994050

Illustration 2

3. Remove bolts (3) . 4. Remove adapter assembly (4) and the O-ring seal.

g00994051

DISASSEMBLY AND ASSEMBLY

043

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil and Water Pump Drive - Disassemble Disassembly Procedure Table 1 Required Tools Tool A

Part Number

Part Description

1P-0520

Driver Gp

Qty 1

Start By: A. Remove the engine oil and water pump drive. Refer to Disassembly and Assembly, "Engine Oil and Water Pump Drive - Remove".

Illustration 1

g00994064

1. Remove O-ring seal (3) from adapter assembly (2) . 2. Use Tooling (A) in order to remove bearing (1) from adapter assembly (2) .

Illustration 2

3. Remove bolts (5) . 4. Remove thrust washers (7) from adapter assembly (4) . 5. Remove adapter assembly (4) from shaft assembly (6) .

g00994065

Illustration 3

6. Remove bolts (8) . 7. Remove gear (9) from shaft assembly (6) .

g00994066

Illustration 4

g00994070

8. Remove O-ring seals (11) from adapter assembly (4) . 9. Use Tooling (A) in order to remove bearing (10) from adapter assembly (4) .

DISASSEMBLY AND ASSEMBLY

044

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil and Water Pump Drive - Assemble Assembly Procedure Table 1 Required Tools Tool

Part Number

A

1P-0520

Part Description Driver Gp

Qty 1

Illustration 1

g00994070

1. Lower the temperature of bearing (10) . 2. Use Tooling (A) in order to install bearing (10) into adapter assembly (4) . The oil hole in the bearing must align with the hole in the adapter assembly. The bearing must not project above the adapter assembly. After assembly, the inner diameter of the bearing must be 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch). 3. Install O-ring seals (11) onto adapter assembly (4) .

Illustration 2

4. Install gear (9) onto shaft assembly (6) . 5. Install bolts (8) .

g00994066

Illustration 3

6. Install adapter assembly (4) onto shaft assembly (6) . 7. Position thrust washers (7) onto adapter assembly (4) . 8. Install bolts (5) .

g00994065

Illustration 4

g00994064

9. Lower the temperature of bearing (1) . 10. Use Tooling (A) in order to install bearing (1) into adapter assembly (2) . After assembly, the inner diameter of the bearing must be 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch). 11. Install O-ring seal (3) onto adapter assembly (2) . End By: Install the engine oil and water pump drive. Refer to Disassembly and Assembly, "Engine Oil and Water Pump Drive - Install".

DISASSEMBLY AND ASSEMBLY

045

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil and Water Pump Drive - Install Installation Procedure

Illustration 1

1. Position the O-ring seal and adapter assembly (4) . 2. Install bolts (3) .

g00994051

Illustration 2

g00994050

3. Position the O-ring seal and adapter assembly (1) . 4. Install bolts (2) . End By: a. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install". b. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".

DISASSEMBLY AND ASSEMBLY

046

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Pan - Remove Removal Procedure 1. Drain the oil into a suitable container.

Illustration 1

g01003122

2. Remove bolts (3) . 3. Position flange (1) and the O-ring seal out of the way from engine oil pump (2) .

Illustration 2

4. Remove bolts (4) .

g01003123

Illustration 3

g01003125

5. Attach a suitable lifting device to the engine. 6. Remove bolts (5) . 7. Remove the engine from the engine oil pan (6). The weight of the 3516 engine is approximately 7500 kg (16500 lb). The weight of the 3520 engine is approximately 10000 kg (22000 lb). 8. Position the engine onto suitable cribbing.

Illustration 4

9. Remove gasket (7) from engine oil pan (6) .

g01003126

DISASSEMBLY AND ASSEMBLY

047

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Pan - Disassemble Disassembly Procedure Start By: A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove".

Illustration 1

1. Remove adapter (1) and cover assembly (2) .

g01003031

Illustration 2

g01003032

2. Remove screen assembly (3) from adapter (1) . 3. Remove the O-ring seals from adapter (1) and cover assembly (2) .

Illustration 3

g01003033

4. Remove bolts (5) in order to remove connector (6) and the O-ring seals. 5. Remove bolts (4), bolts (7), and bolts (10) in order to remove tube assembly (11), housing (12), tube (8), elbow (9), and the O-ring seals.

DISASSEMBLY AND ASSEMBLY

048

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Pan - Assemble Assembly Procedure

Illustration 1

g01003033

1. Position tube assembly (11), housing (12), tube (8), elbow (9), and the O-ring seals. 2. Install bolts (4), bolts (7), and bolts (10). Tighten bolts (4) and bolts (7) to a torque of 47 ± 9 N·m (35 ± 7 lb ft). 3. Position connector (6) and the O-ring seals. 4. Install bolts (5) .

Illustration 2

g01003032

5. Install the O-ring seals onto adapter (1) and cover assembly (2) . 6. Install screen assembly (3) onto adapter (1) .

Illustration 3

g01003031

7. Install adapter (1) and cover assembly (2). Tighten the bolts to a torque of 47 ± 9 N·m (35 ± 7 lb ft). End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Install".

DISASSEMBLY AND ASSEMBLY

049

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Pan - Install Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

A

8T-9014

Silicone Sealant

1

B

9U-5839

Liquid Gasket

1

Illustration 1

Qty

g01003126

1. Apply Tooling (A) and Tooling (B) to the gasket and to the welded joints on the oil pan. 2. Install gasket (7) onto engine oil pan (6) .

Illustration 2

g01003125

3. Attach a suitable lifting device to the engine. 4. Position the engine onto engine oil pan (6). The weight of the 3516 engine is approximately 7500 kg (16500 lb). The weight of the 3520 engine is approximately 10000 kg (22000 lb). 5. Install bolts (5) .

Illustration 3

6. Install bolts (4) .

g01003123

Illustration 4

g01003122

7. Position flange (1) and the O-ring seal onto engine oil pump (2) . 8. Install bolts (3) . 9. Fill the engine with oil. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

DISASSEMBLY AND ASSEMBLY

050

G3516E Service manual (GAS)

Media Number -KENR5271-04

Engine Oil Sequence Valves - Remove and Install Removal Procedure Start By: A. Remove the front drive housing. Refer to Disassembly and Assembly, "Front Drive Housing Remove and Install" or Disassembly and Assembly, "Drive Housing (Front) - Remove and Install". B. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing Remove".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g00912963

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 1. Remove cover (1) from the front of the cylinder block. 2. Remove plunger assembly (2) and spring (3) from the front of the cylinder block.

Illustration 2

g00912966

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 3. Remove the idler gear and the shaft. Remove cover (4) on the rear of the cylinder block.

Illustration 3

g00912969

4. Remove plunger assembly (5) and spring (6) from the rear of the cylinder block.

Installation Procedure

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 4

g00912969

1. Place clean engine oil on spring (6) and plunger assembly (5) . 2. Install spring (6) and plunger assembly (5) .

Illustration 5

g00912966

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 3. Install cover (4) on the rear of the cylinder block. Install the idler gear and the shaft.

Illustration 6

g00912963

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 4. Place clean engine oil on spring (3) and plunger assembly (2) . 5. Install spring (3) and plunger assembly (2) on the front of the cylinder block. 6. Install cover (1) on the front of the cylinder block. End By: a. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Install". b. Install the front drive housing. Refer to Disassembly and Assembly, "Front Drive Housing Remove and Install" or Disassembly and Assembly, "Drive Housing (Front) - Remove and Install".

DISASSEMBLY AND ASSEMBLY

051

G3516E Service manual (GAS)

Media Number -KENR5271-04

Drive Housing (Front) - Remove and Install Removal Procedure Table 1 Required Tools Tool

Part Number

A

138-7575

Part Description Link Bracket

Qty 7

Start By: A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove". B. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove". C. Remove the crankshaft front seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Front Seal and Wear Sleeve - Remove". D. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove". E. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove". F. Remove the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water Pump Remove". G. Remove the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install".

Illustration 1

1. Remove elbow (1) and the gasket. 2. Remove elbow (3) from front cover (2) .

g01066049

Illustration 2

3. Remove cover (4) and the gasket from front housing (2) . 4. Remove covers (5) and the O-ring seals from front housing (2) .

g01066050

Illustration 3

5. Remove clips (6) from front housing (2) .

g01066051

Illustration 4

g01066052

6. Attach Tooling (A) and a suitable lifting device to front housing (2) . 7. Remove bolts (7) from idler shafts (8) . Note: Do not remove bolts (10) from idler shafts (8) . Idler gears (9) do not need to be removed.

Illustration 5

g01066053

8. Remove bolts (11) from front housing (2) . 9. Remove bolts (12) from front housing (2) . 10. Remove front housing (2) and the gasket from the engine. The weight of front housing (2) is approximately 255 kg (560 lb).

Installation Procedure Table 2 Required Tools Tool

Part Number

A

138-7575

Part Description Link Bracket

Qty 7

Illustration 6

g01066053

1. Attach Tooling (A) and a suitable lifting device to front housing (2) . 2. Position front housing (2) and the gasket onto the engine. The weight of front housing (2) is approximately 255 kg (560 lb). Note: The idler gears will need to be aligned. 3. Install bolts (12) into front housing (2) . 4. Install bolts (11) into front housing (2) .

Illustration 7

g01066052

5. Install bolts (7) into idler shafts (8) . Note: Bolts (10) and idler shafts (8) were not removed. Idler gears (9) were not removed. 6. Remove Tooling (A) from front housing (2) .

Illustration 8

7. Install clips (6) onto front housing (2) .

g01066051

Illustration 9

8. Install the O-ring seals and covers (5) onto front housing (2) . 9. Install the gasket and cover (4) onto front housing (2) .

g01066050

Illustration 10

g01066049

10. Install elbow (3) onto front cover (2) . 11. Install the gasket and elbow (1) . End By: a. Install the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install". b. Install the auxiliary water pump. Refer to Disassembly and Assembly, "Auxilary Water Pump Install". c. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install". d. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install". e. Install the crankshaft front seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Front Seal and Wear Sleeve - Install". f. Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install". g. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Install".

DISASSEMBLY AND ASSEMBLY

052

G3516E Service manual (GAS)

Media Number -KENR5271-04

Vibration Damper - Remove and Install Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

2

B

1U-9200

Lever Puller Hoist

1

Illustration 1

1. Remove bolts (1) in order to remove guard (2) . 2. Remove shield assembly (3) .

g00997926

Illustration 2

g00997927

Illustration 3

g00997930

3. Remove two bolts (4) from vibration damper (5) . Attach Tooling (A) , Tooling (B) , and a suitable lifting device to vibration damper (5) . The weight of vibration damper (5) is approximately 204 kg (450 lb). 4. Use Tooling (B) in order to apply equal tension to the suitable lifting device.

Illustration 4

g00997928

5. Remove bolts (6) in order to remove vibration damper (5) . Remove the adapter from the engine.

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

2

B

1U-9200

Lever Puller Hoist

1

Illustration 5

g00997930

1. Attach Tooling (A) , Tooling (B) , and a suitable lifting device to vibration damper (5) . The weight of vibration damper (5) is approximately 204 kg (450 lb). Use Tooling (B) in order to apply equal tension to the suitable lifting device. 2. Position the adapter and vibration damper (5) on the engine.

Illustration 6

g00997928

3. Install bolts (6) onto vibration damper (5) . Tighten bolts (6) to a torque of 1125 ± 100 N·m (830 ± 75 lb ft).

Illustration 7

g00997927

4. Remove Tooling (A) and install two bolts (4) onto vibration damper (5) .

Illustration 8

5. Install shield assembly (3) . 6. Position guard (2) . 7. Install bolts (1) .

g00997926

DISASSEMBLY AND ASSEMBLY

053

G3516E Service manual (GAS)

Media Number -KENR5271-04

Flywheel - Remove and Install Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

9S-9082

Engine Turning Tool

1

B

6V-2078

Stud

2

C

8T-3207

Lifting Bracket

1

Illustration 1

1. Remove cover (1) and the gasket. 2. Remove timing pointer (2) .

g01000245

Illustration 2

3. Remove cover (3) .

g01000246

Illustration 3

g01000247

Illustration 4

g01000249

4. Use Tooling (A) in order to rotate flywheel (4) until Hole (X) is off-center. Note: Rotating the flywheel will aid later when Tooling (C) is installed. 5. Remove two bolts (5) .

Illustration 5

6. Install Tooling (B) . 7. Remove remaining bolts (5) from flywheel (4) . 8. Move flywheel (4) away from the engine onto Tooling (B) .

g01000250

Illustration 6

g01000253

9. Attach Tooling (C) and a suitable lifting device to flywheel (4) . The weight of flywheel (4) is approximately 172 kg (380 lb). 10. Remove flywheel (4) .

Illustration 7

g01000256

11. Remove ring gear (6) from flywheel (4) .

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

B

6V-2078

Stud

2

C

8T-3207

Lifting Bracket

1

D

6V-7820

Torque Multiplier Gp

1

Illustration 8

1. Install Tooling (B) .

g01000442

Illustration 9

g01000447

2. Raise the temperature of ring gear (6) . 3. Install ring gear (6) onto flywheel (4) with the beveled side facing inward.

Illustration 10

g01000253

4. Attach Tooling (C) and a suitable lifting device to flywheel (4) . The weight of flywheel (4) is approximately 172 kg (380 lb). 5. Position flywheel (4) .

Illustration 11

g01000250

6. Lubricate bolts (5) with engine oil. 7. Install bolts (5) into flywheel (4) . 8. Remove Tooling (B) . 9. Install remaining bolts (5) . Use Tooling (D) in order to tighten bolts (5) to a torque of 1150 ± 60 N·m (848 ± 44 lb ft).

Illustration 12

10. Install cover (3) .

g01000246

Illustration 13

11. Install timing pointer (2) . 12. Install cover (1) and the gasket.

g01000245

DISASSEMBLY AND ASSEMBLY

054

G3516E Service manual (GAS)

Media Number -KENR5271-04

Flywheel Housing - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

147-6456

Wedge Removal Tool

1

B

138-7573

Link Bracket

4

C

138-7574

Link Bracket

1

9U-6600

Hand Hydraulic Pump

1

8B-7548

Push-Puller Tool Gp

1

8B-7559

Adapter

2

1P-0820

Hydraulic Puller

1

5H-1504

Hard Washer

3

D

E

138-7575

Link Bracket

2

F

6V-2078

Stud

2

G

169-5464

Quick Cure Primer

-

Start By: A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove". B. Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod - Remove". 1. Use the timing pins in order to properly time the engine. Refer to Testing and Adjusting, "Camshaft Timing". Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".

Illustration 1

g01229405

2. Remove cover (1) .

Illustration 2

3. Use Tooling (A) in order to disconnect harness assemblies (2) . 4. Pull harness assemblies (2) through bracket (3) . 5. Disconnect harness assemblies (4) from bracket (3) .

g00998300

6. Attach Tooling (B) and a suitable lifting device to bracket (3) . The weight of bracket (3) is approximately 36 kg (80 lb). 7. Remove bolts (5) and bracket (3) .

Illustration 3

g00998302

8. Remove bolts (6) and bolts (8) . 9. Remove elbow (7) and the gasket. 10. Remove bolts (10) . 11. Disconnect connector (9) and the O-ring seal.

Illustration 4

g00998303

12. Remove bolts (11) . 13. Disconnect adapter (12) and the gaskets. 14. Disconnect harness assemblies (13) . 15. Remove bolts (15) . 16. Disconnect connector (14) and the O-ring seal.

Illustration 5

g00998304

Illustration 6

g00998305

17. Attach Tooling (B) and a suitable lifting device to regulator housing assembly (16) . The weight of regulator housing assembly (16) is approximately 100 kg (220 lb). 18. Remove bolts (17) . 19. Remove regulator housing assembly (16) .

Illustration 7

g00998306

Illustration 8

g00998307

20. Remove bolts (18) . 21. Remove bracket assembly (19) .

Illustration 9

g00998308

22. Disconnect harness assemblies (20) from engine monitoring control (21) . 23. Remove bolts (22) . 24. Remove engine monitoring control (21) and bracket (23) .

Illustration 10

g00998309

25. Remove bolts (24) . 26. Position bracket (25) out of the way.

Illustration 11

g00998311

27. Remove brackets (26) .

Illustration 12

28. Remove timing pointer (26A) .

g01054295

Illustration 13

g01002798

29. Attach Tooling (C) and a suitable lifting device to flywheel (28) . The weight of flywheel (28) is approximately 172 kg (380 lb). 30. Remove two bolts (27) . Install Tooling (F) . 31. Remove remaining bolts (27) . 32. Remove flywheel (28) .

Illustration 14

g01002799

33. Remove cover assemblies (29) . 34. Remove the crankshaft rear seal and wear sleeve (30) . Refer to Disassembly and Assembly, "Crankshaft Rear Seal and Wear Sleeve - Remove".

Illustration 15

g01002800

35. Remove speed sensor (31) .

Illustration 16

g01002801

36. Remove bolt (32) and timing ring (33) .

Illustration 17

g01002802

37. Remove bolt (34) and plate (35) from camshaft drive gear (36) .

Illustration 18

g01002803

38. Place the three washers of Tooling (D) behind plate (35) and install the bolt and plate (35) to camshaft drive gear (36) .

NOTICE Do not apply more than 51675 kPa (7500 psi) pressure to the hydraulic puller. The adapters are rated at 6 1/2 tons each and the hydraulic puller is rated at 17 tons at 68900 kPa (10000 psi). If too much pressure is applied, the gear may be damaged. 39. Install Tooling (D) on camshaft drive gear (36) . Apply 51675 kPa (7500 psi) to the puller. Use a hammer to tap the head of the puller screw on Tooling (D) . This will break camshaft drive gear (36) free from the camshaft. 40. Repeat Step 38 through Step 39 for the remaining gear.

Illustration 19

g01002804

41. Attach Tooling (E) and a suitable lifting device to flywheel housing (37) . The weight of flywheel housing (37) is approximately 245 kg (540 lb).

Illustration 20

g01002926

42. Remove bolts (38) , bolts (39) , bolts (41) , bolts (42) , bolts (43) , and bolts (44) . 43. Remove flywheel housing (37) . 44. Remove gasket (40) from flywheel housing (37) . 45. After removing flywheel housing (37) , clean the mating surface of the cylinder block and the mating surface of the flywheel housing with Tooling (G) . If necessary, use a gasket scraper and a solvent in order to remove any residual gasket material. Both mating surfaces must be clean, dry, and free of any oil before installation.

DISASSEMBLY AND ASSEMBLY

055

G3516E Service manual (GAS)

Media Number -KENR5271-04

Flywheel Housing - Install Installation Procedure Table 1 Required Tools Tool

Part Number

B

138-7573

Link Bracket

4

C

138-7574

Link Bracket

1

9U-6600

Hand Hydraulic Pump

1

8B-7548

Push-Puller Tool Gp

1

8B-7559

Adapter

2

1P-0820

Hydraulic Puller

1

5H-1504

Hard Washer

3

D

Part Description

Qty

E

138-7575

Link Bracket

2

F

6V-2078

Stud

2

H

238-9586

Camshaft Drive Group

1

J

185-3984 or 4C-5300

Gasket Sealant

-

(1)

(1)

EAME

Note: Refer to Engine News27 March 2006, "Sealing and Installing the Flywheel Housing" for more information. 1. Ensure that the mating surface of the flywheel housing and the engine block are clean. Both mating surfaces must be clean, dry, and free of any oil before Tooling (J) is applied.

Illustration 1

g01259790

2. Apply a 6.0 mm (0.25 inch) bead of Tooling (J) to the mating surface of the flywheel housing. Refer to Illustration 1.

Illustration 2

g01002804

3. Attach Tooling (E) and a suitable lifting device to flywheel housing (37) . The weight of flywheel housing (37) is approximately 245 kg (540 lb).

Illustration 3

g01259792

4. Position flywheel housing (37) . 5. Install bolts (38) , bolts (39) , bolts (41) , bolts (42) , bolts (43) , bolts (44) , and the hard washers. Tighten the 1/2 - NC bolts to a torque of 135 ± 20 N·m (100 ± 15 lb ft). Tighten the 5/8 - NC bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft). 6. Install the crankshaft rear seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Rear Seal and Wear Sleeve - Install".

Illustration 4

g01002798

7. Attach Tooling (C) and a suitable lifting device to flywheel (28) . The weight of flywheel (28) is approximately 172 kg (380 lb).

8. Install Tooling (F) . 9. Position flywheel (28) . 10. Install bolts (27) . 11. Remove Tooling (F) . 12. Install remaining bolts (27) . Tighten bolts (27) to a torque of 1150 ± 60 N·m (840 ± 44 lb ft).

Illustration 5

13. Install timing pointer (26A) .

g01002797

Illustration 6

g01004334

14. Remove access covers (45) from both sides of the rear of the engine.

Illustration 7

g01004348

NOTICE If the camshaft is out of time more than 18 degrees (approximately 1/2 of the timing pin is out of the groove), the valves can make contact with the pistons. This will cause damage to the engine. Refer to Testing and Adjusting, "Camshaft Timing" for more information. 15. Remove timing pin (46) from the storage position on the side of the engine. 16. Turn the camshaft until timing pin (46) can be installed through the cylinder block and into groove (47) that is the camshaft. 17. Repeat Steps 15 through Steps 16 for the camshaft on the opposite side of the engine.

Illustration 8

g01004357

18. Remove bolts (49) , cover (48) , and plug (50) .

Illustration 9

g01259794

19. Install bolt (49) into the flywheel housing through the hole for plug (50) . Use Tooling (H) and a ratchet to turn the flywheel until bolt (49) can be installed through the hole and into the flywheel. This will position the No.1 cylinder at the top center. Refer to the Testing and the Adjusting Module for more information.

Illustration 10

g01002802

Illustration 11

g01002801

20. Use the following procedure in order to install camshaft drive gears (36) . a. Clean the taper of the camshaft and clean the tapered bore of the camshaft gear with a lint free cloth that is saturated with a solvent in order to remove any excess oil. Clean the parts

b. c.

d. e. f. g. h. i. j.

again with a lint free alcohol wipe in order to remove any residue. If the alcohol wipe is dirty after cleaning the parts, clean the parts again with a lint free alcohol wipe until no residue is left on the alcohol wipe. Note: It is critical that the taper of the camshaft and the tapered bore of the camshaft gear are clean, dry, and free of residue before assembly. Ensure that the camshaft timing pins and the timing pin for the flywheel are installed. Place camshaft drive gears (36) in position. Remove the backlash by rotating the gears in the opposite direction of engine rotation. Note: For "Standard Rotation" engines, turn the camshaft drive gears CLOCKWISE. For "Reverse Rotation" engines, turn the camshaft drive gears COUNTERCLOCKWISE. Install bolt (34) and plate (35) . Install bolt (32) and timing ring (33) . Ensure that the hole in the timing ring is properly seated on the locating pin. Tighten the bolt to a torque of 360 N·m (265 lb ft). Place a Mark on the bolt. Place a driver against the retaining plate of the camshaft gear. Strike the driver solidly with a hammer 3 to 4 times. Tighten the bolt again to a torque of 360 N·m (265 lb ft). Repeat Steps 20.h and 20.i until the Mark has turned at least 90 degrees.

21. Remove the timing pins and return the timing pins to the storage position.

Illustration 12

g01004357

22. Install the access covers to both sides of the engine. Remove bolt (49) from the flywheel and install plug (50) , cover (48) , and bolts (49) .

Illustration 13

g01002800

23. Install speed sensor (31) . Refer to Systems Operation, "Engine Speed/Timing Sensor".

Illustration 14

g01229467

24. Install cover assemblies (29) .

Illustration 15

g00998311

25. Install brackets (26) .

Illustration 16

g00998309

26. Position bracket (25) . 27. Install bolts (24) .

Illustration 17

g00998308

28. Position engine monitoring control (21) and bracket (23) . 29. Install bolts (22) . 30. Connect harness assemblies (20) to engine monitoring control (21) .

Illustration 18

g00998306

Illustration 19

g00998307

31. Position bracket assembly (19) . 32. Install bolts (18) .

Illustration 20

g00998304

33. Attach Tooling (B) and a suitable lifting device to regulator housing assembly (16) . The weight of regulator housing assembly (16) is approximately 100 kg (220 lb). 34. Position regulator housing assembly (16) .

Illustration 21

g00998305

35. Install bolts (17) .

Illustration 22

g00998303

36. Position connector (14) and the O-ring seal. 37. Install bolts (15) . 38. Connect harness assemblies (13) . 39. Position adapter (12) and the gaskets. 40. Install bolts (11) .

Illustration 23

g00998302

41. Position connector (9) and the O-ring seals. 42. Install bolts (10) . 43. Position elbow (7) and the gaskets. 44. Install bolts (6) and bolts (8) .

Illustration 24

g00998300

45. Attach Tooling (B) and a suitable lifting device to bracket (3) . The weight of bracket (3) is approximately 36 kg (80 lb). 46. Position bracket (3) . 47. Install bolts (5) . 48. Connect harness assemblies (4) onto bracket (3) . 49. Position harness assemblies (2) onto bracket (3) . 50. Connect harness assemblies (2) .

Illustration 25

g01229405

51. Install cover (1) . End By: a. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod - Install". b. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Install".

DISASSEMBLY AND ASSEMBLY

056

G3516E Service manual (GAS)

Media Number -KENR5271-04

Crankshaft Front Seal and Wear Sleeve - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

1U-7600

Slide Hammer Puller

1

B

1U-7325

Distorter Adapter

1

C

5P-7409

Sleeve Distorter

1

Start By: A. Remove the vibration damper. Refer to Disassembly and Assembly, "Vibration Damper - Remove and Install".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Every time that the crankshaft seal is removed from the wear sleeve, a new wear sleeve and crankshaft seal must be installed.

Illustration 1

g00659180

1. Drill three evenly spaced holes in crankshaft front seal (1) and use Tooling (A) to remove crankshaft front seal (1) from the front housing.

Illustration 2

g00659181

2. Insert Tooling (B) between the front housing and wear sleeve (2) .

NOTICE The use of excessive force on the sleeve distorter can cause the distorter adapter to crack the housing. To help avoid damage to the engine, do not use excessive force to remove the wear sleeve. 3. Insert Tooling (C) between Tooling (B) and wear sleeve (2) . Carefully turn Tooling (C) until the edge of the tool creates a crease in wear sleeve (2) . Repeat this procedure several times around wear sleeve (2) until wear sleeve (2) can be removed by hand.

DISASSEMBLY AND ASSEMBLY

057

G3516E Service manual (GAS)

Media Number -KENR5271-04

Crankshaft Front Seal and Wear Sleeve - Install Installation Procedure Table 1 Required Tools Tool

Part Number 6V-4003

Part Description

Qty

Seal Locator As

1

Bolt

2

D 2N-5006 E

8T-3099

Seal Installer

1

F

9S-8858

Nut

1

G

169-5464

Quick Cure Primer

1

H

4C-9507

Retaining Compound

1

J

1P-0808

Multipurpose Grease

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Every time that the crankshaft seal is removed from the wear sleeve, a new wear sleeve and crankshaft seal must be installed.

Illustration 1

Illustration 2

g01005029

g01207497

1. Attach Tooling (D) to the crankshaft. 2. Clean the outer diameter of the crankshaft and the inner diameter of the new wear sleeve with Tooling (G) .

3. Apply Tooling (H) to the outer diameter of the crankshaft and the inner diameter of the new wear sleeve.

NOTICE If the crankshaft seal and the wear sleeve come apart during installation, the crankshaft seal and the wear sleeve must be replaced.

Note: The front crankshaft seal and the wear sleeve cannot be interchanged with the rear crankshaft seal and the wear sleeve.

NOTICE Do not place engine oil on the crankshaft seal for installation. Lubrication of the crankshaft seal can give a false indication of leakage at a later time.

Illustration 3

g01207499

4. Place front seal (1) and wear sleeve (2) onto Tooling (D) .

Illustration 4

Illustration 5

g01051474

g01005047

5. Place Tooling (E) onto Tooling (D). Apply Tooling (J) onto the face of the washer on Tooling (F). Install Tooling (F) onto Tooling (E). Tighten the nut until Tooling (E) contacts Tooling (D) . 6. Remove the tooling from the crankshaft. End By: Install the vibration damper. Refer to Disassembly and Assembly, "Vibration Damper - Remove and Install".

DISASSEMBLY AND ASSEMBLY

058

G3516E Service manual (GAS)

Media Number -KENR5271-04

Crankshaft Rear Seal and Wear Sleeve - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

1U-7600

Slide Hammer Puller

1

B

6V-3143 or 1U-7325

Distorter Adapter

1

C

5P-7409

Sleeve Distorter

1

Start By: A. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove and Install".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Every time that the crankshaft seal is removed from the wear sleeve, a new wear sleeve and crankshaft seal must be installed.

Illustration 1

g00659239

1. Drill three evenly spaced holes in crankshaft rear seal (1) . Use Tooling (A) in order to remove crankshaft rear seal (1) .

Illustration 2

g00659240

2. Insert Tooling (B) between the rear housing and wear sleeve (2) .

NOTICE The use of excessive force on the sleeve distorter can cause the distorter adapter to crack the housing. To help avoid damage to the engine, do not use excessive force to remove the wear sleeve. 3. Insert Tooling (C) between Tooling (B) and wear sleeve (2) . Carefully turn Tooling (C) until the edge of the tool causes a crease in wear sleeve (2) . Repeat this procedure several times around wear sleeve (2) until wear sleeve (2) can be removed by hand.

DISASSEMBLY AND ASSEMBLY

059

G3516E Service manual (GAS)

Media Number -KENR5271-04

Crankshaft Rear Seal and Wear Sleeve - Install Installation Procedure Table 1 Required Tools Tool

Part Number 6V-4003

Part Description

Qty

Seal Locator As

1

Bolt

2

D 2N-5006 E

8T-3099

Seal Installer

1

F

9S-8858

Nut

1

G

169-5464

Quick Cure Primer

1

H

4C-9507

Retaining Compound

1

J

1P-0808

Multipurpose Grease

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Every time that the crankshaft seal is removed from the wear sleeve, a new wear sleeve and crankshaft seal must be installed.

Illustration 1

Illustration 2

g01005029

g01005030

1. Attach Tooling (D) to the crankshaft. 2. Clean the outer diameter of the crankshaft and the inner diameter of the new wear sleeve with Tooling (G) .

3. Apply Tooling (H) to the outer diameter of the crankshaft and the inner diameter of the new wear sleeve.

NOTICE If the crankshaft seal and the wear sleeve come apart during installation, the crankshaft seal and the wear sleeve must be replaced.

Note: The rear crankshaft seal and the wear sleeve cannot be interchanged with the front crankshaft seal and the wear sleeve.

NOTICE Do not place engine oil on the crankshaft seal for installation. Lubrication of the crankshaft seal can give a false indication of leakage at a later time.

Illustration 3

g01207617

4. Place rear seal (1) and the wear sleeve (2) onto Tooling (D) .

Illustration 4

Illustration 5

g01051474

g01005035

5. Place Tooling (E) onto Tooling (D). Apply Tooling (J) onto the face of the washer on Tooling (F). Install Tooling (F) onto Tooling (E). Tighten the nut until Tooling (E) contacts Tooling (D) . 6. Remove the tooling from the crankshaft. End By: Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove and Install".

DISASSEMBLY AND ASSEMBLY

060

G3516E Service manual (GAS)

Media Number -KENR5271-04

Accessory Drive (Front) - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

8B-7557

Threaded Adapter

1

1P-0074

Slide Hammer Puller Gp

1

A

Start By: A. Remove the auxiliary water pump. Refer to Disassembly and Assembly, "Auxillary Water Pump Remove". B. Remove the vibration damper. Refer to Disassembly and Assembly, "Vibration Damper - Remove and Install". Note: The vibration damper does not need to be removed if the idler gear does not need to be removed.

Illustration 1

g00993333

1. Remove cover (1) and the O-ring seals. 2. Remove cover (2) and the gasket.

Illustration 2

3. Remove bolts (3) . 4. Remove adapter assembly (4) .

g00993334

Illustration 3

5. Remove bolts (5) . 6. Remove gear (6) from auxiliary drive shaft (7) .

g00993335

Illustration 4

g00993336

7. Remove bolts (8) . 8. Remove adapter assembly (9) and the O-ring seals. Auxiliary drive shaft (7) is attached to adapter assembly.

Illustration 5

9. Remove bolts (10) and bolts (11) from idler shaft (12) .

g00993337

Illustration 6

10. Use Tooling (A) in order to remove idler shaft (12) . 11. Remove idler gear (13) .

g00993338

Illustration 7

12. Remove washer assembly (14) .

g00993339

DISASSEMBLY AND ASSEMBLY

061

G3516E Service manual (GAS)

Media Number -KENR5271-04

Accessory Drive (Front) - Disassemble Disassembly Procedure Table 1 Required Tools Tool A

Part Number

Part Description

1P-0520

Driver Gp

Qty 1

Start By: A. Remove the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive (Front) Remove".

Illustration 1

g00993341

1. Remove O-ring seals (3) from adapter assembly (1) . 2. Use Tooling (A) in order to remove bearing (2) from adapter assembly (1) .

Illustration 2

3. Remove bolts (5) . 4. Remove thrust washers (6) . 5. Remove auxiliary drive shaft (4) from adapter assembly (7) .

g00993342

Illustration 3

6. Remove O-ring seals (9) from adapter assembly (7) . 7. Use Tooling (A) in order to remove bearing (8) .

g00993343

Illustration 4

8. Use Tooling (A) in order to remove bearing (10) from gear (11) .

g00993344

Illustration 5

9. Remove dowel (12) from washer (13) .

g00993345

Illustration 6

10. Remove O-ring seal (15) from idler shaft (14) .

g00993346

DISASSEMBLY AND ASSEMBLY

062

G3516E Service manual (GAS)

Media Number -KENR5271-04

Accessory Drive (Front) - Assemble Assembly Procedure

Illustration 1

1. Install O-ring seal (15) onto idler shaft (14) .

g00993346

Illustration 2

2. Install dowel (12) into washer (13) .

g00993345

Illustration 3

3. Lower the temperature of bearing (10) . 4. Install bearing (10) into gear (11) .

g00993344

Illustration 4

5. Install O-ring seals (9) into adapter assembly (7) . 6. Lower the temperature of bearing (8) . 7. Install bearing (8) into adapter assembly (7) .

g00993343

Illustration 5

8. Install auxiliary drive shaft (4) into adapter assembly (7) . 9. Position thrust washers (6) . 10. Install bolts (5) .

g00993342

Illustration 6

g00993341

11. Lower the temperature of bearing (2) . 12. Install bearing (2) . 13. Install O-ring seals (3) into adapter assembly (1) . End By: Install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive (Front) Install".

DISASSEMBLY AND ASSEMBLY

063

G3516E Service manual (GAS)

Media Number -KENR5271-04

Accessory Drive (Front) - Install Installation Procedure

Illustration 1

1. Position washer assembly (14) .

g00993339

Illustration 2

2. Position idler gear (13) and idler shaft (12) .

g00993340

Illustration 3

3. Install bolts (10) and bolts (11) into idler shaft (12) .

g00993337

Illustration 4

g00993336

4. Install adapter assembly (9) and the O-ring seals. Auxiliary drive shaft (7) is attached to adapter assembly. 5. Install bolts (8) .

Illustration 5

6. Position gear (6) onto auxiliary drive shaft (7) . 7. Install bolts (5) .

g00993335

Illustration 6

8. Position adapter assembly (4) . 9. Install bolts (3) .

g00993334

Illustration 7

g00993333

10. Position the gasket. Install cover (2) . 11. Position the O-ring seals. Install cover (1) . End By: a. Install the vibration damper. Refer to Disassembly and Assembly, "Vibration Damper - Remove and Install". b. Install the auxiliary water pump. Refer to Disassembly and Assembly, "Auxillary Water Pump Install".

DISASSEMBLY AND ASSEMBLY

064

G3516E Service manual (GAS)

Media Number -KENR5271-04

Gear Group (Rear) - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

A

1P-0520

Part Description

Qty

Driver Group

1

Start By: A. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Note: The following Step is for a 3508 Engine.

Illustration 1

g01056631

1. The engine must be put in time before the flywheel housing is removed. This is done in order to make sure that the rear gear group is in alignment with the rotation of the engine, as shown.

Illustration 2

g00913045

2. Remove plate (1) and gear (2) .

Illustration 3

g00913049

3. Use Tooling (A) and a suitable press to remove bearing (3) from gear (2) .

Illustration 4

g00913054

4. Remove the bolts, the washers, and camshaft idler gears (4) .

Illustration 5

g01051669

5. Remove washers (6) and shafts (5) from camshaft idler gears (4) . 6. Use Tooling (A) and a suitable press to remove bearings from camshaft idler gears (4) .

Illustration 6

g00913136

7. Remove the bolts from shaft (7) and remove shaft (7) .

Illustration 7

g00913137

8. Remove the bolts and crankshaft gear (8) from the end of the crankshaft.

DISASSEMBLY AND ASSEMBLY

065

G3516E Service manual (GAS)

Media Number -KENR5271-04

Gear Group (Rear) - Install Installation Procedure Table 1 Required Tools Tool

Part Number

A

1P-0520

Part Description Driver Gp

Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

1. Install crankshaft gear (8) and the bolts.

g00913137

Illustration 2

g00913136

2. Install shaft (7) and the bolts. The torque for the bolts is 140 ± 10 N·m (105 ± 5 lb ft).

Illustration 3

Illustration 4

g01051669

g01068502

(4) Camshaft Idler Gear. (9) Bearing. (E) 81.060 ± 0.010 mm (3.1913 ± 0.0004 inch). (F) 1.00 ± 0.25 mm (0.040 ± 0.010 inch).

3. Use Tooling (A) and a suitable press to install the bearings in camshaft idler gears (4) . Install bearing (9) into gear (4) to Depth (F) , as shown. 4. Machine the inside diameter of bearing (9) to Dimension (E) , as shown. Note: The surface finish of Bore (E) must be 0.8 micrometers. Pitch Diameter (H) must be concentric

with a total indicator reading of 0.12 mm (0.005 inch). Surface (G) of gear (4) must be square with Bore (E) within 0.05 mm (0.002 inch). 5. Place clean engine oil on the bearings and install shafts (5) with washers (6) on camshaft idler gears (4) .

Illustration 5

g00913054

6. Install camshaft idler gears (4) and the bolts.

Illustration 6

g01068516

(2) Cluster Idler Gear. (3) Bearing. (A) 75.060 ± 0.010 mm (2.9551 ± 0.0004 inch). (B) 1.5 ± 0.5 mm (0.06 ± 0.02 inch).

7. Use Tooling (A) and a suitable press to install bearing (3) in gear (2) . Install bearing (3) to Depth (B) , as shown.

8. Machine the inside diameter of the bearing to Dimension (A) , as shown. Note: The surface finish of Bore (A) must be 0.8 micrometers. Pitch Diameter (C) must be concentric with a total indicator reading of 0.15 mm (0.006 inch). Surface (D) of gear (2) must be square with Bore (A) within 0.05 mm (0.002 inch). Note: The following Step is for a 3508 Engine.

Illustration 7

g01056631

Note: When you install the rear cluster gear assembly to the crank gear, there are no timing marks on the G3512 and the G3516 engines. On the G3508 engines, the rear cluster gears have timing marks that must be aligned with the marks that are on the cluster gears. 9. Put clean engine oil on the bearing and install the gear assembly on the shaft. Make sure that the marks on the gear assembly and the crankshaft are in alignment with the rotation of the engine, as shown.

Illustration 8

g00913045

10. Place clean engine oil on gear (2) and install gear (2) on the engine. 11. Install plate (1) and the bolts. End By: Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Install".

DISASSEMBLY AND ASSEMBLY

066

G3516E Service manual (GAS)

Media Number -KENR5271-04

Crankcase Breather - Remove and Install Removal Procedure

Illustration 1

1. Remove clamps (1) in order to disconnect hoses (2) . 2. Remove clamps (4) in order to remove crankcase breathers (3) . 3. Remove crankcase breathers (3) .

Installation Procedure

g00997791

Illustration 2

1. Position crankcase breathers (3) . 2. Lightly lubricate the bore for the O-ring seals. Install clamps (4) . 3. Position hoses (2) . 4. Install clamps (1) .

g00997791

DISASSEMBLY AND ASSEMBLY

067

G3516E Service manual (GAS)

Media Number -KENR5271-04

Valve Cover - Remove and Install Removal Procedure

Illustration 1

1. Remove bolts (1) . 2. Remove cover (2) .

g00998234

Illustration 2

g00998235

3. Disconnect harness assembly (3) . 4. Remove bolts (5) . 5. Remove transformer (4) . 6. Remove bolts (7) in order to remove valve cover assembly (6) from base assembly (8) .

Installation Procedure

Illustration 3

1. Position valve cover assembly (6) onto base assembly (8) . 2. Install bolts (7) . 3. Install transformer (4) . 4. Install bolts (5) . 5. Connect harness assembly (3) .

g00998235

Illustration 4

6. Position cover (2) . 7. Install bolts (1) .

g00998234

DISASSEMBLY AND ASSEMBLY

068

G3516E Service manual (GAS)

Media Number -KENR5271-04

Rocker Shaft and Push Rod - Remove Removal Procedure Start By: A. Remove the valve cover. Refer to Disassembly and Assembly, "Valve Cover - Remove and Install".

Illustration 1

g01545376

1. Remove bolts (1) in order to remove shaft assembly (2) from base assembly (3) . 2. Remove valve pushrods (4) .

Illustration 2

3. Remove valve bridges (5) .

g01545374

DISASSEMBLY AND ASSEMBLY

069

G3516E Service manual (GAS)

Media Number -KENR5271-04

Rocker Shaft - Disassemble Disassembly Procedure Table 1 Required Tools Tool

Part Number

A

1P-0510

Part Description Driver Gp

Qty 1

Start By: A. Remove the rocker shaft. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod Remove".

Illustration 1

1. Remove rocker arm assemblies (1) from shaft assembly (2) . 2. Remove spring pin (3) from shaft assembly (2) .

g00985800

Illustration 2

g00985802

3. Remove nut (8) and adjusting screw (9) from rocker arm assembly (1) . 4. Remove retaining ring (6) in order to remove cup (7) from socket (5) . 5. Remove socket (5) from rocker arm assembly (1) . 6. Use Tooling (A) in order to remove sleeve bearing (4) from rocker arm assembly (1) .

DISASSEMBLY AND ASSEMBLY

070

G3516E Service manual (GAS)

Media Number -KENR5271-04

Rocker Shaft - Assemble Assembly Procedure Note: Apply engine oil to all the components during assembly.

Illustration 1

g00985802

1. Lower the temperature of sleeve bearing (4). Install sleeve bearing (4) . Note: The oil holes must be aligned. 2. Install socket (5) into rocker arm assembly (1) . 3. Position cup (7) into socket (5). Install retaining ring (6) . 4. Install nut (8) and adjusting screw (9) into rocker arm assembly (1) .

Illustration 2

g00985800

5. Install spring pin (3) into shaft assembly (2) . 6. Install rocker arm assemblies (1) onto shaft assembly (2) . End By: Install the rocker shaft. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod Install".

DISASSEMBLY AND ASSEMBLY

071

G3516E Service manual (GAS)

Media Number -KENR5271-04

Rocker Shaft and Push Rod - Install Installation Procedure Table 1 Required Tools Tool

Part Number

A

8T-2998

Part Description Lubricant

Illustration 1

1. Install valve bridges (5) .

Qty -

g01545374

Illustration 2

g01545376

2. Apply Tooling (A) to both ends of valve pushrods (4) . Install valve pushrods (4) . 3. Position shaft assembly (2) onto base assembly (3) . Note: Position the spring pin into the correct location. 4. Install bolts (1) . Tighten bolts (1) to a torque of 120 ± 20 N·m (89 ± 15 lb ft). 5. Set the valve lash and valve bridges. Refer to Testing and Adjusting, "Valve Lash and Valve Bridge Adjustment". End By: Install the valve cover. Refer to Disassembly and Assembly, "Valve Cover - Remove and Install".

DISASSEMBLY AND ASSEMBLY

072

G3516E Service manual (GAS)

Media Number -KENR5271-04

Cylinder Head - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

A

138-7575

Part Description Link Bracket

Qty 2

Start By: A. Remove the rocker shaft and the pushrod. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod - Remove".

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

Illustration 1

2. Remove bolts (1) . 3. Remove plate (2) . Note: More than one plate may need to be removed.

g01086750

Illustration 2

4. Remove shield assemblies (3) .

g01086752

Illustration 3

g01086753

5. If necessary, remove the thermocouples from exhaust manifold (6) . 6. Remove bolts (5) . 7. Remove bolts (7) in order to remove clamps (8) from exhaust manifold (6) . 8. Remove exhaust manifold (6) and the seal from cylinder head (4) .

Illustration 4

g01086755

9. Remove bolts (10) in order to remove cover assembly (9) from cylinder head (4) .

Illustration 5

10. Remove gasket (11) and O-ring seals (12) from cylinder head (4) .

g01086757

Illustration 6

11. Remove elbow (15) and the O-ring seals. 12. Remove elbow (16) and the O-ring seals. Note: Remove elbow (16) in order to gain access to bolts (14) . 13. Remove bolts (14) in order to disconnect adapter assembly (13) .

g01086759

Illustration 7

14. Remove the gasket from cylinder head (4) . 15. Remove bolts (17) from cylinder head (4) .

g01086760

Illustration 8

g01086762

16. Attach Tooling (A) and a suitable lifting device to cylinder head (4) . The weight of cylinder head (4) is approximately 50 kg (110 lb). 17. Remove bolts (18) . 18. Remove cylinder head (4) .

Illustration 9

g01086764

19. Remove head gasket (19) , seals (20) , seals (21) , and O-ring seal (23) from spacer plate (22) . 20. Remove spacer plate (22) .

Illustration 10

21. Remove O-ring seal (25) and gasket (24) from the engine block.

g01086765

DISASSEMBLY AND ASSEMBLY

073

G3516E Service manual (GAS)

Media Number -KENR5271-04

Cylinder Head - Disassemble Disassembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

5S-1330

Valve Spring Compressor

1

166-7441

Valve Seat Extractor

1

165-5647

Valve Seat Extractor

1

B

8S-2263

Spring Tester

1

C

7M-3975

Valve Guide Driver

1

D

235-9751

Drive Adapter As

1

E

5P-0944

Dowel Puller Gp

1

A

Start By: A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove".

Illustration 1

g01086846

Note: Mark lifter assemblies for installation purposes. 1. Remove lifter assemblies (1) from cylinder head (2) .

Illustration 2

2. Remove lifter guide springs (3) from lifter assemblies (1) .

g01086847

Illustration 3

g01086848

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 3. Install Tooling (A) in order to compress valve spring (5) and valve spring (4) .

Illustration 4

4. Remove retainer locks (6) from valve (7) . 5. Remove Tooling (A) .

g01086852

Illustration 5

g01086854

6. Remove rotocoil assembly (9) , valve spring (5) , valve spring (4) , and washer (8) from valve (7) .

Illustration 6

g01086855

7. Remove valve (7) from cylinder head (2) . 8. Repeat Step 3 through Step 7 in order to remove the remaining valves.

Illustration 7

g00598111

9. Use Tooling (B) in order to check valve spring force. Refer to Specifications, "Cylinder Head Valves" for the correct valve spring force.

Illustration 8

g01378241

10. Use Tooling (A) to remove the valve seat inserts from the cylinder head. 11. Thoroughly clean the valve seat bores.

Illustration 9

g01086856

Illustration 10

g01086857

12. Use Tooling (C) in order to remove inlet valve guides (10) and exhaust valve guides (11) from cylinder head (2) .

Illustration 11

g01086858

13. Use Tooling (D) in order to remove adapter (12) .

Illustration 12

14. Remove O-ring seal (13) and washer (14) from adapter (12) .

g01086859

Illustration 13

g01086860

15. Use Tooling (E) in order to remove dowels (15) from cylinder head (2) .

DISASSEMBLY AND ASSEMBLY

074

G3516E Service manual (GAS)

Media Number -KENR5271-04

Cylinder Head - Assemble Assembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

5S-1330

Valve Spring Compressor

1

C

7M-3975

Valve Guide Driver

1

D

235-9751

Drive Adapter As

1

F

4C-5597

Anti-Seize Compound

-

G

4C-9506

Retaining Compound

-

Illustration 1

1. Install dowels (15) into cylinder head (2) .

g01086860

Illustration 2

g01086859

2. Install O-ring seal (13) and washer (14) onto adapter (12) .

Illustration 3

3. Apply Tooling (F) to adapter (12) .

g01086858

4. Use Tooling (D) in order to install adapter (12) . Tighten adapter (12) to a torque 120 ± 10 N·m (89 ± 7 lb ft).

Illustration 4

g01086857

5. Use Tooling (C) in order to install inlet valve guides (10) and exhaust valve guides (11) into cylinder head (2) . 6. Install inlet valve guides (10) and exhaust valve guides (11) with a height of 26 ± 0.5 mm (1.0 ± 0.02 inch) above the face of cylinder head (2) . 7. Lower the temperature of the valve seat inserts to a temperature of -20 °C (-4 °F). Apply Tooling (G) and install valve seat inserts with Tooling (A) . Do not use a hammer to install the valve seat inserts.

Illustration 5

8. Install valve (7) into cylinder head (2) .

g01086855

Illustration 6

g01086854

9. Install washer (8) , valve spring (4) , valve spring (5) , and rotocoil assembly (9) onto valve (7) .

Illustration 7

g01086848

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 10. Install Tooling (A) in order to compress valve spring (5) and valve spring (4) .

Illustration 8

g01086852

11. Install retainer locks (6) onto valve (7) . 12. Remove Tooling (A) . 13. Repeat Step 8 through Step 11 in order to install the remaining valves.

Illustration 9

14. Install lifter guide springs (3) onto lifter assemblies (1) .

g01086847

Illustration 10

g01086846

Note: The lifter assemblies are stamped "LEFT". 15. Install lifter assemblies (1) into cylinder head (2) . End By: Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

DISASSEMBLY AND ASSEMBLY

075

G3516E Service manual (GAS)

Media Number -KENR5271-04

Cylinder Head - Install Installation Procedure Table 1 Required Tools Tool

Part Number

A

138-7575

Link Bracket

2

B

5P-3931

Anti-Seize Compound

-

C

- (1)

Nickel based anti-seize compound

-

(1)

Part Description

Qty

Refer to Technical Information Bulletin, TIBU 5269 for Manufacturer Part Numbers.

Illustration 1

1. Install O-ring seal (25) and gasket (24) onto the engine block.

g01086765

Illustration 2

g01086764

2. Install spacer plate (22) . 3. Install head gasket (19) , seals (20) , seals (21) , and O-ring seal (23) onto spacer plate (22) .

Illustration 3

g01086762

Illustration 4

g01086760

Illustration 5

g01089250

4. Attach Tooling (A) and a suitable lifting device to cylinder head (4) . The weight of cylinder head (4) is approximately 50 kg (110 lb). 5. Position cylinder head (4) . 6. Clean bolts (17) . 7. Apply engine oil to the threads of bolts (17) and install bolts (17) . 8. Tighten bolts (17) in a numerical order to a torque of 30 ± 5 N·m (22 ± 4 lb ft). 9. Tighten bolts (17) again in a numerical order to a torque of 270 ± 35 N·m (200 ± 26 lb ft). 10. Tighten bolts (17) again in a numerical order to a torque of 450 ± 20 N·m (330 ± 15 lb ft). 11. Tighten bolts (18) to a torque of 55 ± 10 N·m (40 ± 7 lb ft). 12. Position the gasket onto cylinder head (4) .

Illustration 6

13. Connect adapter assembly (13) . 14. Install bolts (14) . 15. Install the O-ring seals and elbow (16) . 16. Install the O-ring seals and elbow (15) .

g01086759

Illustration 7

17. Position gasket (11) and O-ring seals (12) onto cylinder head (4) .

g01086757

Illustration 8

18. Position cover assembly (9) onto cylinder head (4) . 19. Install bolts (10) .

g01086755

Illustration 9

g01086753

20. Position exhaust manifold (6) and the seal onto cylinder head (4) . 21. Position clamps (8) onto exhaust manifold (6) . 22. Install bolts (7) . 23. Apply Tooling (B) to bolts (5) . Simultaneously tighten the diagonally opposite bolts (5) to the following torque 55 ± 5 N·m (41 ± 4 lb ft). 24. If necessary, install the thermocouples on exhaust manifold (6) . Apply Tooling (C) to the thermocouples prior to installation. If the thermocouples are straight, tighten the nuts to a torque of 25 ± 5 N·m (18 ± 4 lb ft). If the thermocouples have a 90 degree bend, tighten the nuts to a torque of 12 ± 3 N·m (105 ± 27 lb in).

Illustration 10

25. Install shield assemblies (3) .

g01086752

Illustration 11

g01086750

26. Install plate (2) . 27. Install bolts (1) . 28. Fill the cooling system. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations". End By: Install the rocker shaft and the pushrod. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod - Install".

DISASSEMBLY AND ASSEMBLY

076

G3516E Service manual (GAS)

Media Number -KENR5271-04

Piston Cooling Jets - Remove and Install Removal Procedure Start By: A. Remove the engine oil pump, if necessary. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Remove the cylinder block cover from the side of the engine.

Illustration 1

g00913178

Illustration 2

g00913185

2. Remove bolts (1) and retainer (2) . 3. Remove piston cooling jet (3) from the inside of the engine.

Installation Procedure

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 3

g00913185

Illustration 4

g00913178

1. Position piston cooling jet (3) in the engine block. Ensure that the oil holes in the end of the jet are facing toward the piston. 2. Install retainer (2) and bolts (1) .

3. Install the cylinder block cover on the side of the engine. End By: Install the engine oil pump, if necessary. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".

DISASSEMBLY AND ASSEMBLY

077

G3516E Service manual (GAS)

Media Number -KENR5271-04

Bearing Clearance - Check Measurement Procedure Table 1 Required Tools Tool

Part Number 198-9142

Part Description

Qty

Plastic Gauge

1

198-9143

Plastic Gauge

1

198-9144

Plastic Gauge

1

198-9145

Plastic Gauge

1

A

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Caterpillar does not recommend the checking of the actual bearing clearances particularly on small engines. This is because of the possibility of obtaining inaccurate results and the possibility of damaging the bearing or the journal surfaces. Each Caterpillar engine bearing is quality checked for specific wall thickness. Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).

NOTICE Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.

The technician must be very careful to use Tooling (A) correctly. The following points must be remembered: l l l

Ensure that the backs of the bearings and the bores are clean and dry. Ensure that the bearing locking tabs are properly seated in the tab grooves. The crankshaft must be free of oil at the contact points of Tooling (A) .

1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap. Note: Do not allow Tooling (A) to extend over the edge of the bearing.

2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. Note: Do not turn the crankshaft when Tooling (A) is installed. 3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.

Illustration 1

g00473227

Typical Example

4. Remove all of Tooling (A) before you install the bearing cap. Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications, "Crankshaft" for the correct clearances.

DISASSEMBLY AND ASSEMBLY

078

G3516E Service manual (GAS)

Media Number -KENR5271-04

Connecting Rod Bearings - Remove and Install Removal Procedure Table 1 Required Tools Tool

Part Number

A

5R-7425

(1)

Part Description Barring Gp (1)

Qty 1

The 9S-9082 Engine Turning Tool is alternate tooling.

Start By: A. Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets Remove and Install".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Use Tooling (A) to turn the flywheel in order to access the connecting rod cap that will be removed.

Illustration 1

g01064418

Note: Inspect the connecting rod and connecting rod cap for the proper identification mark. The connecting rod and the connecting rod cap should have an etched number on the side. The number should match the cylinder number. Mark the connecting rod and the connecting rod cap, if necessary. 2. Remove bolts (1) and connecting rod cap (2) from the crankshaft. 3. Push the connecting rod away from the crankshaft and remove the upper half of the connecting rod bearing.

Illustration 2

g01064420

4. Remove lower half (3) of the connecting rod bearing from connecting rod cap (2) .

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

B

6V-4876

Lubricant

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Check the clearance of the bearings. Refer to Disassembly and Assembly, "Bearing Clearance Check" for the correct procedure. 2. Place clean engine oil on the connecting rod bearings.

Illustration 3

g01064420

3. Install lower half (3) of the connecting rod bearing in connecting rod cap (2). Ensure that the tab on the back of the bearing is in the bearing tab groove on the connecting rod cap. 4. Install the upper half of the connecting rod bearing in the connecting rod. Ensure that the tab on the back of the bearing is in the bearing tab groove on the connecting rod. 5. Position the connecting rod on the crankshaft.

Illustration 4

g01064418

6. Position connecting rod cap (2) onto the connecting rod. Ensure that the number on the side of connecting rod cap (2) corresponds to the number that is on the connecting rod. 7. Apply Tooling (B) to bolts (1) and install bolts (1) .

Illustration 5

g01064455

(4) Side of the connecting rod with the chamfer (5) Location pin

a. b. c. d.

Tighten Bolts (A) and (B) to 90 ± 5 N·m (65 ± 4 lb ft). Tighten Bolts (C) and (D) to 90 ± 5 N·m (65 ± 4 lb ft). Tighten Bolts (C) and (D) again to 90 ± 5 N·m (65 ± 4 lb ft). Tighten all of the bolts for an additional 90 ± 5 degrees (1/4 turn).

8. Check the side clearance that is between two of the connecting rods that are on the same journal. The clearance must be 0.85 ± 0.332 mm (0.034 ± 0.0130 inch). End By: Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets Remove and Install".

DISASSEMBLY AND ASSEMBLY

079

G3516E Service manual (GAS)

Media Number -KENR5271-04

Piston and Connecting Rods - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

9S-9082

Engine Turning Tool

1

B

1P-1861

Retaining Ring Pliers

1

C

6V-4020

Piston Ring Expander

1

5P-8639

Hydraulic Press

1

5P-9725

Hydraulic Cylinder

1

8F-0024

Hose Assembly

1

1P-2375

Connecting Coupler

1

1P-2376

Connecting Coupler

1

1U-5230

Hand Hydraulic Pump

1

5P-8640

Bar Clamp

1

D

E

6V-3042

Adapter

1

F

6V-3043

Spacer

1

G

5P-8649

Adapter

1

Start By: A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove". B. Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets Remove and Install".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Use Tooling (A) to turn the engine in order to access the bolts in the connecting rod cap. 2. Mark the cylinder number on each connecting rod and the corresponding connecting rod cap.

Note: The front of the engine is opposite the flywheel end. The No. 1 cylinder is at the front of the engine on the right side. The No. 2 cylinder is on the left side.

Illustration 1

g00582418

3. Remove bolts (1) and connecting rod cap (2) from the connecting rod. 4. Remove the bearings from connecting rod cap (2) and the connecting rod.

Illustration 2

g00582419

5. Push piston (3) out of the cylinder liner until the piston rings are completely out of the cylinder liner. 6. Remove the piston and connecting rod assembly.

Illustration 3

g01051820

7. Use Tooling (B) to remove the retaining rings that hold piston pin (4) . 8. Remove piston pin (4) . 9. Remove piston (3) from connecting rod (5) .

Illustration 4

g00582421

10. Use Tooling (C) to remove piston rings (6) from piston (3) . 11. Clean the piston ring grooves with an acceptable ring groove tool. Refer to Guideline For Reusable Parts, SEBF8059, "Procedure To Clean And Inspect 3500 Series Engine Pistons" for the correct procedure for cleaning the pistons. 12. Raise the temperature of the connecting rod. Note: Do not use a direct flame in order to heat the connecting rod.

Illustration 5

g01089121

13. Place Tooling (F) in the base plate of Tooling (D) . Place the connecting rod on the base plate. 14. Place the piston pin bearing in the center of the port assembly on Tooling (D) . Install pin (9) in the center of the bore for the piston pin. 15. Install Tooling (G) . Align the hole in the adapter with the hole that is in the base plate of Tooling (D) . 16. Install the bar clamp and clamp pin (10) . Note: The old bearing is pushed out while the new bearing is installed. 17. Position Tooling (E) with the tapered side facing downward. The piston pin bearing joint must be aligned with the hole in the adapter and the hole in the base plate of Tooling (D) . 18. Place pusher (7) on adapter (11) . 19. Use Tooling (D) to push new piston pin bearing (8) into the connecting rod until adapter (11) makes contact with the connecting rod. 20. Remove the connecting rod and the old piston pin bearing from Tooling (D) . 21. After the piston pin bearing is installed, measure the diameter of the bearing bore. The correct diameter is 70.000 ± 0.008 mm (2.7559 ± 0.0003 inch). 22. Refer to Special Instruction, SEHS7295, "Use Of Piston Pin Bearing Removal And Installation Tools" for more information.

DISASSEMBLY AND ASSEMBLY

080

G3516E Service manual (GAS)

Media Number -KENR5271-04

Piston and Connecting Rods - Install Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

9S-9082

Engine Turning Tool

1

B

1P-1861

Retaining Ring Pliers

1

C

6V-4020

Piston Ring Expander

1

H

1U-7616

Piston Ring Compressor

1

J

6V-4876

Lubricant

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g00582421

1. Use Tooling (C) to install piston rings (6) on piston (3) . 2. The ends of the oil control piston ring should be 180 degrees away from the oil ring end gap. The white colored section of the oil ring spring should also be visible at the oil ring end gap. 3. Install the intermediate ring with the side that is marked "UP" toward the top of the piston. Position the intermediate ring with the green strip on the right side of the end gap.

4. Install the top piston ring with the red strip on the right side of the end gap. 5. The piston ring end gaps must be approximately 120 degrees away from each other after installation.

Illustration 2

g01051820

6. Place clean engine oil on piston pin (4), the piston pin bearing, and the bore in piston pin (4) . 7. Position connecting rod (5) in piston (3) and install piston pin (4) . 8. Use Tooling (B) to install the retaining rings that hold piston pin (4) . 9. Install the upper half of the connecting rod bearing in connecting rod (5). Ensure that the tab on the back of the bearing is in the bearing tab groove on connecting rod (5) .

Illustration 3

g01056335

NOTICE Improper installation of the piston and connecting rod assembly will result in severe damage to the engine. Make sure that the side of the connecting rod bore with the chamfer is oriented next to the surface of the crankshaft thrust plate. The square side of the connecting rod bore must be next to the other connecting

rod that is on the same crankshaft journal. 10. Place clean engine oil on the piston rings and the cylinder liner bore. Use Tooling (H) to compress the piston rings. 11. Install the piston and connecting rod assembly in the engine.

Illustration 4

g00582418

12. Install the lower half of the connecting rod bearing in connecting rod cap (2). Ensure that the tab on the back of the bearing is in the bearing tab groove on connecting rod cap (2) . 13. Check the clearance of the bearings. Refer to Disassembly and Assembly, "Bearing Clearance Check" for the correct procedure. 14. Place clean engine oil on the upper half and on the lower half of the connecting rod bearing. 15. Apply Tooling (J) to the threads of the bolts and the threads in connecting rod caps (2) . 16. Position connecting rod cap (2) on the connecting rod and install bolts (1) in connecting rod cap (2) .

Illustration 5

g01087388

(12) Side of the connecting rod with the chamfer (13) Location pin

17. Tighten Bolts (A) and (B) to a torque of 90 ± 5 N·m (65 ± 4 lb ft). 18. Tighten Bolts (C) and (D) to a torque of 90 ± 5 N·m (65 ± 4 lb ft). 19. Tighten Bolts (C) and (D) again to a torque of 90 ± 5 N·m (65 ± 4 lb ft). 20. Tighten all of the bolts for an additional 90 ± 5 degrees. 21. Check the side clearance that is between two of the connecting rods that are on the same journal. The clearance must be 0.85 ± 0.332 mm (0.034 ± 0.0130 inch). 22. Use Tooling (A) to turn the engine in order to access the bolts in the connecting rod cap. End By: a. Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install". b. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

DISASSEMBLY AND ASSEMBLY

081

G3516E Service manual (GAS)

Media Number -KENR5271-04

Cylinder Liner - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

5P-8665

Cylinder Liner Puller

1

Start By: A. Remove the pistons and the connecting rod assemblies. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove".

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Drain the coolant from the cooling system and the engine block into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change". 2. Place covers over the crankshaft journals in order to shield the journals from dirt and coolant. 3. Use Tooling (A) in order to remove the cylinder liner.

Illustration 1

g01004731

4. Remove O-ring seals (1) and filler band (3) from cylinder liner (2) .

DISASSEMBLY AND ASSEMBLY

082

G3516E Service manual (GAS)

Media Number -KENR5271-04

Cylinder Liner - Install Installation Procedure Table 1 Required Tools Tool

Part Number 1U-9895

B

Part Description

Qty

Crossblock

1

3H-0465

Push-Puller Plate

2

8F-6123

Bolt

2

0S-1575

Bolt

4

3B-1925

Washer

4

C

8T-0455

Liner Projection Tool Group

1

D

2P-8260

Cylinder Liner Installer

1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Cylinder Liner Projection Before installing the cylinder liner, use the following procedure to measure the cylinder liner projection. 1. Make sure that these items are clean and dry: top surface of the cylinder block, bore for the cylinder liner, spacer plate and cylinder liner. Remove any nicks from the top of the spacer plate. 2. Install a new gasket for the spacer plate and install the spacer plate. Refer to Disassembly and Assembly, "Cylinder Head - Install". 3. Do not install the O-ring seals or the filler band on the cylinder liner. Position the cylinder liner in the cylinder bore. 4. Secure the spacer plate and the cylinder liner in position with Tooling (B) according to the following procedure: a. Install four bolts and washers around the cylinder liner. b. Tighten the bolts around the cylinder liner evenly to a torque of 95 N·m (70 lb ft). c. Install the rest of Tooling (B). Ensure that the crossblock is in position at the center of the cylinder liner. Ensure that the surface of the cylinder liner is clean. Tighten the bolts that hold

the crossblock in the position evenly to a torque of 70 N·m (50 lb ft). d. Measure the distance from the bottom of the crossblock to the top of the spacer plate. The measurements on both sides of the cylinder liner must be equal. If the measurements are different, tighten the bolts again. 5. Use Tooling (C) in order to measure the liner projection. 6. Mount the dial indicator into the gauge body. Use the back of the gauge block to zero the dial indicator. 7. Place the gauge body on the spacer plate with the indicator point on the liner flange. Read the dial indicator in order to determine the amount of liner projection. Measure the projection at four equally distant points around the cylinder liner. Measure the projection at the outer flange of the liner. Do not measure the projection at the inner ring. The liner projection must be 0.060 to 0.200 mm (0.0024 to 0.0079 inch). The maximum acceptable difference between the high measurements and the low measurements is 0.05 mm (0.002 inch). Note: If the measurements around the liner are different, rotate the liner to a different position within the bore. If the liner projection is not within specifications, move the liner to a different bore. Inspect the top face of the cylinder block. Measure the cylinder block bore for the liner. If the bore is too shallow, the bore may require rework.

Illustration 1

g01087469

8. If the liner projection is not 0.13 ± 0.070 mm (0.005 ± 0.0030 inch), measure the thickness of the following items: (4) Spacer plate ... 12.31 ± 0.025 mm (0.490 ± 0.0010 inch) (5) Cylinder liner flange ... 12.65 ± 0.02 mm (0.500 ± 0.0010 inch) (6) Spacer plate gasket ... 0.21 ± 0.025 mm (0.010 ± 0.0010 inch) 9. When the liner projection is correct, make alignment marks on the liner and the cylinder block. 10. Remove Tooling (B) and (C). Remove the liner, the spacer plate, and the gasket for the spacer plate.

Install the Cylinder Liner

Illustration 2

g01004731

1. Put liquid soap on the grooves for O-ring seals (1) and on the O-ring seals. Install the O-ring seals on cylinder liner (2). Also, coat the cylinder block bore for the liner with liquid soap. 2. Dip filler band (3) in clean engine oil. Immediately install filler band (3) onto cylinder liner (2) . 3. Immediately install the cylinder liner before the filler band can expand. Ensure that the marks that are on the cylinder liner and the cylinder block are aligned. 4. Use Tooling (D) in order to press the cylinder liner into the cylinder block. End By: Install the pistons and the connecting rod assemblies. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install".

DISASSEMBLY AND ASSEMBLY

083

G3516E Service manual (GAS)

Media Number -KENR5271-04

Camshaft - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

238-9586

Camshaft Drive Group

1

1P-0820

Hydraulic Puller

1

8B-7548

Push-Puller Tool Group

1

8B-7559

Adapter

2

5H-1504

Hard Washer

3

9U-6600

Hand Hydraulic Pump

1

Pilot Assembly

2

Bolt

2

B

125-0200 C 4J-7945 D

125-0201

Guide Assembly

1

E

8T-3169

Crank Assembly

1

Start By: A. Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod - Remove".

Illustration 1

1. Remove access covers (1) from each side of the engine.

g01004115

Illustration 2

g01004116

Illustration 3

g01004117

2. Push valve lifters (2) away from the camshaft. Hold valve lifters (2) in position with an O-ring seal.

Illustration 4

g01004119

3. Remove bolts (3) and clamps (4). Use two people in order to remove exhaust manifold (5). The weight of exhaust manifold (5) is approximately 45 kg (100 lb).

Illustration 5

4. Remove bolts (7) . 5. Remove bracket (8) . 6. Disconnect tube assembly (6) . 7. Remove cover (9) and cover (10) .

g01004121

Illustration 6

g01004123

8. Install Tooling (C) .

Illustration 7

9. Remove speed sensor (11) .

g01004124

Illustration 8

10. Remove cover assemblies (12) .

g01004125

Illustration 9

g01004126

11. Remove bolt (13) . 12. Remove timing ring (14) .

Illustration 10

g01004154

13. Remove bolt (15) and plate (16) from camshaft drive gear (17) .

Illustration 11

g01004157

NOTICE Do not apply more than 51675 kPa (7500 psi) pressure to the hydraulic puller. The adapters are rated at 6 1/2 tons each and the hydraulic puller is rated at 17 tons at 68900 kPa (10000 psi). If too much pressure is applied, the gear may be damaged. 14. Place the washers from Tooling (B) behind plate (16). Install the bolt and plate (16) onto camshaft drive gear (17) . 15. Install Tooling (B) on camshaft drive gear (17). Apply 51675 kPa (7500 psi) to the puller and hit the screw on the puller with a hammer until camshaft drive gear (17) is free from the camshaft. Remove Tooling (B) and camshaft drive gear (17) . 16. Repeat Step 14 through Step 15 for the remaining camshaft drive gear.

Illustration 12

17. Remove bolts (18) and thrust washer (19) .

g01004153

Illustration 13

g01004158

18. Install Tooling (C) onto camshaft (20) . Note: Tooling (D) can be installed on the flywheel housing in order to remove the camshaft from the rear. Tooling (D) can also be installed on the front housing in order to remove the camshaft from the front of the engine. 19. Install Tooling (D) on the flywheel housing. 20. Install Tooling (E) on the end of Tooling (C) . Note: The camshafts are in two pieces. 21. Rotate the camshaft with Tooling (E). Pull camshaft (20) out of the engine until a suitable lifting device can be attached. The weight of the 3516 engine camshaft is approximately 80 kg (176 lb). The weight of the 3520 engine camshaft is approximately 100 kg (220 lb). Remove camshaft (20) from the engine.

Illustration 14

g01004159

22. Remove bolts (23) in order to separate the camshafts. Remove spacer (22). Remove dowel (21), if necessary. 23. Repeat Step 17 through Step 22 for the remaining camshaft.

DISASSEMBLY AND ASSEMBLY

084

G3516E Service manual (GAS)

Media Number -KENR5271-04

Camshaft - Install Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

238-9586

Camshaft Drive Group

1

125-0200

Pilot Assembly

2

Bolt

2

C 4J-7945 D

125-0201

Guide Assembly

1

E

8T-3169

Crank Assembly

1

Illustration 1

1. Install dowel (21), if necessary.

g01004159

Note: If the dowel was removed from the half of the camshaft, install the dowel. The dowel should be 22.00 ± 0.5 mm (0.870 ± 0.02 inch). Note: Ensure that the camshafts are installed according to the marks on the ends of the camshafts. 2. Position spacer (22) . 3. Install bolts (23) in order to connect the camshafts. Tighten bolts (23) to a torque of 54 ± 7 N·m (40 ± 5 lb ft).

Illustration 2

g01004158

4. Install Tooling (C) to both ends of camshaft (20) . Note: Tooling (D) can be installed on the flywheel housing in order to install the camshaft from the rear. Tooling (D) can also be installed on the front housing in order to install the camshaft from the front of the engine. 5. Install Tooling (D) on the flywheel housing. Do not tighten bolts on Tooling (D) . Note: Ensure that the camshaft and camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft. Place clean engine oil on the camshaft bearings. 6. Attach a suitable lifting device to camshaft (20). The weight of the 3516 engine camshaft is approximately 80 kg (176 lb). The weight of the 3520 engine camshaft is approximately 100 kg (220 lb). 7. Install camshaft (20) into Tooling (D) . 8. Install Tooling (E) on the end of Tooling (C) . 9. Position the front half of camshaft (20) in the engine until Tooling (C) is in the first camshaft

bearing. 10. Rotate camshaft (20) and tighten the bolts for Tooling (D) . 11. Rotate camshaft (20) and insert camshaft (20) until camshaft (20) is slightly protruding from Tooling (D) . 12. Remove Tooling (C), Tooling (D), and Tooling (E) .

Illustration 3

13. Install bolts (18) and thrust washer (19) .

g01004153

Illustration 4

g01005218

NOTICE If the camshaft is out of time more than 18 degrees (approximately 1/2 of the timing pin is out of the groove), the valves can make contact with the pistons. This will cause damage to the engine. Refer to Testing and Adjusting, "Camshaft Timing" for more information. 14. Remove timing pin (24) from the storage position on the side of the engine. 15. Turn the camshaft until timing pin (24) can be installed through the cylinder block and into groove (25) that is in the camshaft. 16. Repeat Steps 14 and 15 for the camshaft on the opposite side of the engine.

Illustration 5

g01005219

17. Remove bolts (27), cover (26), and plug (28) .

Illustration 6

g01005220

18. Install one bolt (27) into the flywheel housing through the hole for the plug. Use Tooling (A) and a ratchet to turn the flywheel until bolt (27) can be installed through the hole and into the flywheel. This will position the No. 1 cylinder at the top center. Refer to the Testing and Adjusting Module for more information.

Illustration 7

g01005221

Illustration 8

g01005222

19. Use the following procedure in order to install camshaft drive gears (17) on both sides of the engine. a. Clean the taper of the camshaft and clean the tapered bore of the camshaft gear with a lint free cloth that is saturated with a solvent in order to remove any excess oil. Clean the parts again with a lint free alcohol wipe in order to remove any residue. If the alcohol wipe is dirty after cleaning the parts, clean the parts again with a lint free alcohol wipe until no residue is left on the alcohol wipe. Note: It is critical that the taper of the camshaft and the tapered bore of the camshaft gear are clean, dry, and free of residue before assembly. b. Ensure that the camshaft timing pins and the timing pin for the flywheel are installed. c. Place camshaft drive gears (17) in position. Remove the backlash by rotating the gears in the opposite direction of engine rotation. Note: For "Standard Rotation" engines, turn the camshaft drive gears CLOCKWISE. For "Reverse Rotation" engines, turn the camshaft drive gears COUNTERCLOCKWISE. d. Install bolt (15) and plate (16) . e. Install bolt (13) and timing ring (14). Ensure that the hole in the timing ring is properly seated on the locating pin. f. Tighten the bolt to a torque of 360 N·m (265 lb ft). g. Place a Mark on the bolt. h. Place a driver against the retaining plate of the camshaft gear. Strike the driver solidly with a hammer 3 to 4 times. i. Tighten the bolt again to a torque of 360 N·m (265 lb ft). j. Repeat Steps 19.h and 19.i until the Mark has turned at least 90 degrees.

20. Remove the timing pins and return the timing pins to the storage position.

Illustration 9

g01005219

21. Remove bolt (27) from the flywheel and install plug (28) and cover (26) .

Illustration 10

g01004124

Typical example

22. Install speed sensor (11). Refer to Testing and Adjusting, "Engine Speed/Timing Sensor".

Illustration 11

23. Position cover (9) and cover (10) . 24. Connect tube assembly (6) . 25. Position bracket (8) . 26. Install bolts (7) .

g01004121

Illustration 12

g01004119

27. Use two people in order to position exhaust manifold (5). The weight of exhaust manifold (5) is approximately 45 kg (100 lb). Install bolts (3) and clamps (4) .

Illustration 13

28. Install cover assemblies (12) .

g01004125

Illustration 14

29. Remove O-ring seals from valve lifters (2) .

g01004117

Illustration 15

g01004115

30. Install access covers (1) on each side of the engine. End By: Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod - Install".

DISASSEMBLY AND ASSEMBLY

085

G3516E Service manual (GAS)

Media Number -KENR5271-04

Camshaft Bearings - Remove Removal Procedure Table 1 Required Tools Tool

Part Number 6V-4077

Part Description

Qty

Camshaft Bearing Tool

1

125-2739

(1)

Bearing Pilot

1

125-2740

(1)

Back Up Plate

1

125-2741

(1)

Bearing Sleeve

1

A

B

8S-2241

Camshaft Bearing Tool Group

1

C

5P-5247

Hydraulic Puller

1

D

8H-0684

Ratchet Wrench

1

(1)

Alternate Tooling for camshaft bearings with a large diameter

Start By: A. Remove the camshafts. Refer to Disassembly and Assembly, "Camshaft - Remove".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g01208871

1. Use the following steps to install Tooling (A) . a. Install the pilot group in camshaft bearing (1) (not shown). b. Place the backup plate in position and ensure that camshaft bearing (1) (not shown) is between the two parts. c. Install the bolt that holds Tooling (A) together. d. Use the extensions to obtain the correct length for Tooling (A) . e. Install the puller plate on the bolt and the flywheel housing or the front housing. Note: Tooling (B) can be used to remove the camshaft bearings when the flywheel housing and the front housing have been removed.

Illustration 2

g01208875

2. Install Tooling (C) on Tooling (A) . Pull camshaft bearing (1) from the cylinder block. Note: Tooling (D) can be used in place of Tooling (C) , if necessary.

DISASSEMBLY AND ASSEMBLY

086

G3516E Service manual (GAS)

Media Number -KENR5271-04

Camshaft Bearings - Install Installation Procedure Table 1 Required Tool Tool

Part Number 6V-4077

Part Description

Qty

Camshaft Bearing Tool

1

125-2739

(1)

Bearing Pilot

1

125-2740

(1)

Back Up Plate

1

125-2741

(1)

Bearing Sleeve

1

A

B

8S-2241

Camshaft Bearing Tool Group

1

C

5P-5247

Hydraulic Puller

1

D

8H-0684

Ratchet Wrench

1

(1)

Alternate Tooling for camshaft bearings with a large diameter

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g00578338

1. Install camshaft bearing (1) on Tooling (A) . Note: Tooling (B) can be used to install the camshaft bearings when the flywheel housing and the

front housing have been removed. 2. Position camshaft bearing (1) and Tooling (A) in the bore. Note: The joint in camshaft bearing (1) must be on the horizontal centerline of the bore. The upper oil hole must be 20 ± 5 degrees above the horizontal centerline of the bore. The lower oil hole of camshaft bearing (1) should be 20 ± 5 degrees below the horizontal centerline of the bore. The joints of camshaft bearing (1) on the right side of the engine must face the inside of the cylinder block. The joints of camshaft bearing (1) on the left side of the engine must face the outside of the cylinder block.

Illustration 2

g01208939

3. Install Tooling (C) on Tooling (A) and pull camshaft bearing (1) (not shown) into the bore. Note: Tooling (D) can be used in place of Tooling (C) . 4. After camshaft bearing (1) (not shown) is installed, measure the bore. The bore must be 92.00 ± 0.06 mm (3.620 ± 0.002 inch). End By: Install the camshafts. Refer to Disassembly and Assembly, "Camshaft - Install".

DISASSEMBLY AND ASSEMBLY

087

G3516E Service manual (GAS)

Media Number -KENR5271-04

Crankshaft Main Bearings - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

A

9S-9082

Engine Turning Tool

1

B

9U-5023

Main Bearing Wrench

1

C

2P-5517

Main Bearing Tool

1

D

230-5843 (1) or 236-6688 (2)

Main Bearing Cap Tool

2

(1)

Use with 19.0 mm (3/4 inch) main bearing cap bolts.

(2)

Use with 22.2 mm (7/8 inch) main bearing cap bolts.

Qty

Start By: A. Remove the oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g00930577

1. Remove covers (1) from the side of the engine. 2. Use Tooling (A) in order to rotate the crankshaft. Rotate the crankshaft in order to position the counterweight on the top.

Illustration 2

g00930580

3. Use Tooling (B) and loosen the bolts for the main bearing cap.

Illustration 3

g00930589

4. Remove the two outer bolts for main bearing cap (2) and install Tooling (D). Install Tooling (D) until Tooling (D) bottoms out in the block. Adjust nuts (3) on Tooling (D) until nuts (3) make contact with main bearing cap (2). Remove the two inner bolts for main bearing cap (2) .

Illustration 4

g00930593

5. Loosen nuts (3) evenly in order to lower main bearing cap (2). Lower main bearing cap (2) to the end of the bolt on Tooling (D) in order to gain access to the main bearings.

Illustration 5

g00930603

6. Use Tooling (A) and rotate the crankshaft until the oil hole of the crankshaft journal is just below the side of the main bearing without the tab. Install Tooling (C) and remove the upper bearing.

Illustration 6

g00930606

7. Remove lower main bearing (4) from main bearing cap (2) .

DISASSEMBLY AND ASSEMBLY

088

G3516E Service manual (GAS)

Media Number -KENR5271-04

Crankshaft Main Bearings - Install Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

A

9S-9082

Engine Turning Tool

1

B

9U-5023

Main Bearing Wrench

1

C

2P-5517

Main Bearing Tool

1

D

230-5843 (1) or 236-6688 (2)

Main Bearing Cap Tool

2

E

9S-7351

Torque Wrench

1

(1)

Use with 19.0 mm (3/4 inch) main bearing cap bolts.

(2)

Use with 22.2 mm (7/8 inch) main bearing cap bolts.

Qty

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Measure the clearances of the main bearings. Refer to Disassembly and Assembly, "Bearing Clearance - Check".

NOTICE Ensure that the upper halves and the lower halves of the main bearings are installed with the tabs fitting into the notch in the cylinder block and the notch in the main bearing cap.

Illustration 1

g00930606

2. Coat the main bearings with clean engine oil. Install new lower main bearing (4) into main bearing cap (2) . 3. Install the new upper main bearing with the side without the tab into the side of the block with the tab. Use your hand and roll the upper main bearing into position. Use Tooling (A) and rotate the crankshaft. Rotate the crankshaft until the oil hole is positioned in front of the side of the upper main bearing with the tab. 4. Install Tooling (C) and finish rolling the upper main bearing into position. Make sure that Tooling (C) does not slide under the upper main bearing. 5. Remove Tooling (C) .

Illustration 2

g00930593

Illustration 3

g00930745

6. Tighten nuts (3) on Tooling (D) in order to raise main bearing cap (2) to the block. Nuts (3) must be tightened evenly in order for main bearing cap (2) to fit into the block. 7. Coat the threads of the bolts for the main bearing caps and coat the underside of the bolt heads with clean engine oil. Install the two inner bolts for the main bearing cap. Remove Tooling (D) and install the two outer bolts for the main bearing cap.

Illustration 4

g00930580

Illustration 5

g01001689

Note: Install main bearing caps with the part number and FRONT toward the front of the block. Each cap has a number. Each cap must be installed in the same position as the correct number on the side of the cylinder block pan rail. 8. Tighten the bolts in the letter sequence to the following torque. Use Tooling (E) and Tooling (B) and tighten the bolts to a torque of 190 ± 14 N·m (140 ± 10 lb ft). 9. Tighten the bolts in the letter sequence to the following torque. Tighten the bolts for an additional 180 ± 5 degrees (1/2 turn).

Illustration 6

g00930577

10. Install covers (1) onto the side of the engine.

End By: Install the oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".

DISASSEMBLY AND ASSEMBLY

089

G3516E Service manual (GAS)

Media Number -KENR5271-04

Crankshaft - Remove Removal Procedure Table 1 Required Tools Tool

Part Number

A

138-7576

Part Description

Qty

Link Bracket

2

Start By: A. Remove the drive housing. Refer to Disassembly and Assembly, "Drive Housing (Front) - Remove and Install". B. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing Remove". C. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove". D. Remove the rocker shaft and the pushrod. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod - Remove". 1. Position the engine in the horizontal position. Note: It is not necessary to remove the counterweights from the crankshaft, if the piston and connecting rod assemblies have been removed from the engine.

Illustration 1

g00914774

2. Place identification marks on counterweights (1) . Remove counterweights (1) .

Illustration 2

g00914776

3. Remove connecting rod bearing caps (2) . Push the connecting rods away from the crankshaft. Remove the connecting rod bearings from the connecting rods and connecting rod caps (2) .

Illustration 3

g00914800

4. Remove the center main bearing and thrust plates (3) .

Illustration 4

g01058477

5. Attach Tooling (A) and a suitable lifting device to crankshaft (5) . 6. Remove the remaining main bearing caps (4) . Remove the lower half of crankshaft main bearings from main bearing caps (4) . 7. Remove crankshaft (5) . The weight of the 3516 crankshaft with the counterweights is approximately 800 kg (1764 lb). The weight of the 3516 crankshaft without the counterweights is approximately 520 kg (1146 lb). The weight of the 3520 crankshaft with the counterweights is approximately 920 kg (2028 lb). The weight of the 3520 crankshaft without the counterweights is approximately 580 kg (1280 lb). 8. Remove the upper half of crankshaft main bearings from the cylinder block.

Illustration 5

g00914805

9. If necessary, remove bolts (6) and crankshaft gear (7) from each end of the crankshaft.

DISASSEMBLY AND ASSEMBLY

090

G3516E Service manual (GAS)

Media Number -KENR5271-04

Crankshaft - Install Installation Procedure Table 1 Required Tools Tool

Part Number

A

138-7576

Link Bracket

2

B

6V-4876

Lubricant

1

C

9U-5023

Main Bearing Wrench

1

D

9S-7351

Torque Wrench

1

Illustration 1

Part Description

Qty

g00914805

1. If necessary, install bolts (6) and crankshaft gear (7) to each end of the crankshaft. 2. Install the upper half of crankshaft main bearings in the cylinder block.

Illustration 2

g01058477

3. Attach Tooling (A) and a suitable lifting device to crankshaft (5) . 4. Position crankshaft (5) . The weight of the 3516 crankshaft with the counterweights is approximately 800 kg (1764 lb). The weight of the 3516 crankshaft without the counterweights is approximately 520 kg (1146 lb). The weight of the 3520 crankshaft with the counterweights is approximately 920 kg (2028 lb). The weight of the 3520 crankshaft without the counterweights is approximately 580 kg (1280 lb). 5. Install the lower half of crankshaft main bearings in main bearing caps (4) . Install main bearing caps (4) . Coat the threads of the bolts for the main bearing caps and coat the underside of the bolt heads with clean engine oil.

Illustration 3

g00914800

6. Install thrust plates (3) and the center main bearing cap.

Illustration 4

g01001689

Note: Install main bearing caps with the part number and FRONT toward the front of the block. Each cap has a number. Each cap must be installed in the same position as the correct number on the side of the cylinder block pan rail. 7. Tighten the bolts in the letter sequence to the following torque. Use Tooling (C) and Tooling (D) and tighten the bolts to a torque of 190 ± 14 N·m (140 ± 10 lb ft). 8. Tighten the bolts in the letter sequence to the following torque. Tighten the bolts for an additional 180 ± 5 degrees (1/2 turn).

Illustration 5

g00914776

9. Install the connecting rod bearings in the connecting rods and connecting rod caps (2) . Position connecting rod bearing caps (2) .

Illustration 6

g01003565

10. Apply Tooling (B) to the bolts. 11. Tighten Bolts (A) and (B) to a torque of 90 ± 5 N·m (66 ± 4 lb ft). 12. Tighten Bolts (C) and (D) to a torque of 90 ± 5 N·m (66 ± 4 lb ft). 13. Tighten Bolts (C) and (D) again to a torque of 90 ± 5 N·m (66 ± 4 lb ft). 14. Tighten the bolts for an additional turn of 90 ± 5 degrees.

Illustration 7

g00914774

Note: Do not reuse counterweight bolts. 15. Apply Tooling (B) to the counterweight bolts. 16. Install counterweights (1) . Tighten bolts to a torque of 70 ± 5 N·m (52 ± 4 lb ft). Turn the bolts for an additional 120 ± 5 degrees.

End By: a. Install the rocker shaft and the pushrod. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod - Install". b. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Install". c. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Install". d. Install the drive housing. Refer to Disassembly and Assembly, "Drive Housing (Front) - Remove and Install".

Media Number -KENR6833-02

G3516E Service manual (GAS) Specifications Engine Design Spark Plug Air Lines - Compressor Bypass Air Inlet Elbow Gas Engine Ignition Fuel Lines Camshaft Valve Mechanism Cylinder Head Cylinder Head Valves Turbocharger Exhaust Manifold Air Cleaner Engine Oil Pump Engine Oil Pump Engine Oil Filter Engine Oil Cooler Bypass Valve Engine Oil Pan Crankcase Breather Water Pump Thermostatic Valve Water Temperature Regulator Water Temperature Regulator Water Temperature Regulator Water Temperature Regulator Cylinder Block Crankshaft Crankshaft Wear Sleeves and Seals Connecting Rod Connecting Rod and Main Bearing Journals Piston and Rings Oil Control Piston Ring (1) Intermediate Piston Ring (2) Top Piston Ring (3) Piston Pin (4) Pin Retainer (5) Cylinder Liner Camshaft Bearing Position Gear Group (Front) Gear Group (Rear) Auxiliary Drive (Lower Left Hand) Engine Mount Vibration Damper Guard Flywheel Housing Cover Flywheel Flywheel Housing Belt Tension Chart Accessory Drive Alternator and Regulator Alternator Mounting Electric Starting Motor

INDEX 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031

032 033 034 035 036 037 038 039 040 041 042 043 044 045 046

Engine Speed Sensor Temperature Sensor Temperature Sensor - Thermocouple Temperature Sensor Pressure Sensor Pressure Sensor Pressure Sensor Detonation Sensor Jacket Water Inlet Pressure Switch Disconnect Switch Engine Speed/Timing Sensor Engine Speed/Timing Sensor Magnetic Switch Junction Box

047 048 049 050 051 052 053 054 055 056 057 058 059 060

SPECIFICATIONS

001

G3516E Service manual (GAS)

Media Number -KENR6833-02

Engine Design

Illustration 1

g01053672

Cylinder and valve location (A) Inlet valve (B) Exhaust valve

Number and arrangement of cylinders ... 60 degree V-16 Valves per cylinder ... 4 Displacement ... 69 L (4210 cu in) Bore ... 170 mm (6.7 inch) Stroke ... 190 mm (7.5 inch) Combustion ... Spark ignited When the crankshaft is viewed from the flywheel end, the crankshaft rotates in the following direction. ... Counterclockwise Firing order Standard rotation CCW ... 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8 Valve lash setting for 1200 RPM and 1500 RPM engines Inlet ... 0.38 mm (0.015 inch) Exhaust ... 1.12 mm (0.040 inch) Valve lash setting for 1800 RPM engines Inlet ... 0.38 mm (0.015 inch) Exhaust ... 1.02 mm (0.040 inch) Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right side of the engine are seen from the flywheel end. The number 1 cylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the left side.

SPECIFICATIONS

002

G3516E Service manual (GAS)

Media Number -KENR6833-02

Spark Plug S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Illustration 1

g01434342

(1) Installation torque for the spark plug ... 50 ± 4 N·m (37 ± 3 lb ft)

SPECIFICATIONS

003

G3516E Service manual (GAS)

Media Number -KENR6833-02

Air Lines - Compressor Bypass S/N - -

Illustration 1 (1) Coupling

(2) Torque for four bolts ... 45 ± 1 N·m (33 ± 1 lb ft) (3) Torque for four bolts ... 41 ± 1 N·m (30 ± 1 lb ft) (4) Torque for two hex socket screws ... 15 ± 1 N·m (11 ± 1 lb ft)

g01346170

SPECIFICATIONS

004

G3516E Service manual (GAS)

Media Number -KENR6833-02

Air Inlet Elbow S/N - -

Illustration 1

g01348847

(1) Apply 4C-5599 Anti-Seize Compound to the threads of two clamp assemblies before assembly.

SPECIFICATIONS

005

G3516E Service manual (GAS)

Media Number -KENR6833-02

Gas Engine Ignition S/N - -

Illustration 1

g01426931

(2) Wiring harness (3) Transformer

(4) Torque for the internal terminal of the 150-2050 Extension As for the spark plug (1) ... 2.70 ± 0.25 N·m (24 ± 2 lb in)

SPECIFICATIONS

006

G3516E Service manual (GAS)

Media Number -KENR6833-02

Fuel Lines S/N - -

Illustration 1

g01111430

Top view

(1) Torque for the four clamps of the two joints ... 21 ± 1 N·m (15 ± 1 lb ft)

SPECIFICATIONS

007

G3516E Service manual (GAS)

Media Number -KENR6833-02

Camshaft S/N - GAS1-UP , S/N - SLY1-UP

Illustration 1

g01388892

(1) Torque for 16 bolts ... 55 ± 7 N·m (41 ± 5 lb ft) (A) Thickness of groove in new camshaft ... 8.75 ± 0.05 mm (0.344 ± 0.002 inch) (C) Protrusion of the dowel from the rear of the left camshaft ... 12.0 ± 0.5 mm (0.47 ± 0.02 inch) (D) Thickness of new thrust washer ... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) (E) Diameter of bearing journal ... 85.88 ± 0.02 mm (3.381 ± 0.001 inch) Bore in bearings for camshaft after assembly ... 86.15 ± 0.06 mm (3.392 ± 0.002 inch) (F) Dimensions for dowel Protrusion of the dowel from the rear of the left camshaft's front half ... 22.0 ± 0.5 mm (0.87 ± 0.02 inch) Protrusion of the dowel from the front of the right camshaft's rear half ... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)

Illustration 2

g01388893

(G) Camshaft lobe lift Specified camshaft lobe lift Exhaust lobe ... 9.901 mm (0.3898 inch) Inlet lobe ... 7.400 mm (0.2913 inch) In order to determine the camshaft lobe lift, use the following procedure: 1. Measure camshaft lobe height (H) . 2. Measure base circle (J) . 3. Subtract the base circle that is found in Step 2 from the camshaft lobe height that is found in Step 1. The difference is the actual camshaft lobe lift (G).

SPECIFICATIONS

008

G3516E Service manual (GAS)

Media Number -KENR6833-02

Valve Mechanism S/N - -

Illustration 1

g01426967

(1) Torque for two jam nuts ... 70 ± 15 N·m (50 ± 11 lb ft) (2) Torque for two nuts ... 30 ± 4 N·m (22 ± 3 lb ft) (3) Dowel Diameter of the new dowel ... 11.008 ± 0.004 mm (0.4334 ± 0.0002 inch) Bore in the valve bridge for the dowel ... 11.07 ± 0.03 mm (0.436 ± 0.001 inch) Bore in the cylinder head for the dowel ... 10.968 ± 0.020 mm (0.4318 ± 0.0008 inch) (4) Torque for two bolts ... 120 ± 20 N·m (90 ± 15 lb ft)

(5) The two lifter guide springs must not be used again. Always install new lifter guide springs. (A) Dimensions for the rocker arm shaft Diameter ... 37.084 ± 0.013 mm (1.4600 ± 0.0005 inch) Bore in the bearings for the rocker arm shaft ... 37.140 ± 0.015 mm (1.4622 ± 0.0006 inch) (B) Dimensions for the valve lash Valve lash for 1200 rpm engines and for 1500 rpm engines Inlet ... 0.38 mm (0.015 inch) Exhaust ... 1.12 mm (0.044 inch) Valve lash for 1800 rpm engines Inlet ... 0.38 mm (0.015 inch) Exhaust ... 1.02 mm (0.040 inch) (C) Height to the top of the dowel ... 66.5 ± 0.5 mm (2.62 ± 0.02 inch) (D) Dimensions for the lifter assembly Diameter of the lifter assembly ... 29.900 ± 0.010 mm (1.1772 ± 0.0004 inch) Bore in the cylinder head for the lifter assembly ... 30.000 ± 0.025 mm (1.1811 ± 0.0010 inch)

SPECIFICATIONS

009

G3516E Service manual (GAS)

Media Number -KENR6833-02

Cylinder Head S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Illustration 1

g01427683

Top view Bolt tightening sequence

NOTICE Cleaning agents may contain chlorine that will cause stress corrosion on bolt heads. This can result in failure of the bolt. Use the appropriate

cleaning procedure for bolts.

Use the following procedure in order to tighten the cylinder head bolts. Refer to Illustration 1 for the tightening sequence: 1. Clean the bolts with a wire brush. Wipe the bolts with a dry cloth. Coat the bolt threads with clean engine oil. 2. Tighten bolt (1) through bolt (8) in the numerical sequence to 30 ± 5 N·m (22 ± 4 lb ft). 3. Tighten bolt (1) through bolt (8) in the numerical sequence to 270 ± 35 N·m (200 ± 26 lb ft). 4. Tighten bolt (1) through bolt (8) in the numerical sequence to 450 ± 20 N·m (330 ± 15 lb ft). 5. Tighten bolts (9) and (10) to 55 ± 10 N·m (41 ± 7 lb ft).

Illustration 2

g01427403

(11) Coat the bore in the head and the O-ring seal with liquid soap before assembly. Note: Before assembly, apply 4C-5599 Anti-Seize Compound to the threads of the adapter. (12) Torque for the adapter ... 120 ± 10 N·m (90 ± 7 lb ft) (B) Height of the new cylinder head ... 142.00 ± 0.15 mm (5.591 ± 0.006 inch)

Illustration 3

g01427427

Section A-A

(13) Apply 6V-6640 Sealant to the bore of the three cup plugs before assembly. (D) Depth of the cup plug from the cylinder head surface ... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

Illustration 4

g01427430

Section C-C

(14) Apply 6V-6640 Sealant to the bore of the five cup plugs before assembly. (E) Depth of the cup plug from the bottom of the chamfer in the cylinder head surface ... 1.0 ± 0.5 mm (0.04 ± 0.02 inch)

Illustration 5

g01427668

Bottom view

Illustration 6

g01427679

Section F-F

(J) Depth of the cup plug from the cylinder head surface ... 25.5 ± 0.5 mm (1.00 ± 0.02 inch)

Illustration 7

g01427681

Section G-G

(K) Depth of the cup plug from the cylinder head surface ... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

Illustration 8

g01427682

Section H-H

(L) Depth of the cup plug from the cylinder head surface ... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

SPECIFICATIONS

010

G3516E Service manual (GAS)

Media Number -KENR6833-02

Cylinder Head Valves S/N - -

Illustration 1

(1) 281-6157 Spring Quantity ... 4 Length under test force ... 59.29 mm (2.334 inch) Test force ... 562 ± 28 N (126.3 ± 6.3 lb) Free length after test ... 75.8 mm (2.98 inch) Outside diameter ... 43.47 mm (1.711 inch) (2) 194-4902 Spring Quantity ... 4 Length under test force ... 50.34 mm (1.982 inch) Test force ... 146.0 ± 7.3 N (32.8 ± 1.6 lb) Free length after test ... 60.7 mm (2.39 inch) Outside diameter ... 30.7 mm (1.21 inch)

g01427300

Note: Coat the inlet valve stems and the exhaust valve stems with clean engine oil prior to installation into the cylinder head. (A) Dimensions for the valves Diameter of the new valves ... 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch) Bore in intake and exhaust valve guides after installation of valve guides into cylinder head assembly ... 9.467 ± 0.013 mm (0.3727 ± 0.0005 inch) (B) Height from the top of the cylinder head to the top of the valve guides ... 26.0 ± 0.5 mm (1.02 ± 0.02 inch) (C) Angle of valve that faces the valve seat insert ... 19.25 ± 0.25 degrees (D) Outside diameter of the valve heads ... 56.00 ± 0.15 mm (2.205 ± 0.006 inch)

Illustration 2

g01427346

(E) Depth of counterbore for valve seat inserts ... 25.500 ± 0.250 mm (1.0039 ± 0.0098 inch) (F) Angle of the valve face of the valve seat insert ... 20.25 ± 0.25 degrees Note: For installation, reduce the temperature of the valve seat inserts to -20 °C (-4 °F). Apply 4C-9506 Retaining Compound to the outside diameter of the valve seat inserts and install the valve seat inserts. Do not hammer the valve seat inserts. (G) Dimensions for the valve seat inserts Diameter of counterbore for valve seat inserts ... 60.000 ± 0.025 mm (2.3622 ± 0.0010 inch) Outside diameter of valve seat inserts ... 60.115 ± 0.015 mm (2.3667 ± 0.0006 inch)

SPECIFICATIONS

011

G3516E Service manual (GAS)

Media Number -KENR6833-02

Turbocharger S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP

Illustration 1

g01427707

Typical example Top view of the engine

Note: Apply 4C-5599 Anti-Seize Compound to the bearing surfaces of 24 hard washers (1) and to the threads of 24 bolts (2) .

Illustration 2

g01427708

(3) Torque for 18 bolts of the compressor housing ... 65 ± 5 N·m (48 ± 4 lb ft) (4) Torque for 12 bolts of the turbine housing ... 40 ± 5 N·m (30 ± 4 lb ft)

SPECIFICATIONS

012

G3516E Service manual (GAS)

Media Number -KENR6833-02

Exhaust Manifold S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP

Illustration 1

g01428034

(1) Apply 4C-5599 Anti-Seize Compound to the threads of the bolts and the surface of the hard washers before assembly. Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts (2) and the surface of the hard washers. (2) Torque for the bolts ... 240 ± 40 N·m (175 ± 30 lb ft) (3) Use the following procedure in order to tighten the bolts: Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts and the surface of the hard washers before assembly. 1. Tighten the bolts to 55 ± 5 N·m (41 ± 4 lb ft). 2. Again, tighten the bolts to 55 ± 5 N·m (41 ± 4 lb ft). Note: Install bellows assemblies with the flow direction, as shown. (4) Allowable offset for the bellows assemblies from the center of the casting's inner diameter ... 1.5 mm

(0.06 inch) Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts (5) and surface of the hard washers before assembly. (5) Torque for the bolts ... 50 ± 10 N·m (37 ± 7 lb ft) (6) Use the following procedure in order to tighten the clamps: Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts, bearing surfaces and inside diameter of the clamps before assembly. 1. Tighten the bolts of the clamps to 25 ± 6 N·m (18 ± 4 lb ft). 2. Lightly tap around the clamps. 3. Again, tighten the bolts of the clamps to 25 ± 6 N·m (18 ± 4 lb ft).

SPECIFICATIONS

013

G3516E Service manual (GAS)

Media Number -KENR6833-02

Air Cleaner S/N - -

Illustration 1

(1) Maximum torque for eight clamp bolts ... 10 N·m (90 lb in)

g01428046

SPECIFICATIONS

014

G3516E Service manual (GAS)

Media Number -KENR6833-02

Engine Oil Pump S/N - -

Illustration 1

g01459732

(1) Lubricate the bore of the O-ring seal lightly with 5P-3975 Rubber Lubricant immediately before assembly of the engine oil pump.

Illustration 2

g01459725

(2) 2S-2760 Spring Length under test force ... 117.14 mm (4.612 inch) Test force ... 499 ± 24 N (112.2 ± 5.4 lb) Approximate free length after test ... 152.91 mm (6.020 inch) Outside diameter ... 27.00 mm (1.063 inch)

Illustration 3

g01459726

(B) Dimensions for the gears Length of new gear ... 84.000 ± 0.015 mm (3.3071 ± 0.0006 inch) Depth of the bore in the oil pump body for the new gear ... 84.15 ± 0.02 mm (3.313 ± 0.001 inch) (C) Dimensions for the shafts Diameter of new shaft ... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the new shaft ... 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) (D) Extension of the hollow dowel from the oil pump cover ... 6.0 ± 0.5 mm (0.24 ± 0.02 inch) (E) Distance from the end of the pump shaft assembly to the gear face ... 34.0 ± 0.5 mm (1.34 ± 0.02 inch) (F) Dimensions for the pump drive shaft Diameter of new pump drive shaft ... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the pump drive shaft ... 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) (G) Distance from the end of the pump drive shaft assembly to the gear face ... 47.0 ± 0.5 mm (1.85 ± 0.02 inch) (H) Installation depth of the sleeve bearing in the pump cover ... 1.5 ± 0.5 mm (0.06 ± 0.02 inch) (J) Installation depth of the sleeve bearing in the oil pump body assembly. ... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

Illustration 4

g01502139

(K) Extension of the dowel from the oil pump cover ... 6.0 ± 1.0 mm (0.24 ± 0.04 inch)

Illustration 5

g01459731

(L) Position of the bearing joints from the centerline through the bearing bores ... 45 ± 15 degrees Bench test specifications Unrestricted flow rate at 700 rpm ... 220 L/min (58 US gpm) Pump pressure at 300 rpm with fully blocked outlet ... 710 to 770 kPa (105 to 110 psi) Note: Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure that the pump rotates freely.

SPECIFICATIONS

015

G3516E Service manual (GAS)

Media Number -KENR6833-02

Engine Oil Pump S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP

Illustration 1

g01554195

Note: The rotation of the drive gear is clockwise when you view the engine oil pump from the drive end. Note: Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure that the pump rotates freely. (1) 2S-2760 Spring Length under test force ... 117.14 mm (4.612 inch) Test force ... 499 ± 24 N (112.2 ± 5.4 lb) Approximate free length after test ... 152.91 mm (6.020 inch) Outside diameter ... 27 mm (1.1 inch)

Illustration 2

g01890213

(2) Before assembly, lubricate the O-ring seal lightly with 5P-3975 Rubber Lubricant . (B) Dimensions for the gears Length of new gear ... 84.000 ± 0.015 mm (3.3071 ± 0.0006 inch) Depth of the bore in the oil pump body for the new gear ... 84.15 ± 0.02 mm (3.313 ± 0.001 inch) (C) Dimensions for the pump shaft Diameter of new shaft ... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the new shaft after assembly ... 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) (D) Extension of hollow dowel from the oil pump cover ... 6.0 ± 1.0 mm (0.24 ± 0.04 inch) (E) Distance from the end of the idler shaft to the gear face ... 34.0 ± 0.5 mm (1.34 ± 0.02 inch) (F) Dimensions for the pump drive shaft Diameter of new shaft ... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the new shaft after assembly ... 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) (G) Distance from the end of the shaft to the gear face ... 47.0 ± 0.5 mm (1.85 ± 0.02 inch) (H) Installation depth of the sleeve bearing in the pump cover ... 1.5 ± 0.5 mm (0.06 ± 0.02 inch) (J) Installation depth of the sleeve bearing in the oil pump body assembly ... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

Illustration 3

g01883675

Illustration 4

g01883677

(K) Position of bearing joints from the centerline through the bearing bores ... 45 ± 15 degrees

Illustration 5

g01883017

(3) Pump cover

(L) Extension of the hollow dowel from the oil pump cover ... 6.0 ± 0.5 mm (0.24 ± 0.02 inch) Bench test specifications Unrestricted flow rate at 700 rpm ... 220 L/min (58.1 US gpm) Pump pressure at 300 rpm with fully blocked outlet ... 570 to 630 kPa (83 to 91 psi )

SPECIFICATIONS

016

G3516E Service manual (GAS)

Media Number -KENR6833-02

Engine Oil Filter S/N - -

Illustration 1

g01388901

Right side view

(1) Torque for the plug ... 100 ± 15 N·m (75 ± 11 lb ft) (2) Engine oil filter assembly ... Apply clean engine oil to the sealing surface of the filter element. Screw the filter element onto the mounting base until the sealing surface contacts the base. Then tighten the filter element for an additional one full turn (360 degrees). Note: There is a spring for each cooling jet sequence valve. (3) 6B-9202 Spring Length under test force ... 68.3 mm (2.69 inch) Test force ... 85 to 100 N (19.0 to 22.4 lb) Free length after test ... 112.8 mm (4.44 inch) Outside diameter ... 24.61 mm (0.969 inch) (4) Plunger for the cooling jet sequence valves

Both of the cooling jet sequence valves must start to open at the following pressure difference: ... 130 ± 30 kPa (19 ± 4.5 psi) Both of the cooling jet sequence valves must be fully open at the following pressure difference: ... 200 ± 30 kPa (29 ± 4.5 psi) (5) O-ring seal ... Lubricate the bore lightly with the lubricant that is being sealed. (6) O-ring seal ... Lubricate the bore lightly with the lubricant that is being sealed. (7) 7G-6713 Spring Length under test force ... 57.2 mm (2.25 inch) Test force ... 109 ± 5 N (25 ± 1.1 lb) Free length after test ... 99.7 mm (3.93 inch) Outside diameter ... 21.23 mm (0.836 inch) (8) Opening pressure for the plunger for the engine oil filter bypass valves ... 203 ± 20 kPa (29 ± 3 psi) Note: The plunger must move freely in the bore.

Illustration 2

g01394068

Rear view

(9) O-ring seal ... Lubricate the bore lightly with the lubricant that is being sealed. (10) O-ring seal ... Lubricate the bore lightly with the lubricant that is being sealed.

Illustration 3

g01394069

(11) O-ring seal ... Lubricate the bore lightly with the lubricant that is being sealed.

SPECIFICATIONS

017

G3516E Service manual (GAS)

Media Number -KENR6833-02

Engine Oil Cooler Bypass Valve S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Illustration 1 Front view

g01439261

Illustration 2

g01438811

Section A-A

(1) Pressure difference for opening the oil cooler bypass valve ... 180 ± 20 kPa (26 ± 3 psi) (2) 2W-1635 Spring Length under test force ... 102.0 mm (4.02 inch) Test force ... 518 ± 26 N (116.5 ± 5.8 lb) Free length after test ... 143.4 mm (5.65 inch) Outside diameter ... 37.251 mm (1.4666 inch)

Illustration 3

g01438810

Right side view

Illustration 4

g01439262

View B-B

(3) Lubricate the bore of the seven O-ring seals with the lubricant that is being sealed.

SPECIFICATIONS

018

G3516E Service manual (GAS)

Media Number -KENR6833-02

Engine Oil Pan S/N - -

Illustration 1

g01448462

Typical example

(1) Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate the bores of the O-ring seals. (2) As required, apply 8T-9014 Silicone Sealant or 138-8436 Liquid Gasket to the joints of the gasket. (4) Torque for two oil drain plugs ... 145 ± 15 N·m (105 ± 11 lb ft) In order to prevent stress on the tube assembly (6) , use the following tightening procedure during assembly: 1. Tighten two bolts (5) to 47 ± 9 N·m (35 ± 7 lb ft). 2. Tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft).

SPECIFICATIONS

019

G3516E Service manual (GAS)

Media Number -KENR6833-02

Crankcase Breather S/N - -

Illustration 1

g01348907

(1) Hose clamps (2) Filler cap assembly

(3) Lubricate the bore of the four O-rings lightly with the lubricant that is being sealed.

SPECIFICATIONS

020

G3516E Service manual (GAS)

Media Number -KENR6833-02

Water Pump S/N - -

Illustration 1

g01609454

(1) Lubricate the bore of two O-ring seals lightly with glycerin or an approved equivalent.

Illustration 2

g01609453

(2) Lubricate the O-ring seal with P-80 Rubber lubricant or an approved equivalent. (3) Bearing locknut Torque for the bearing locknut ... 300 ± 30 N·m (220 ± 22 lb ft) Torque for the setscrew ... 4.00 ± 1.25 N·m (35 ± 11 lb in) (4) Lubricate the pump shaft lightly with clean engine oil before pressing the impeller onto the pump shaft. The end of the pump shaft must be flush with the face of the impeller within 0.000 ± 0.076 mm (0.0000 ± 0.0030 inch).

NOTICE Improper handling can damage the ceramic seal. If the shaft is bumped during installation, the ceramic seal that is internal to the pump may crack leading to a coolant leak from the weep hole. Caution should be taken during installation not to make hard contact to the shaft. The pump should also be completely inserted during installation. Do not allow the shaft to support the weight of the pump during installation.

(5) Use the following procedure in order to install the water pump seal: 1. Install the seal dry. 2. Install the seal within two minutes of the removal of the seal from the shipping sleeve.

3. Install the seal by using a slow motion and even motion. 4. Use the correct installation tool. Maximum leakage per minute for the water pump seal at 138 kPa (20 psi) of air pressure must be less than 24 cc (1.5 in3). (6) Use the following procedure in order to install the seal group: 1. Use 207-1600 Rubber Lubricant in order to aid in assembly. 2. Use the installation tool and hand pressure to seat the ceramic ring and the rubber seal in the pump housing. 3. Remove the spring from the seal assembly. 4. Use the installation tool and hand pressure to press the seal assembly on the shaft until the seal faces make light contact. 5. Install the spring. Maximum leakage per minute for the seal group at 138 kPa (20 psi) of air pressure must be less than 20 cc (1.2 in3).

SPECIFICATIONS

021

G3516E Service manual (GAS)

Media Number -KENR6833-02

Thermostatic Valve S/N - GAS1-UP , S/N - SLY1-UP , S/N - TJD1-UP

Illustration 1

g01428095

(1) Water temperature regulator Quantity ... 2 Start to open temperature ... 34 °C (93 °F) Fully open temperature ... 42 °C (108 °F) Maximum operating temperature ... 99 °C (210 °F) (2) Apply glycerin or an approved equivalent to the bore of the two O-ring seals. (A) Minimum opening distance at fully open temperature ... 9.0 ± 0.5 mm (0.35 ± 0.02 inch)

SPECIFICATIONS

022

G3516E Service manual (GAS)

Media Number -KENR6833-02

Water Temperature Regulator S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP

Illustration 1

g01399583

Typical example

Start to open temperature ... 87 to 89 °C (189 to 192 °F) Fully open temperature ... 98 °C (208 °F) (A) Minimum opening distance at 98 °C (208 °F) ... 10.4 mm (0.41 inch) Maximum time from fully closed position at 85 °C (185 °F) to fully open position at 100 °C (212 °F) ... Two minutes Maximum time from fully open position at 100 °C (212 °F) to fully closed position at 85 °C (185 °F) ... Two minutes

SPECIFICATIONS

023

G3516E Service manual (GAS)

Media Number -KENR6833-02

Water Temperature Regulator S/N - -

Illustration 1

g01527879

Start to open temperature ... 81 to 84 °C (178 to 183 °F) Fully open temperature ... 92 °C (198 °F) (A) Minimum opening distance at fully open temperature ... 10.4 mm (0.41 inch) Maximum opening time from closed position at 79 °C (174 °F) to fully open position at 94 °C (201 °F) ... Three minutes Maximum opening time from fully open position at 94 °C (201 °F) to closed position at 79 °C (174 °F) ... Six minutes

SPECIFICATIONS

024

G3516E Service manual (GAS)

Media Number -KENR6833-02

Water Temperature Regulator S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP

Illustration 1

g01449799

Start to open temperature ... 86 to 90 °C (187 to 194 °F) Fully open temperature ... 98 °C (208 °F) (A) Minimum opening distance at fully open temperature ... 10.4 mm (0.41 inch)

SPECIFICATIONS

025

G3516E Service manual (GAS)

Media Number -KENR6833-02

Water Temperature Regulator S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP

Illustration 1

g01365083

(1) Water temperature regulator (2) Seal

(A) Minimum stroke at full open temperature ... 10.4 mm (0.41 inch) Opening temperature ... 87 to 89 °C (189 to 192 °F) Fully open temperature ... 98 °C (208 °F) Force that is required to separate valve from seat Test temperature ... 80 °C (176 °F) Force ... 165 ± 9 N (37 ± 2.0 lb) Maximum rate for valve leakage Test temperature ... 80 °C (176 °F) Test pressure ... 210 kPa (30 psi)

Maximum leakage ... 10 cc (0.6 in3) Maximum opening time for valve Temperature at fully closed position ... 85 °C (185 °F) Temperature at fully open position ... 100 °C (212 °F) Maximum opening time ... 2 minutes Maximum closing time for valve Temperature at fully open position ... 100 °C (212 °F) Temperature at fully closed position ... 85 °C (185 °F) Maximum closing time ... 2 minutes

SPECIFICATIONS

026

G3516E Service manual (GAS)

Media Number -KENR6833-02

Cylinder Block S/N - -

Illustration 1 Front view

g01417382

Illustration 2

g01434393

Right side view

Note: During assembly, the bottom of spacer plates, top of cylinder block and both sides of plate gasket must be free of fuel, oil, water, gasket adhesives, assembly compounds and any other contaminants. (A) Thickness of the spacer plate ... 12.313 mm (0.4848 inch) (B) Thickness of the plate gasket between the cylinder block and spacer plate ... 0.194 to 0.218 mm (0.0076 to 0.0086 inch) (C) Extension of the dowel from the top face of the cylinder block ... 21.0 ± 0.5 mm (0.83 ± 0.02 inch) (1) Torque for four plugs ... 100 ± 15 N·m (75 ± 11 lb ft) (2) Lubricate the bore of the O-ring seals lightly with the lubricant that is being sealed. (D) Height of the cylinder liner For the correct method of determining the height of the cylinder liner, refer to Testing And Adjusting, "Cylinder Liner Projection". (E) Bore in the block for the camshaft bearings ... 98.000 ± 0.020 mm (3.8583 ± 0.0008 inch) (F) The oil holes in the camshaft bearings must be positioned from horizontal at the following angle: ... 20 ± 5 degrees Note: All centerlines through the oil holes in the camshaft bearings (F) and the camshaft bearing joints (3) must be in the position that is shown for each side of the cylinder block. (G) New dimension from centerline of crankshaft bearing bore to the top of the block ... 586 mm (23.1 inch) (H) New dimension from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 230 mm (9.1 inch) (J) Bore in the block for the main bearings Standard, original new size ... 169.742 ± 0.020 mm (6.6827 ± 0.0008 inch) 0.63 mm (0.025 inch) larger than original size ... 170.372 ± 0.020 mm (6.7075 ± 0.0008 inch) (K) Dimension for crankshaft main bearing cap Width of crankshaft main bearing cap ... 340.030 ± 0.015 mm (13.3870 ± 0.0006 inch) Width of cylinder block for crankshaft main bearing cap ... 339.985 ± 0.015 mm (13.3852 ± 0.0006 inch) Tight press fit between the sides of the crankshaft main bearing cap and the cylinder block ... 0.075 mm (0.0030 inch) Loose press fit between the sides of the crankshaft main bearing cap and the cylinder block ... 0.015 mm (0.0006 inch) (4) Main bearing cap Use the following procedure to tighten the crankshaft main bearing cap bolts:

1. Install main bearing caps with the part number and "FRONT" toward the front of the block. Each cap has a number. Each cap must be installed in the same position as the correct number on the side of the cylinder block pan rail. 2. Before assembly, apply clean engine oil on the threads of the bolts. 3. Tighten bolt (5) through bolt (8) in the numerical sequence that is shown in Illustration 1 to a torque of 190 ± 14 N·m (140 ± 10 lb ft). 4. Tighten bolt (5) through bolt (8) again in the numerical sequence to a rotation of 180 ± 5 degrees. (L) Extension of the dowel from the rear face of the cylinder block ... 6.0 ± 0.5 mm (0.24 ± 0.02 inch) (M) Extension of the dowel from the front face of the cylinder block ... 6.0 ± 0.5 mm (0.24 ± 0.02 inch) (N) Extension of the dowel from the rear face of the cylinder block ... 19.0 ± 0.5 mm (0.75 ± 0.02 inch) (P) Extension of the dowel from the front face of the cylinder block ... 40.0 ± 0.5 mm (1.57 ± 0.02 inch)

SPECIFICATIONS

027

G3516E Service manual (GAS)

Media Number -KENR6833-02

Crankshaft S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Illustration 1

g01419944

(1) Thrust plates

Refer to Specifications, "Connecting Rod And Main Bearing Journals" for more information. (B) Crankshaft end play ... 0.17 to 0.63 mm (0.007 to 0.025 inch) (2) Torque for the plugs ... 50 ± 7 N·m (37 ± 5 lb ft) Note: Do not reuse counterweight bolts. (3) Use the following procedure to tighten the bolts of the counterweight: 1. Before assembly, lubricate the threads of the bolts, the bolt shank, the washers and the contact surface under the bolt head with 6V-4876 Lubricant . 2. Tighten all the bolts evenly to 70 ± 5 N·m (50 ± 4 lb ft). 3. Rotate each bolt for an additional 120 ± 5 degrees.

SPECIFICATIONS

028

G3516E Service manual (GAS)

Media Number -KENR6833-02

Crankshaft Wear Sleeves and Seals S/N - -

Illustration 1

g01414669

(1) Flywheel housing group (2) Front housing group

Note: The crankshaft seal group cannot be used once the seal has been separated from the wear sleeve. Note: Make sure that the correct crankshaft seal group is installed on each end of the crankshaft. (3) 113-8433 Crankshaft Seal Gp l

Install the crankshaft seal group in the flywheel housing group on a standard rotation engine.

l

Install thecrankshaft seal group in the front housing group on a reverse rotation engine.

(4) 113-8432 Crankshaft Seal Gp l

Install the crankshaft seal group in the front housing group on a standard rotation engine.

l

Install the crankshaft seal group in the flywheel housing group on a reverse rotation engine.

(A) The crankshaft seal group is installed from both ends of the crankshaft at the following distance. ... 8.0 ± 0.5 mm (0.31 ± 0.02 inch) (B) The wear sleeve is installed from both ends of the crankshaft at the following distance. ... 0.5 ± 0.5 mm (0.02 ± 0.02 inch)

SPECIFICATIONS

029

G3516E Service manual (GAS)

Media Number -KENR6833-02

Connecting Rod S/N - -

Illustration 1

g01416660

(A) Angle above the centerline on either side of the bearing joint for the sleeve bearing for the piston pin. ... 10 degrees Note: The connecting rod must be heated prior to installation of the sleeve bearing for the piston pin. Do not use a torch to heat the connecting rod. (B) The connecting rod may be heated from 175 to 260 °C (347 to 500 °F) for the installation of the

sleeve bearing for the piston pin. Minimum length for heating the connecting rod ... 105 mm (4.1 inch) Note: Thoroughly lubricate the piston pin with clean engine oil prior to assembly of the piston and the connecting rod. (C) Dimensions for the piston pin Bore in the sleeve bearing for the piston pin after installation of the sleeve bearing ... 70.000 ± 0.008 mm (2.7559 ± 0.0003 inch) Bore in the connecting rod for the sleeve bearing for the piston pin ... 75.760 ± 0.015 mm (2.9827 ± 0.0006 inch) (D) Distance between the center of the bearings ... 380 mm (15.0 inch) (E) Protrusion of the dowel from the connecting rod cap ... 4.0 ± 0.5 mm (0.16 ± 0.02 inch) (F) Bore in the connecting rod for the bearing for the crankshaft connecting rod journal after applying final torque to the connecting rod bolts ... 143.028 ± 0.015 mm (5.6310 ± 0.0006 inch) (G) Bore in the connecting rod bearing for crankshaft ... 135.133 to 135.194 mm (5.3202 to 5.3226 inch) (1) Etch the cylinder number on the connecting rod and the cap in this location. Mark the connecting rod and the cap with numbers. Mark the numbers on the same side of the connecting rod as the bearing retainer notch. Note: Install the connecting rod in the engine with the part number to the rear of the engine.

Illustration 2

g01526418

View H-H (3) Location pin for correct installation of connecting rod caps

(2) The chamfer side must be adjacent to the crank pin thrust surface when the connecting rod and piston group is assembled in the engine. Side clearance between two connecting rods on the same new crankshaft pin ... 0.850 ± 0.332 mm (0.0335 ± 0.0131 inch) Use the following procedure for tightening the connecting rod bolts: Note: Bolt 1 and bolt 2 must be on the same end of the connecting rod cap that has bearing tabs and location pin (3) . 1. Before assembly, apply 6V-4876 Lubricant on the bolt threads, the bolt shank and the bolt seat. 2. Tighten the bolt 1 and bolt 2 to 90 ± 5 N·m (66 ± 4 lb ft).

3. Tighten the bolt 3 and bolt 4 to 90 ± 5 N·m (66 ± 4 lb ft). 4. Again, tighten the bolt 3 and bolt 4 to 90 ± 5 N·m (66 ± 4 lb ft). 5. Tighten all bolts for an additional 90 ± 5 degrees.

SPECIFICATIONS

030

G3516E Service manual (GAS)

Media Number -KENR6833-02

Connecting Rod and Main Bearing Journals S/N - Refer to Guidelines For Reusable Parts, SEBF8009, "Main Bearings And Connecting Rod Bearings" for more information. Connecting Rod Bearing Journals Table 1 Diameter Of Crankshaft Journal (Bearing Surface) For Connecting Rod Bearings Original Size Journal

135.000 ± 0.025 mm (5.3150 ± 0.0010 inch)

Undersize Journal 0.63 mm (0.025 inch)

134.370 ± 0.025 mm (5.2902 ± 0.0010 inch)

Undersize Journal 1.27 mm (0.050 inch)

133.730 ± 0.025 mm (5.2650 ± 0.0010 inch)

Clearance between bearing and new journal ... 0.107 to 0.218 mm (0.0042 to 0.0086 inch) Main Bearing Journals Table 2 Diameter Of Crankshaft Journal (Bearing Surface) For Main Bearings Original Size Journal

160.000 ± 0.025 mm (6.2992 ± 0.0010 inch)

Undersize Journal 0.63 mm (0.025 inch)

159.370 ± 0.025 mm (6.2744 ± 0.0010 inch)

Undersize Journal 1.27 mm (0.050 inch)

158.730 ± 0.025 mm (6.2492 ± 0.0010 inch)

Clearance between bearing and new journal ... 0.122 to 0.241 mm (0.0048 to 0.0095 inch)

SPECIFICATIONS

031

G3516E Service manual (GAS)

Media Number -KENR6833-02

Piston and Rings S/N - GAS1-UP , S/N - SLY1-UP

Illustration 1

g01445652

Oil Control Piston Ring (1) The ends of the oil control piston ring should be a distance of 180 degrees from the ring end gap when the oil control piston ring is assembled. The white colored portion of the piston ring must be visible at the ring end gap. Width of groove in new piston for the oil control piston ring ... 5.050 ± 0.010 mm (0.1988 ± 0.0004 inch) Thickness of new oil control piston ring ... 4.954 ± 0.019 mm (0.1950 ± 0.0007 inch) Clearance between the groove and the new oil control piston ring ... 0.067 to 0.125 mm (0.0026 to 0.0049 inch) When the new oil control piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. ... 0.70 ± 0.19 mm (0.028 ± 0.007 inch) Increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore ... 0.08 mm (0.003 inch)

Intermediate Piston Ring (2)

Install the intermediate piston ring with the "UP-2" side toward the top of the piston. The intermediate piston ring must be installed with the green colored stripe to the right of the ring end gap. Width of groove in new piston for intermediate piston ring ... 3.600 ± 0.010 mm (0.1417 ± 0.0004 inch) Thickness of new intermediate piston ring ... 3.470 ± 0.020 mm (0.1366 ± 0.0008 inch) Clearance between the groove and the new intermediate piston ring ... 0.100 to 0.160 mm (0.0039 to 0.0063 inch) When the new intermediate piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. ... 0.80 ± 0.20 mm (0.031 ± 0.008 inch) Increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore ... 0.08 mm (0.003 inch)

Top Piston Ring (3) Install the top piston ring with the "UP-1" side toward the top of the piston. The top piston ring must be installed with the red colored stripe to the right of the ring end gap. Width of groove in new piston for the top piston ring ... 3.600 ± 0.010 mm (0.1417 ± 0.0004 inch) Thickness of new top piston ring ... 3.470 ± 0.013 mm (0.1366 ± 0.0005 inch) Clearance between the groove and the new piston ring ... 0.130 to 0.190 mm (0.0051 to 0.0075 inch) When the piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. ... 0.65 ± 0.15 mm (0.026 ± 0.006 inch) Increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore ... 0.08 mm (0.003 inch) Note: After the piston rings have been installed, rotate the piston rings so that the end gaps are 120 degrees from each other.

Piston Pin (4) Note: Lubricate the piston pin with clean engine oil before assembly. Outside diameter ... 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch) Length ... 137.60 ± 0.13 mm (5.417 ± 0.005 inch) (A) Piston pin bore (vertical) ... 70.38 ± 0.10 mm (2.771 ± 0.004 inch)

Pin Retainer (5) Note: Install the pin retainer with the gap toward the top of the piston. Thickness of new pin retainer ... 2.40 ± 0.08 mm (0.094 ± 0.003 inch) Width of groove in new piston for the pin retainer ... 2.75 ± 0.15 mm (0.108 ± 0.006 inch)

SPECIFICATIONS

032

G3516E Service manual (GAS)

Media Number -KENR6833-02

Cylinder Liner S/N - -

Illustration 1

g01399536

(A) Bore in new cylinder liner ... 170.025 ± 0.025 mm (6.6939 ± 0.0010 inch) (B) Thickness of flange (1) on cylinder liner ... 12.65 ± 0.02 mm (0.498 ± 0.001 inch) Use the liner again with any used piston or any new piston if all the measurements are in the following range. Use a FLEX-HONE first. ... 170.000 to 170.152 mm (6.6929 to 6.6989 inch) Use the liner again with the original piston if the measurements of the upper bore are in the following range. Use a FLEX-HONE first. ... 170.000 to 170.229 mm (6.6929 to 6.7019 inch) Use the following procedure to install the cylinder liner: 1. Apply liquid soap on the cylinder block liner bore surfaces and the rubber seals that are on the lower end of the cylinder liner. 2. Dip the filler band (2) completely in clean engine oil for a moment. 3. Immediately install the filler band in the groove that is under the flange. 4. Immediately install the cylinder liner into the cylinder block before the expansion of the filler band. Note: Refer to Reuse And Salvage Guidelines, SEBF8049, "Visual Inspection of the Piston" for more information. Also, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8068, "Cylinder Liners" for more information.

SPECIFICATIONS

033

G3516E Service manual (GAS)

Media Number -KENR6833-02

Camshaft Bearing Position S/N - -

Illustration 1

g01439280

Right side view

The dimensions for installing the camshaft bearings are from the rear face of the cylinder block. For engines that have 8 cylinders, use dimensions (L) , (K) , (J) , (H) , and (G) . For engines that have 12 cylinders, use dimensions (L) , (K) , (J) , (H) , (G) , (F) , and (E) . For engines that have 16 cylinders, use dimensions (L) , (K) , (J) , (H) , (G) , (F) , (E) , (D) and (C) . For engines that have 20 cylinders, use all of the dimensions. Note: The oil holes must be aligned at the correct angle when the bearings are installed. Refer to Specifications, "Cylinder Block" for the correct angle. Dimensions (A) ... 2740.0 ± 1.5 mm (107.87 ± 0.06 inch) (B) ... 2470.0 ± 1.5 mm (97.24 ± 0.06 inch) (C) ... 2200.0 ± 1.5 mm (86.61 ± 0.06 inch) (D) ... 1930.0 ± 1.5 mm (75.98 ± 0.06 inch) (E) ... 1660.0 ± 1.5 mm (65.35 ± 0.06 inch) (F) ... 1390.0 ± 1.5 mm (54.72 ± 0.06 inch)

(G) ... 1120.0 ± 1.5 mm (44.09 ± 0.06 inch) (H) ... 850.0 ± 1.5 mm (33.46 ± 0.06 inch) (J) ... 580.0 ± 1.5 mm (22.83 ± 0.06 inch) (K) ... 310.0 ± 1.5 mm (12.20 ± 0.06 inch) (L) ... 40.0 ± 1.5 mm (1.57 ± 0.06 inch)

SPECIFICATIONS

034

G3516E Service manual (GAS)

Media Number -KENR6833-02

Gear Group (Front) S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Illustration 1

g01428397

Typical example (5) Idler gear assembly (6) Water pump drive gear (7) Crankshaft gear

Note: Install the socket setscrew to the bottom of the threaded hole. (1) Torque for the socket setscrew ... 6 ± 1 N·m (53 ± 9 lb in) (2) Pump drive shaft assembly

Bore in sleeve bearing after assembly ... 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) Diameter of new pump drive shaft assembly. ... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) (3) Lubricate the bore of the O-ring seals lightly with lubricant that is being sealed. (4) Thrust washer Thickness of new thrust washer ... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) Width of groove in new pump drive shaft assembly. ... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) End play for the pump drive shaft assembly ... 0.175 to 0.325 mm (0.0069 ± 0.0128 inch) (8) Idler shaft Diameter of the idler shaft ... 105.88 ± 0.02 mm (4.168 ± 0.001 inch) Bore in the sleeve bearing for idler shaft ... 105.970 ± 0.010 mm (4.1720 ± 0.0004 inch)

SPECIFICATIONS

035

G3516E Service manual (GAS)

Media Number -KENR6833-02

Gear Group (Rear) S/N - -

Illustration 1

g01365017

Rear gear train (1) Ring (3) Idler gear assembly (13) Plate

Note: Before assembly, it is critical that the taper of the camshaft and the tapered bore of the camshaft drive gear are clean, dry, and free of residue. Refer to Disassembly and Assembly for the installation procedure for the left camshaft drive gear (2) . (5) Torque for the bolts ... 140 ± 10 N·m (105 ± 7 lb ft) (6) Gear shaft After the sleeve bearing is installed in the gear the sleeve bearing must be machined to size. Diameter of the gear shaft ... 74.990 ± 0.010 mm (2.9524 ± 0.0004 inch) Bore in the sleeve bearing for the gear shaft after machining ... 75.060 ± 0.010 mm (2.9551 ± 0.0004 inch) Maximum roughness average (Ra) ... 0.8 micrometer (32 microinch) Refer to Disassembly and Assembly for the installation procedure for the right camshaft drive gear (7) .

(8) Idler shaft After the sleeve bearing is installed in the gear the sleeve bearing must be machined to size. Diameter of the idler shaft ... 81.000 ± 0.010 mm (3.1890 ± 0.0004 inch) Bore in the sleeve bearing for the idler shaft after machining ... 81.060 ± 0.010 mm (3.1913 ± 0.0004 inch) Maximum roughness average (Ra) ... 0.8 micrometer (32 microinch)

Illustration 2

g01256372

Vertical line

(9) Use the following procedure to tighten the bolt for the camshaft drive gears: 1. Tighten the bolt for the camshaft drive gear to 360 ± 40 N·m (260 ± 30 lb ft). 2. Mark a vertical line on the head of the bolt for the camshaft drive gear. Refer to Illustration 2. 3. Place a driver against the retaining plate of the camshaft drive gear. Strike the driver solidly with a hammer 3 to 4 times. 4. Tighten the bolt for the camshaft drive gear again to 360 ± 40 N·m (260 ± 30 lb ft).

Illustration 3

g01256393

5. Repeat Steps 3 and 4 until the mark on the bolt turns a minimum of 90 degrees. Refer to Illustration 3. (10) Torque for the bolts ... 240 ± 20 N·m (175 ± 15 lb ft) (11) Torque for the bolts ... 240 ± 20 N·m (175 ± 15 lb ft)

Illustration 4

g01365021

Rear view of engine

(14) The mark on the balancer gear assembly (4) must be in alignment with the mark on the crankshaft gear (12) .

SPECIFICATIONS

036

G3516E Service manual (GAS)

Media Number -KENR6833-02

Auxiliary Drive (Lower Left Hand) S/N - GAS1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1-UP , S/N - TJD1-UP

Illustration 1

g01417857

(1) Diameter of new shaft ... 105.880 ± 0.020 mm (4.1685 ± 0.0008 inch) (2) Bore in bearing of idler gear assembly after installation ... 105.970 ± 0.010 mm (4.1720 ± 0.0004 inch) (3) Bore in bearing of adapter assembly after installation ... 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) (4) Diameter of new pump drive shaft ... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) (5) Thrust washer Thickness of new thrust washer ... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) Width of groove of thrust washer in new pump drive shaft ... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)

SPECIFICATIONS

037

G3516E Service manual (GAS)

Media Number -KENR6833-02

Engine Mount S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJC1-UP

Illustration 1

Rated load ... 26700 N (6000 lb) Maximum deflection ... 19.00 mm (0.748 inch)

g01010006

SPECIFICATIONS

038

G3516E Service manual (GAS)

Media Number -KENR6833-02

Vibration Damper Guard S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Illustration 1

(1) Torque for the four bolts ... 15 ± 3 N·m (11 ± 2 lb ft) (2) Torque for the six locking bolts ... 15 ± 3 N·m (11 ± 2 lb ft)

g01437889

SPECIFICATIONS

039

G3516E Service manual (GAS)

Media Number -KENR6833-02

Flywheel Housing Cover S/N - -

Illustration 1 Typical example

(1) Torque for the five plugs ... 70 ± 15 N·m (50 ± 11 lb ft)

g01393065

SPECIFICATIONS

040

G3516E Service manual (GAS)

Media Number -KENR6833-02

Flywheel S/N - -

Illustration 1

g01447953

Typical example

Refer to Systems Operation/Testing and Adjusting, "Flywheel - Inspect" for the correct method of flywheel inspection. Note: Align the dash mark on the flywheel with the dash mark on the crankshaft. Note: Lubricate the threads of the 12 bolts (1) with clean engine oil or 6V-4876 Lubricant or graphite base lubricant. (1) Torque for 12 bolts ... 1150 ± 60 N·m (840 ± 44 lb ft)

041

SPECIFICATIONS

G3516E Service manual (GAS)

Media Number -KENR6833-02

Flywheel Housing S/N - For information on inspecting the flywheel housing, refer to Systems Operation/Testing and Adjusting. Note: Before installation of the flywheel housing, inspect the front face of the flywheel housing and the rear face of the cylinder block. The components must be free of the following substances: oil, fuel, water, gasket adhesive, assembly compounds and any other foreign material. To seal the joint between the flywheel housing and the cylinder block, apply 1U-8846 Gasket Sealant or apply 185-3983 Gasket Sealant to the mating surface of the flywheel housing.

Illustration 1

g01532155

Rear view of engine

Table 1 Flywheel Housing Bolt Installation Chart Bolt 1

Diameter inch 1/2

Bolt Length

Part Number

mm

inch

9X-8875

88.9

3.50

2

1/2

1A-7669

177.8

7.00

3

1/2

9X-8873

57.15

2.250

4

5/8

1D-4590

120.65

4.750

5

1/2

9S-1374

203.2

8.00

6

1/2

8S-9089

114.3

4.50

Tighten the bolts that hold the flywheel housing to the engine block evenly. Refer to Illustration 1 and Table 1 for the locations and for identification of the bolts. (1) Torque for four bolts ... 135 ± 20 N·m (100 ± 15 lb ft) (2) Torque for two bolts ... 135 ± 20 N·m (100 ± 15 lb ft) (3) Torque for six bolts ... 135 ± 20 N·m (100 ± 15 lb ft) (4) Torque for 16 bolts ... 270 ± 40 N·m (200 ± 30 lb ft) (5) Torque for two bolts ... 135 ± 20 N·m (100 ± 15 lb ft) (6) Torque for four bolts ... 135 ± 20 N·m (100 ± 15 lb ft)

Illustration 2

g01438396

Left side view of engine

(7) Apply 1U-8846 Gasket Sealant to the surface of the gasket before assembly.

SPECIFICATIONS

042

G3516E Service manual (GAS)

Media Number -KENR6833-02

Belt Tension Chart S/N - Note: Do not use the belt tension chart for belts with tensioners that are spring loaded. Table 1 Belt Tension Chart

Gauge Reading Size of Belt

8RIB POLY - RIB

Width of Belt

27.82 mm (1.095 inch)

Belt Tension (Force) "Initial"

Belt Tension (Force) "Used"

(1)

(2) (3)

800 ± 22 N (180 ± 5 lb)

489 ± 44 N (110 ± 10 lb)

Suggested Gauge (Force)

Suggested Gauge (Frequency) Belt Tension (Frequency) "Initial" (1)

Belt Tension (Frequency) "Used" (2) (3)

Basic Gauge Number

BT-33-109

Gauge Number

98 ± 10 HZ

76 ± 8 HZ

Clavis Type 14

Measure the tension of the belt that is farthest from the engine. (1)

Belt tension "lnitial" is for a new belt.

(2)

Belt tension "Used" is for a belt that has operated for 30 minutes or more of operation at the rated speed.

(3)

If a belt falls below the "Used" belt tension, the belt should be tightened again to the high side of the "Used" belt tension.

SPECIFICATIONS

043

G3516E Service manual (GAS)

Media Number -KENR6833-02

Accessory Drive S/N - GAS1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1-UP

Illustration 1

g01438277

(1) Diameter of new shaft ... 105.880 ± 0.020 mm (4.1685 ± 0.0008 inch) Note: After the bearing is installed in the idler gear the bearing must be machined to size. (2) Idler gear assembly Bore in the bearing after assembly ... 105.970 ± 0.010 mm (4.1720 ± 0.0004 inch) Maximum roughness average (Ra) ... 0.8 micrometer (32 microinch) (3) Auxiliary drive shaft

Diameter of new auxiliary drive shaft ... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Width of groove in new auxiliary drive shaft ... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) End play for auxiliary drive shaft ... 0.175 to 0.325 mm (0.0069 to 0.0128 inch) (4) Thrust washer Quantity ... 4 Thickness of one new thrust washer ... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) (5) Bore in the sleeve bearing after assembly ... 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) (6) Lubricate the bore of the five O-ring seals lightly with the lubricant that is being sealed. (7) Shaft Diameter of new shaft ... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Width of groove in new shaft ... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) End play for shaft ... 0.175 to 0.325 mm (0.0069 to 0.0128 inch)

SPECIFICATIONS

044

G3516E Service manual (GAS)

Media Number -KENR6833-02

Alternator and Regulator S/N - -

Illustration 1

g01074415

Illustration 2

g01560100

Voltage ... 24 V Amperage ... 60 Amp Polarity ... Negative ground Rotation ... Either direction Minimum full load current at 5000 rpm ... 54 Amp Minimum full load current at 1500 rpm ... 19 Amp Turn on speed ... 2600 rpm Output voltage ... 28 ± 1 V (1) Final installation torque for locknut ... 102 ± 7 N·m (75 ± 5 lb ft) (2) (B-) terminal. Final installation torque for nut ... 7.1 ± 0.8 N·m (65 ± 7 lb in) (3) (B+) terminal. Final installation torque for nut ... 7.1 ± 0.8 N·m (65 ± 7 lb in)

SPECIFICATIONS

045

G3516E Service manual (GAS)

Media Number -KENR6833-02

Alternator Mounting S/N - -

Illustration 1 Front view and right side view

(2) Adjust the belt tension of the serpentine belt according to the 197-9087 Tension Chart . Note: Maximum misalignment between pulley assembly (1) and pulley (3) is 0.4 degrees. (4) Tighten the pulley retaining nut to the following torque. ... 110 ± 10 N·m (80 ± 7 lb ft) (5) Lubricate the sealing lip of the lip type seal lightly with the lubricant that is being sealed.

g01388560

SPECIFICATIONS

046

G3516E Service manual (GAS)

Media Number -KENR6833-02

Electric Starting Motor S/N - -

Illustration 1

g01394255

When the electric starting motor is viewed from the pinion end, the motor rotates in the following direction. ... Clockwise No load conditions at 25 °C (77 °F) Speed ... 6950 ± 1650 rpm Current draw ... 115 ± 25 Amp Voltage ... 23 VDC (B) The clearance between the pinion and the housing is the following value. ... 9.1 mm (0.36 inch) (1) Final installation torque for the ground terminal nut ... 30.5 ± 3.5 N·m (270 ± 30 lb in) (2) Final installation torque for the ground terminal nut ... 2.25 ± 0.25 N·m (20 ± 2 lb in) Note: The switch terminal must be insulated with heat shrink tubing. Do not use molded terminals. (3) Final installation torque for the switch terminal nut ... 2.25 ± 0.25 N·m (20 ± 2 lb in) (4) Final installation torque for the motor terminal nut ... 30.5 ± 3.5 N·m (270 ± 30 lb in) Note: A maximum of three cable terminals or wire terminals may be used with the battery terminal nut. A maximum of two of the terminals may be equal to or greater than 0 AWG. (5) Final installation torque for the battery terminal nut ... 30.5 ± 3.5 N·m (270 ± 30 lb in)

(6) Final installation torque for the motor frame terminal nut ... 30.5 ± 3.5 N·m (270 ± 30 lb in) Solenoid Current consumption at 20V and 25 °C (77 °F) Pull-in windings ... 49.3 ± 3.3 Amp Hold-in windings ... 6.8 Amp max

SPECIFICATIONS

047

G3516E Service manual (GAS)

Media Number -KENR6833-02

Engine Speed Sensor S/N - -

Illustration 1

g01448928

Operating temperature ... -40 to 150 °C (-40 to 320 °F) Clearance between the speed sensor group and the flywheel ring gear ... 0.50 to 0.75 mm (0.020 to 0.030 inch) Use the following procedure to install the speed sensor group (1) : 1. Install the speed sensor group into the 5/8 threaded hole and turn until the magnetic core makes contact with a tooth of the flywheel ring gear. 2. Back out 180 degrees. 3. Tighten the nut to 25 ± 5 mm (221± 44 inch).

SPECIFICATIONS

048

G3516E Service manual (GAS)

Media Number -KENR6833-02

Temperature Sensor S/N - -

Illustration 1

g01445314

(1) Final installation torque for the temperature sensor group ... 20 ± 3 N·m (15 ± 2 lb ft) Operating temperature ... -40 to 120 °C (-40 to 248 °F) Operating voltage ... 4.75 to 8.50 VDC Output type ... Analog

SPECIFICATIONS

049

G3516E Service manual (GAS)

Media Number -KENR6833-02

Temperature Sensor - Thermocouple S/N - -

Illustration 1

g01428684

(1) Final installation torque for the nut ... 12 ± 3 N·m (105 ± 27 lb in) Operating temperature ... -40 to 1095 °C (-40 to 2003 °F) Medium ... Engine coolant, engine oil, fuel, air, hydraulic oil, and exhaust Output type ... Thermocouple

SPECIFICATIONS

050

G3516E Service manual (GAS)

Media Number -KENR6833-02

Temperature Sensor S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP

Illustration 1

g01428683

(2) Signal (3) Ground

(1) Final installation torque for the temperature sensor group ... 20 ± 5 N·m (15 ± 4 lb ft) Operating temperature ... -40 to 150 °C (-40 to 302 °F) Output type ... Passive

SPECIFICATIONS

051

G3516E Service manual (GAS)

Media Number -KENR6833-02

Pressure Sensor S/N - -

Illustration 1

g01046622

(1) Final installation torque for the pressure sensor group ... 10 ± 2 N·m (90 ± 18 lb in) Medium ... Engine oil and diesel fuel Operating voltage ... 5.00 ± 0.25 VDC Operating temperature ... -40 to 125 °C (-40 to 257 °F)

SPECIFICATIONS

052

G3516E Service manual (GAS)

Media Number -KENR6833-02

Pressure Sensor S/N - -

Illustration 1

g01445317

(1) Final installation torque for the pressure sensor group ... 10 ± 2 N·m (90 ± 18 lb in) Operating temperature ... -40 to 125 °C (-40 to 257 °F) Operating voltage ... 5.00 ± 0.25 VDC Note: Install the pressure sensor so that the pressure port is lower than the wire end. Mount the pressure sensor as close to vertical as possible.

SPECIFICATIONS

053

G3516E Service manual (GAS)

Media Number -KENR6833-02

Pressure Sensor S/N - -

Illustration 1

g01154731

(1) Final installation torque for the pressure sensor group ... 10 ± 2 N·m (90 ± 18 lb in) Operating temperature ... -40 to 125°C (-40 to 257 °F) Operating voltage ... 5.0 ± 0.5 VDC

SPECIFICATIONS

054

G3516E Service manual (GAS)

Media Number -KENR6833-02

Detonation Sensor S/N - -

Illustration 1

g01444643

(1) Final installation torque for the detonation sensor group ... 15 ± 3 N·m (11 ± 2 lb ft) Operating temperature ... -40 to 121 °C (-40 to 250 °F) Operating voltage ... 8.00 ± 0.25 VDC

SPECIFICATIONS

055

G3516E Service manual (GAS)

Media Number -KENR6833-02

Jacket Water Inlet Pressure Switch S/N - -

Illustration 1

g01428698

Note: Apply 4C-4030 Thread Lock Compound to the threads of the pressure switch. (1) Final installation torque for the pressure switch ... 22 ± 3 N·m (16 ± 2 lb ft) Operating temperature ... -40 to 121 °C (-40 to 250 °F) Position and condition Contact position (A) and (B) ... Normally open below deactuation pressure Contact position (B) and (C) ... Normally closed below deactuation pressure Actuation pressure at -40 to 121 °C (-40 to 250 °F) ... 462 ± 41 kPa (67 ± 6 psi) Deactuation pressure at -40 to 121 °C (-40 to 250 °F) ... 462 ± 41 kPa (67 ± 6 psi)

SPECIFICATIONS

056

G3516E Service manual (GAS)

Media Number -KENR6833-02

Disconnect Switch S/N - -

Illustration 1

g01428700

(1) Final installation torque for the full nuts ... 19 ± 2 N·m (168 ± 18 lb in) (2) Final installation torque for the nut ... 23 ± 4 N·m (204 ± 35 lb in) Actuating torque ... 2.03 ± 0.34 N·m (17.97 ± 3.01 lb in) Contact rating ... 1000 Amp Maximum voltage drop for contact at rated current ... 0.3 Volt Operating temperature ... -40 to 85 °C (-40 to 185 °F)

SPECIFICATIONS

057

G3516E Service manual (GAS)

Media Number -KENR6833-02

Engine Speed/Timing Sensor S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP

Illustration 1

g01519083

Note: Before installation, coat the sensor assembly's threads with 4c-5599 Anti-Seize Compound . (1) Final installation torque for the sensor assembly ... 40 ± 5 N·m (30 ± 4 lb ft) Operating temperature ... −40 to 121 °C (−40 to 250 °F) Operating voltage ... 12 to 14 V (2) Sliphead Before installation, make sure that the sliphead is fully extended.

SPECIFICATIONS

058

G3516E Service manual (GAS)

Media Number -KENR6833-02

Engine Speed/Timing Sensor S/N - -

Illustration 1

g01372538

(1) Final installation torque for the speed sensor group ... 40 ± 5 N·m (30 ± 4 lb ft) Operating voltage ... 12 to 14 VDC Operating temperature ... -40 to 120 °C (-40 to 248 °F) Output frequency ... 9 to 10000 Hz Duty cycle ... 50 %

SPECIFICATIONS

059

G3516E Service manual (GAS)

Media Number -KENR6833-02

Magnetic Switch S/N - -

Illustration 1

g01521217

Note: Mount the terminal end of the switch upward in a vertical plane. Note: The magnetic switch must be isolated from engine vibration. Contact position ... Normally open Nominal system voltage ... 24 VDC Duty cycle ... Intermittent Resistance at 25 °C (77 °F) ... 17.7 ± 0.4 Ohms Operating temperature ... -60 to 121 °C (-76 to 250 °F) (1) Final installation torque for nuts ... 1.70 ± 0.25 N·m (15 ± 2 lb in) (2) Final installation torque for full nuts ... 3.60 ± 0.40 N·m (30 ± 4 lb in)

SPECIFICATIONS

060

G3516E Service manual (GAS)

Media Number -KENR6833-02

Junction Box S/N - GAS1-UP , S/N - GSB1-UP , S/N - GZC1-UP , S/N - GZZ1-UP , S/N - SLY1-UP , S/N - TJB1UP , S/N - TJC1-UP , S/N - TJD1-UP

Illustration 1

g01428703

(1) Circuit breaker assembly Quantity ... 2 Maximum voltage ... 80 VDC (240 VAC) Nominal current rating ... 2.5 amperes (2) Circuit breaker assembly Maximum voltage ... 80 VDC (240 VAC) Nominal current rating ... 10 amperes (3) Circuit breaker assembly Maximum voltage ... 80 VDC (240 VAC) Nominal current rating ... 35 amperes (4) Final installation torque for the two bronze nuts ... 20 ± 1 N·m (15 ± 1 lb ft)

Media Number -KENR6834-03

G3516E Service manual (GAS) Systems Operation Electronic Control System Operation Electronic Control Module (ECM) Start/Stop Control Engine Governing Integrated Temperature Sensing Module Electronic Control System Parameters Configuration Parameters Timing Control "First Desired Timing" "Second Desired Timing" Air/Fuel Ratio Control "Fuel Quality Input Type Configuration" "Fuel Quality Sensor LHV Lower Limit" "Fuel Quality Sensor LHV Upper Limit" "Fuel Quality" "Gas Specific Gravity" "Fuel Specific Heat Ratio" "Desired Emission Gain Adjustment Percentage" "Air/Fuel Proportional Gain" "Air/Fuel Integral Gain" Speed Control "Low Idle Speed" "Minimum Engine High Idle Speed" "Maximum Engine High Idle Speed" "Engine Acceleration Rate" "Desired Speed Input Configuration" "Governor Type Setting" "Engine Speed Droop" Governor Gain Settings "Governor Gain Factor" "Governor Stability Factor" "Governor Compensation Factor" "Auxiliary Proportional Governor Gain 1" "Auxiliary Integral Governor Gain 1" "Auxiliary Derivative Governor Gain 1" Start/Stop Control Parameters "Driven Equipment Delay Time" "Crank Terminate RPM" "Engine Purge Cycle Time" "Cooldown Duration" "Cycle Crank Time" "Engine Overcrank Time" "Engine Speed Drop Time" "Engine Pre-Lube Time Out Period" Monitoring and Protection "High Inlet Air Temp Engine Load Setpoint" "Impending Shutdown Delay Enable Status" "Impending Shutdown Delay Time" Power Monitoring "Generator Output Power Sensor Scale Factor" "Generator Output Power Sensor Offset"

INDEX 001 002 003 004 005 006

"Engine Output Power" "Engine Driven Accessory Load Configuration" Information for the ECM "Engine Serial Number" "Equipment ID" Customer Passwords "Total Tattletale" Engine Sensors Electronic Service Tools Caterpillar Electronic Technician (ET) Engine Monitoring System Monitoring Parameters "Low System Voltage" "High Engine Coolant Temperature" "Low Engine Coolant Temperature" "Engine Overspeed" "High Engine Oil Temperature" "High Oil Filter Differential Pressure" "Low Oil Filter Differential Pressure" "High Fuel Temperature" "Low Fuel Pressure" "High Eng Oil to Eng Coolant Diff Temp" "Low Gas Fuel Differential Pressure" "High Gas Fuel Differential Pressure" "High System Voltage" Trip Points of the Engine Load for High Inlet Air Temperature "High Inlet Air Temperature at Low Engine Load" "High Inlet Air Temperature at High Engine Load" "High Fuel Pressure" Conditions for Parameters Ignition System Ignition Transformers and Spark Plugs Fuel System Operation Air/Fuel Ratio Control Inputs from the Customer Fuel Quality Engine Load Open Loop Mode Charge Density Feedback Aftercooler Compressor Bypass Exhaust Manifold Turbocharger Valve System Components Lubrication System Cooling System Jacket Water System Separate Circuit Cylinder Block, Liners and Heads Pistons, Rings and Connecting Rods Crankshaft Camshaft Air Starting System Electric Starting System Power Supply Requirements for the Control System

007 008 009

010 011 012

013 014 015 016 017 018 019

020 021 022 023 024 025 026

Grounding Practices Alternator Starting Solenoid Starting Motor Starting Motor Protection Circuit Breaker

027 028 029 030 031

SYSTEMS OPERATION

001

G3516E Service manual (GAS)

Media Number -KENR6834-03

Electronic Control System Operation One Electronic Control Module (ECM) is installed on the engine. A second ECM is optional. The second ECM is called the Auxiliary Sensing Module (ASM). The ASM improves the genset's ability to maintain a consistent level of frequency and voltage through improved processing of the signal. The ECM controls most of the functions of the engine. The operator's interface with the engine control is provided by the Caterpillar Electronic Technician (Cat ET) and by the control panel. For information on Cat ET, refer to Systems Operation/Testing and Adjusting, "Electronic Service Tools". There are two possible configurations for the engine's control system. Illustrations 1 and 2 are diagrams of the components in the engine's electronic control system.

Illustration 1

g01300921

Control system with an Auxiliary Sensing Module (ASM)

Illustration 2 Control system without an Auxiliary Sensing Module (ASM)

g01300922

SYSTEMS OPERATION

002

G3516E Service manual (GAS)

Media Number -KENR6834-03

Electronic Control Module (ECM) There are two possible configurations for the control system. Refer to Illustrations 1 and 2.

Illustration 1 Rear view (1) ECM

g01301888

Illustration 2

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Rear view (1) ECM (2) Auxiliary Sensing Module (ASM)

One ECM is installed on the engine. ECM (1) controls the engine's functions. Auxiliary Sensing Module (ASM) (2) is optional. Both modules are environmentally sealed units that are in an engine mounted terminal box. The ECM monitors various inputs from sensors in order to activate relays, solenoids, etc at the appropriate levels. The ECM supports the following primary functions: l l l l l l l

Start/stop control Control of ignition Governing of the engine Air/fuel ratio control Monitoring of the detonation sensors Diagnostics of the electrical system Monitoring and protection of engine operation

Auxiliary Sensing Module (ASM) (2) improves the genset's ability to maintain a consistent level of frequency and voltage. The modules do not have a removable personality module. The software is changed by programming a flash file into the module via the Caterpillar Electronic Technician (Cat ET).

SYSTEMS OPERATION

003

G3516E Service manual (GAS)

Media Number -KENR6834-03

Start/Stop Control The Electronic Control Module (ECM) contains the logic and the outputs for control of starting and of shutdown. The ECM responds to signals from the following components: engine control, emergency stop switch, remote start, data link and driven equipment. The following Steps describe the electronic control system's start/stop sequencing: 1. The ECM receives one of the following signals for start-up: ¡ The engine control is set to the "START" mode. ¡ The engine control is in the "AUTO" mode and the remote start/stop initiate contact closes. 2. After receiving a signal for start-up, the ECM waits for the programmable "Driven Equipment Delay Time" prior to cranking. The ECM will not start the engine until the input for driven equipment is grounded. If the driven equipment's input circuit is opened during engine operation, the engine will shut down. 3. After input for the driven equipment is grounded, the ECM supplies +Battery voltage to the solenoid for the starting motor. The starting motor cranks the engine without fuel and without ignition until the "Engine Purge Cycle Time" has elapsed. The "Engine Purge Cycle Time" allows any unburned fuel to exit through the exhaust system prior to ignition. This helps prevent combustion in the exhaust system. 4. After the "Engine Purge Cycle Time" has elapsed, the Gas Shutoff Valve (GSOV) is energized. The GSOV may be energized by the ECM, or by the customer's equipment. The ECM energizes the ignition transformers. The ECM sends a fuel command to the fuel metering valve in order to supply sufficient fuel for a combustible air/fuel mixture. The ECM also sends a throttle command to the throttle actuator. The engine has an energize-to-run type of GSOV. This means that the GSOV must be energized in order to open. When the GSOV is open, fuel is allowed to flow to the engine. 5. After the engine starts and the programmable crank terminate speed is achieved, the ECM removes the voltage from the starting motor's solenoid. The pinion of the starting motor disengages from the flywheel ring gear. 6. The engine runs until the ECM receives a shutdown signal. The following conditions cause a shutdown signal: ¡ The remote start/stop initiate contact opens when the engine control switch is in the "AUTO" position. ¡ The engine control is in the "COOLDOWN /STOP" mode. ¡ The "EMERGENCY STOP" button is pressed. ¡ The ECM senses an undesirable operating condition and an engine shutdown is initiated. The engine control "OFF/RESET" is not recommended for normal shutdown. The "EMERGENCY STOP" is not recommended for normal shutdown. Only the "EMERGENCY STOP" and an overspeed condition will cause both the fuel and the ignition to be stopped immediately. The cool down cycle will not operate. Any shutdown that is initiated by the ECM is the result of a condition that is undesirable and/or unplanned. One of the following conditions initiates a normal shutdown: ¡ The engine control switch is turned to the "COOLDOWN/STOP" position. ¡ The engine control switch is in the "AUTO" position and the remote start/stop initiate contact opens.

7. The engine operates for the programmable cool down period before the engine stops. After the cool down period, the ECM removes the +Battery voltage from the solenoid for the GSOV and the fuel flow is stopped. 8. The ignition continues to operate without a fuel supply until the engine speed is less than 40 rpm. Then, the ECM terminates the ignition. The engine coasts to a stop. If the engine speed is not reduced by at least 100 rpm during the programmable "Engine Speed Drop Time", the ECM terminates the ignition. The ECM activates an emergency stop.

SYSTEMS OPERATION

004

G3516E Service manual (GAS)

Media Number -KENR6834-03

Engine Governing

Illustration 1

g01011687

Diagram of the governing system

The Electronic Control Module (ECM) continuously strives to achieve the engine speed that is desired for the operating condition. The desired engine speed is determined by these factors: Desired Speed Input - A signal of either 0 to 5 VDC or 4 to 20 mA can provide this input. The "Desired Speed Input Configuration" determines the input that is used by the ECM. This input can be provided by a potentiometer. Programmable Parameters - The Caterpillar Electronic Technician (Cat ET) is used to program these parameters that affect the desired engine speed: "Low Idle Speed", "Minimum High Idle Speed" and "Maximum High Idle Speed". The programmable "Engine Accel. Rate" determines the rate of acceleration of the desired speed and rate of deceleration of the desired speed. The "Governor Type Setting" parameter can be set to "Droop" or to "Isochronous". Refer to Systems Operation/Testing and Adjusting, "Electronic Control System Parameters" for additional information on these parameters. Idle/Rated Switch - The idle/rated switch is optional. If the idle/rated switch is used, the engine speed can also be affected by the engine oil pressure: l l

l

If the idle/rated switch is in the idle position, the ECM will always select the low idle speed. If the engine oil pressure is less than the setpoint for the low pressure warning, the ECM will always select the low idle speed. If the engine oil pressure is greater than the setpoint for the low pressure warning and the idle/rated switch is in the rated position, the ECM will select the rated speed.

The actual engine speed is detected via a signal from the engine speed/timing sensor. The ECM compares the actual engine speed to the desired engine speed. The ECM functions as an electronic governor in order to develop a throttle command. The electronic governor uses gains in order to provide stable operation. Two sets of gains are available. The ECM uses the value of the "Grid Status" parameter in order to determine the set of gains that is used. If the "Grid Status" is OFF, the ECM uses the gains for the primary governor. If the "Grid Status" is ON, the ECM uses the gains for the auxiliary governor. The governor's throttle command is a percent of the maximum position of the throttle. The value of the throttle command can be viewed on Cat ET. The throttle command is sent to the throttle actuator. The throttle actuator is mechanically connected to the throttle body. There is no feedback for the throttle position.

SYSTEMS OPERATION

005

G3516E Service manual (GAS)

Media Number -KENR6834-03

Integrated Temperature Sensing Module The location of the Integrated Temperature Sensing Module (ITSM) depends on the configuration of the control system. Refer to Illustration 1.

Illustration 1 Rear view (1) ITSM

g01445855

Illustration 2 Typical exhaust system on 60 Hz engines (2) Thermocouple for the left turbocharger outlet (3) Thermocouple for the temperature of the left turbocharger inlet (4) Thermocouple for the right turbocharger outlet (5) Thermocouple for the temperature of the right turbocharger inlet (6) Thermocouples for the outlets of the cylinders

g01301830

Illustration 3

g01301831

Typical exhaust system on 50 Hz engines (2) Thermocouple for the right turbocharger outlet (3) Thermocouple for the temperature of the left turbocharger inlet (5) Thermocouple for the temperature of the right turbocharger inlet (6) Thermocouples for the outlets of the cylinders

The Integrated Temperature Sensing Module (ITSM) monitors thermocouples that measure the engine's exhaust temperatures. The ITSM calculates the average exhaust temperature for each bank. The temperatures are broadcast over the Cat Data Link for use with other modules. Thermocouples measure the exhaust temperatures from the exhaust port of each cylinder. To observe the value of the output of the thermocouples, use Caterpillar Electronic Technician (ET) to view the "Cylinder #X Exhaust Port". The "X" is the number for the particular cylinder. A thermocouple is mounted at the inlet for the exhaust gas of each turbocharger turbine. To observe the value of the output of the thermocouples, use Cat ET to view the "Left Bank Turbine Inlet Temp" or the "Right Bank Turbine Inlet Temp". A thermocouple is mounted at the outlet for the exhaust gas of each turbocharger turbine. To observe the value of the output of the thermocouples, use Cat ET to view the "Left Bank Turbine Outlet Temp" or the "Right Bank Turbine Outlet Temp". The following conditions can activate an alarm or a shutdown. The trip points can be programmed with Cat ET.

l l l

The temperature is higher than the limit that is programmed. The temperature is lower than the limit that is programmed. The temperature of a cylinder deviates significantly from the average temperature for all of the cylinders.

006

SYSTEMS OPERATION

G3516E Service manual (GAS)

Media Number -KENR6834-03

Electronic Control System Parameters Configuration Parameters Certain parameters are unique for each engine application. Table 2 is a list of the parameters that can be configured for G3500C and G3500E Engines. The parameters are described below. The parameters are programmed into the Electronic Control Module (ECM) via the Caterpillar Electronic Technician (Cat ET). The values of the parameters can be viewed on the "Configuration" screen of Cat ET. Table 1 Configuration Parameters for G3500C and G3500E Engines Timing Control "First Desired Timing" "Second Desired Timing" Air/Fuel Ratio Control "Fuel Quality Input Type Configuration"

(1)

"Fuel Quality Sensor LHV Lower Limit"

(1)

"Fuel Quality Sensor LHV Upper Limit"

(1)

"Fuel Quality" "Gas Specific Gravity" "Fuel Specific Heat Ratio" "Desired Emission Gain Adjustment Percentage" "Air/Fuel Proportional Gain" "Air/Fuel Integral Gain" Speed Control "Low Idle Speed" "Minimum Engine High Idle Speed" "Maximum Engine High Idle Speed" "Engine Acceleration Rate" "Desired Speed Input Configuration" "Governor Type Setting" "Engine Speed Droop" "Governor Gain Factor"

"Governor Stability Factor" "Governor Compensation Factor" "Auxiliary Proportional Governor Gain 1" "Auxiliary Integral Governor Gain 1" "Auxiliary Derivative Governor Gain 1" Start/Stop Control "Driven Equipment Delay Time" "Crank Terminate RPM" "Engine Purge Cycle Time" "Cooldown Duration" "Cycle Crank Time" "Engine Overcrank Time" "Engine Speed Drop Time" "Engine Pre-Lube Time Out Period" Monitoring and Protection "High Inlet Air Temp Engine Load Set Point" "Impending Shutdown Delay Enable Status" "Impending Shutdown Delay Time"

(2)

(2)

Power Monitoring "Generator Output Power Sensor Scale Factor" "Generator Output Power Sensor Offset" "Engine Output Power" "Engine Driven Accessory Load Configuration" Information for the ECM "Engine Serial Number" "Equipment ID" "Customer Password #1" "Customer Password #2" "Total Tattletale" (1)

This parameter applies to engines that are equipped with software that supports a remote fuel quality input.

(2)

This parameter applies to engines that are equipped with software that supports impending shutdowns.

Timing Control

The "Desired Timing" parameters allow the customer to electronically program the timing of the ignition spark of the electronic system in order to meet the needs for specific applications and specific installations. The desired timing value can be changed while the engine is running or while the engine is stopped. The value that is entered for the desired timing is the ignition timing when the engine is operating at rated speed and at full load. Note: The actual ignition timing at a given instance may vary from the desired timing value. This variance is due to variations in the engine speed or the detonation. The range for programming the desired timing is 0 to 40 degrees before the top center (TC) position.

"First Desired Timing" The "First Desired Timing" is determined with the methane number of the primary fuel that is used. Use the Engine Performance Sheet, "Fuel Usage Guide". The ECM selects the "First Desired Timing" when terminal P1-20 is an open circuit.

"Second Desired Timing" The "Second Desired Timing" is determined with the methane number of the alternate fuel that is used and the Engine Performance Sheet, "Fuel Usage Guide". When this input is connected to the digital return or to the - Battery, the engine control will use the "Second Desired Timing". If an alternate fuel is not used, enter the same timing that was entered in the "First Desired Timing".

Air/Fuel Ratio Control Before the initial start-up, a current gas analysis is required. Periodic gas analyses are also recommended. Data from the gas analysis must be entered into Caterpillar Software, LEKQ6378, "Methane Number Program". The results are programmed into the ECM. Note: It is very important to use the Caterpillar Software, LEKQ6378, "Methane Number Program". Use of only the data from the gas analysis can result in incorrect settings.

"Fuel Quality Input Type Configuration" Within the configuration screen for the master ECM, there are four parameters that relate to the fuel quality: l l l l

"Fuel Quality Input Type Configuration" "Fuel Quality Sensor LHV Lower Limit" "Fuel Quality Sensor LHV Upper Limit" "Fuel Quality"

Be sure that the configuration parameter for "Fuel Quality Input Type Configuration" is set for the proper system. The "Fuel Quality Input Type Configuration" can be set to one of the following values: l l

"Configuration" "4-20 mA"

When the "Fuel Quality Input Type Configuration" parameter is set to "Configuration", a fixed value must be set for the "Fuel Quality" parameter. Engines that run on a consistent fuel supply typically use this type of system. The "Fuel Quality Sensor LHV Lower Limit" and "Fuel Quality Sensor LHV Upper

Limit" parameters are not available. When the "Fuel Quality Input Type Configuration" parameter is set to "4-20 mA", the ECM will determine the fuel's LHV according to the value of the signal from the fuel quality sensor. The "4-20mA" signal is provided by the customer via a sensor that measures fuel quality. The "Fuel Quality Sensor LHV Lower Limit" and "Fuel Quality Sensor LHV Upper Limit" parameters are used to set the lower limit and the upper limit of the range of LHV. Engines that run on an inconsistent fuel supply typically use this type of system. Engines that run on gas from a coal seam or landfill are examples of inconsistent fuel supply.

"Fuel Quality Sensor LHV Lower Limit" This parameter is only available when the "Fuel Quality Input Type Configuration" is set to "4-20 mA". The ECM uses the value of this parameter to set the lower limit of the fuel's LHV when the input signal is 4 mA. For example, if the value of this parameter is "300", the ECM will set the fuel's LHV to 300 when the input signal is 4 mA. The adjustable range is 100 to 650. The default is 250. The range between the "Fuel Quality Sensor LHV Lower Limit" and "Fuel Quality Sensor LHV Upper Limit" cannot exceed 600 BTU.

"Fuel Quality Sensor LHV Upper Limit" This parameter is only available when the "Fuel Quality Input Type Configuration" is set to "4-20 mA". The ECM uses the value of this parameter to set the upper limit of the fuel's LHV when the input signal is 20 mA. For example, if the value of this parameter is "900", the ECM will set the fuel's LHV to 900 when the input signal is 20 mA. The adjustable range is 500 to 1250. The default is 850. The range between the "Fuel Quality Sensor LHV Lower Limit" and "Fuel Quality Sensor LHV Upper Limit" cannot exceed 600 BTU. The ECM uses a linear scale between the lower limit and the upper limit. Refer to Illustration 1.

Illustration 1

g01110253

Example of LHV versus signal strength (X) LHV (Y) Signal strength in milliamperes

In this example, the lower limit is 300. The upper limit is 900. An input signal of 16 mA equals an LHV of 750.

"Fuel Quality" This parameter is available when the "Fuel Quality Input Type Configuration" is set to "Configuration" or with software not equipped with remote fuel quality input. This is the fuel's Low Heat Value (LHV). The air/fuel ratio control of the ECM will compensate for some inaccuracy in this setting. The ECM assumes a corrected value that is multiplied by the "Fuel Correction Factor". This factor can be displayed on the Cat ET screen. The "Fuel Quality" parameter can be used to change the air/fuel ratio when the engine is operating in the open loop mode. To richen the air/fuel mixture, reduce the value. The calculation will compensate for the reduced LHV by increasing the fuel flow. To lean the air/fuel mixture, increase the value. The calculation will compensate for the increased LHV by reducing the fuel flow.

"Gas Specific Gravity" This is the fuel's specific gravity in relation to the specific gravity of air. The ECM does not use this information. The ECM provides the information to the fuel metering valve via the CAN data link. The fuel metering valve requires an input for the "Gas Specific Gravity" in order to precisely meter the fuel flow.

"Fuel Specific Heat Ratio" This is a ratio of the fuel's specific heat at a constant pressure and at a constant volume. The ratio is also known as "k". The ratio is related to the expansion of the gas across the fuel metering valve. The ECM does not use this information. The ECM provides the information to the fuel metering valve via the CAN data link. The fuel metering valve requires an input for the "Fuel Specific Heat Ratio" in order to precisely meter the fuel flow.

"Desired Emission Gain Adjustment Percentage" This is an adjustment for the level of the engine's exhaust emissions for engine operation at full load. The adjustable range is 85 to 115 percent. The default value is 100 percent. This parameter can be adjusted in 0.1% increments. Refer to Testing and Adjusting, "Air/Fuel Ratio Control - Adjust".

"Air/Fuel Proportional Gain" The "Air/Fuel Proportional Gain" determines the speed of the "Fuel Correction Factor" response in adjusting for the difference between the actual charge density and the desired charge density. The factory default setting is 0. This value should not require adjustment. If problems occur, this is one of the last parameters that should be adjusted. The adjustable range is -50 to +50. Negative values reduce the speed of the fuel correction factor response and positive values increase the speed of the fuel correction factor response.

"Air/Fuel Integral Gain" The "Air/Fuel Integral Gain" determines the response of the fuel correction factor to the error that is accumulated over time for the air/fuel ratio. The factory default setting is 0. This value should not require adjustment. If problems occur, this is one of the last parameters that should be adjusted. The adjustable range is -50 to +50. Negative values reduce the speed of the fuel correction factor response and positive values increase the speed of the fuel correction factor response.

Speed Control "Low Idle Speed" Program this parameter to the desired low idle rpm. The low idle rpm can be programmed within the range of 500 to 1100 rpm.

"Minimum Engine High Idle Speed" Program this parameter to the desired minimum high idle rpm. The desired high idle speed is regulated by the desired speed input. The regulation is linear in proportion to the input. An input of 0 VDC or 4 mA results in the minimum high idle rpm. For the 50 Hz arrangement, the minimum high idle speed can be programmed between 900 rpm and 1500 rpm. The default value is 1400 rpm. For the 60 Hz arrangement, there are two speed ratings: 1200 rpm and 1800 rpm. For the 1200 rpm engine rating, the minimum high idle speed can be programmed between 900 rpm and 1200 rpm. It has a default value of 1100 rpm. For the 1800 rpm engine rating, the minimum high idle speed can be programmed between 900 rpm and 1800 rpm. The default value is 1600 rpm. The "Minimum High Idle Speed" and the "Maximum High Idle Speed" determine the slope of the desired speed input.

"Maximum Engine High Idle Speed" Program this parameter to the desired maximum high idle rpm. The actual high idle speed is regulated by the desired speed input. The regulation is linear in proportion to the input. An input 5 V DC or 20 mA results in the maximum high idle rpm. For the 50 Hz arrangement, the maximum high idle speed can be programmed between 1500 rpm and 1900 rpm. The default value is 1600 rpm. For the 60 Hz arrangement, there are two speed ratings: 1200 rpm and 1800 rpm. For the 1200 rpm engine rating, the maximum high idle speed can be programmed between 1200 rpm and 2200 rpm. It has a default value of 1300 rpm. For the 1800 rpm engine rating, the minimum high idle speed can be programmed between 1800 rpm and 2200 rpm. The default value is 2000 rpm.

"Engine Acceleration Rate" This parameter controls the rate of desired speed change when the idle/rated switch changes. For example, the desired speed can be programmed to accelerate at a rate of 50 rpm per second when the "Idle/Rated" switch is turned to the "Rated" position.

"Desired Speed Input Configuration"

This parameter determines the signal input to the ECM for control of the desired speed. The signal can be either 0 to 5 VDC or 4 to 20 mA. The ECM uses a linear scale between the lower input and the upper input. Refer to Illustrations 2 and 3.

Illustration 2

Example of 0 to 5 VDC desired speed input (X) Engine RPM (Y) Voltage

g01443138

Illustration 3

g01443144

4 to 20 mA

Note: The ECM is not configured to accept a pulse width modulated signal for input of the desired engine speed. If you try to select a Pulse Width Modulated input (PWM), the ECM will reject the selection. An error will be generated.

"Governor Type Setting" The "Governor Type Setting" parameter can be set to "Droop Operation" or to "Isochronous Mode". This setting is dependent upon the application of the engine.

"Engine Speed Droop" This programmable parameter allows precise control of the speed droop. The "Governor Type Setting" parameter must be set to "Droop". The droop can be programmed to a value between 0 and 10 percent.

Governor Gain Settings Refer to Testing and Adjusting, "Engine Governing - Adjust" for the adjustment procedure for the governor.

"Governor Gain Factor" This parameter is based on a proportional multiplier. The "Governor Gain Factor" determines the speed of

the throttle actuator's response in adjusting for the difference between the actual speed and the desired speed. Increasing this value provides a faster response to the difference between the actual speed and the desired speed. This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "Off". If changing this value causes no effect, check the "Grid Status" in order to make sure that the status is "Off". This parameter is intended to be used for synchronization during engine operation at no load.

"Governor Stability Factor" This parameter is based on an integral multiplier. The "Governor Stability Factor" controls the speed for elimination of the error in the difference between the actual speed and the desired speed. Increasing this value provides less damping. This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "Off". If changing this value causes no effect, check the "Grid Status" in order to make sure that the status is "Off". This parameter is intended to be used for synchronization during engine operation at no load.

"Governor Compensation Factor" This parameter is based on a derivative multiplier. The "Governor Compensation Factor" is used to adjust for the time delay between the control signal and the movement of the throttle actuator. If this value is too low, the engine speed will slowly hunt. If this value is too high, the engine speed will rapidly fluctuate. This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "Off". If changing this value causes no effect, check the "Grid Status" in order to make sure that the status is "Off". This parameter is not currently enabled. This parameter is intended to be used for synchronization during engine operation at no load. This parameter is not currently enabled.

"Auxiliary Proportional Governor Gain 1" This parameter is based on a proportional multiplier. The "Auxiliary Proportional Governor Gain 1" determines the speed of the throttle actuator's response in adjusting for the difference between the actual speed and the desired speed. Increasing this value provides a faster response to the difference between the actual speed and the desired speed. This parameter is intended to be used during loaded engine operation. This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "On". If this value is changed and the "Grid Status" is "Off", the stability of the engine will not change. If changing this value causes no effect, check the "Grid Status" in order to make sure that the status is "On".

"Auxiliary Integral Governor Gain 1" This parameter is based on an integral multiplier. The "Auxiliary Integral Governor Gain 1" controls the speed for elimination of the error in the difference between the actual speed and the desired speed. Increasing this value provides less damping. This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "On". If this value is changed and the "Grid Status" is "Off", the stability of the engine will not change. If changing this value causes no effect, check the "Grid Status" in order to make sure that the status is "On". This parameter is intended to be used during loaded engine operation.

"Auxiliary Derivative Governor Gain 1" This parameter is based on a derivative multiplier. The "Auxiliary Derivative Governor Gain 1" is used to adjust for the time delay between the control signal and the movement of the throttle actuator. If this

value is too low, the engine speed will slowly hunt. If this value is too high, the engine speed will rapidly fluctuate. This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "On". If this value is changed and the "Grid Status" is "Off", the stability of the engine will not change. If changing this value causes no effect, check the "Grid Status" in order to make sure that the status is "On". This parameter is intended to be used during loaded engine operation. This parameter is not currently enabled.

Start/Stop Control Parameters "Driven Equipment Delay Time" The ECM accepts an input from the driven equipment that indicates when the equipment is ready for operation. When the input is grounded, the driven equipment is ready. The ECM will not start the engine until this input is grounded. The ECM can be programmed to wait for a certain period of time after receiving a start command before starting the engine. This allows the driven equipment to get ready for operation. When the ECM receives a start command, the ECM will wait for the amount of time that is programmed into the "Driven Equipment Delay Time". If the "Driven Equipment Delay Time" elapses and the input is not grounded, an event code is activated. The engine will not start. If the "Driven Equipment Delay Time" is programmed to "0" the delay is disabled. If the ECM receives a start command and the driven equipment is not ready, an event code is activated. The engine will not start.

"Crank Terminate RPM" The ECM disengages the starting motor when the engine speed exceeds the programmed "Crank Terminate RPM". The default value of 250 rpm should be sufficient for all applications.

"Engine Purge Cycle Time" The "Engine Purge Cycle Time" is the duration of engine cranking without fuel before the actual start-up. The ignition is disabled during this time. The "Engine Purge Cycle Time" allows any unburned fuel to exit through the exhaust before you run the engine.

"Cooldown Duration" When the ECM receives a "Stop" request, the engine will continue to run in the "Cooldown Mode" for the programmed cooldown period. The "Cooldown Mode" is exited early if a request for an emergency stop is received by the ECM. If the "Cooldown Duration" is programmed to zero, the engine will immediately shut down when the ECM receives a "Stop" request.

"Cycle Crank Time" The "Cycle Crank Time" is the duration of time for activation of the starting motor and the gas shutoff valve for start-up. If the engine does not start within the specified time, the attempt to start is suspended for a "Rest Cycle" that is equal to the "Cycle Crank Time".

"Engine Overcrank Time"

The "Engine Overcrank Time" is the duration for attempting an engine start-up. An event is generated if the engine does not start within this period of time. Example Setting

Table 2 Examples of the Settings for Start-up Parameter

Time

"Purge Cycle Time"

10 seconds

"Cycle Crank Time"

30 seconds

"Overcrank Time"

45 seconds

The following sequence will occur if the parameters are programmed according to the example in Table 3: 1. The fuel and the ignition are OFF. The engine will crank for 10 seconds in order to purge gas from the engine and from the exhaust system. 2. The fuel and the ignition are enabled. The engine will continue to crank for a maximum of 30 seconds. 3. If the engine does not start, the ignition, the fuel, and the starting motor are disabled for a 30 second "Rest Cycle". With this example, a complete cycle is 70 seconds: a purge cycle of 10 seconds, a cycle crank of 30 seconds and a rest cycle of 30 seconds. A maximum of one crank cycle is recommended. The "Overcrank Time" of 45 seconds allows one crank cycle.

"Engine Speed Drop Time" This parameter is activated when the ECM receives the signal for stopping the engine. This input ensures the shutdown in case the Gas Shutoff Valve (GSOV) does not close. If the ECM is controlling the GSOV, the ECM removes power from the GSOV after the cooldown period has elapsed. If the customer's equipment is controlling the GSOV, the customer's equipment removes power from the GSOV after the cooldown period has elapsed. In either case, the fuel is shut off. The ignition continues until the engine speed drops below 40 rpm. If the engine rpm does not drop at least 100 rpm within the programmed drop time, the ECM terminates the ignition and the ECM issues an emergency stop. The default for this parameter is 15 seconds.

"Engine Pre-Lube Time Out Period" At the time of this publication, this parameter is not active.

Monitoring and Protection "High Inlet Air Temp Engine Load Setpoint"

The programmable setpoint is a value that separates low engine load from high engine load for events that are activated by high inlet air temperature. An "Engine Load Factor" can be displayed on a Cat ET status screen. If the load factor is less than the setpoint and the inlet air temperature reaches the trip point, a "High Inlet Air Temperature at Low Engine Load" event is activated. If the load factor is greater than the setpoint and the inlet air temperature reaches the trip point, a "High Inlet Air Temperature at High Engine Load" event is activated.

"Impending Shutdown Delay Enable Status" Note: This parameter may be "read only" on some applications. This parameter can be programmed to "DISABLED" or "ENABLED". The default is "ENABLED". This parameter determines the control system's response to level 2 events. DISABLED - The level 2 event is not active. ENABLED - The engine continues to run for the length of time that is programmed for the "Impending Shutdown Delay Time" parameter.

"Impending Shutdown Delay Time" This parameter can be programmed to a period of time between "0" minutes and "10" minutes. The default value is "10". The engine will shut down after the programmed period of time if a level two event occurs and the "Impending Shutdown Delay Enable Status" parameter is programmed to "ENABLED". The ECM will immediately shut down the engine when a level 2 event occurs if this parameter is programmed to "0" and the "Impending Shutdown Delay Enable Status" parameter is programmed to "ENABLED".

Power Monitoring The ECM monitors the generator's output power in order to accurately control the air/fuel ratio. The ECM uses an output from one of the following sources in order to monitor the generator's output power: l l l

Electronic Modular Control Panel II+ (EMCP II+) Programmable Logic Controller (PLC) Wattmeter

The PLC and the wattmeter are also called power sensors. The ECM uses the values of the "Power Monitoring" parameters to determine the generator's actual power output. The electronic control module's value of the generator's actual power output is displayed on Cat ET as the "Generator Real kW" parameter in Status Group 1. If the value of this parameter is within one percent of the generator's actual power output, the ECM will accurately control the air/fuel ratio.

"Generator Output Power Sensor Scale Factor" If the generator is equipped with the EMCP II+, information on the generator's output is provided to the ECM via the Cat Data Link. The value for the "Generator Output Power Sensor Scale Factor" parameter is inactive. No adjustment is necessary for this parameter. For power monitoring with a power sensor, the ECM accepts a linear signal with a range of 0 VDC to 4.8 VDC. The signal from the power sensor increases from 0 VDC to 4.8 VDC as the generators output increases. For best resolution, as much of the full scale should be used as possible. The kW power sensor should be selected such that the maximum is 110 percent of the generator's rated output. For example, if the generator has a rated output of 1700 ekW, the maximum output is 1870 ekW. When the generator's output is 1870 ekW, the power sensor will provide a signal of approximately 4.8 VDC.

The ECM requires a scale factor in order to determine the generator's output. The scale factor is determined by the power sensors full scale range. The equation that is used to determine the scale factor is provided in Table 4. Table 3 Computing the Value for the "Generator Output Power Sensor Scale Factor" (R x 1.1) ÷ 4.8 R is the generator's rated output in kilowatts. Table 4 Computing the Value for the "Generator Output Power Sensor Scale Factor" Power Sensor Maximum Rated Output In kW = kW / volt Power Sensor Maximum Rated Output Voltage For example, if the generator's rated output is 1700 ekW, the correct value for the "Generator Output Power Sensor Scale Factor" parameter is 390. In this example, the relationship between the voltage level of the signal and the generator's output is shown in Illustration 4 .

Illustration 4

g01062926

In this example, the value of the "Generator Output Power Sensor Scale Factor" parameter is 390.

The ECM multiplies the signal voltage by the scale factor in order to estimate the generator's output. In this example, a signal level of 3.5 VDC indicates that the generator output is approximately 1365 ekW. After the ECM estimates the generator's output, the ECM adds the value of the "Generator Output Power Sensor Offset" parameter to the estimate. This refines the electronic control module's estimate of the generator's actual output.

"Generator Output Power Sensor Offset" If the generator is equipped with the EMCP II+, information on the generator's output is provided to the ECM via the Cat Data Link. The value for the "Generator Output Power Sensor Offset" parameter is

inactive. No adjustment is necessary for this parameter. If the generator is equipped with a power sensor, the power sensor's output may not be zero when the generator's output is zero. When this occurs, the power sensor has an offset voltage. The offset voltage may be positive or negative. In most cases, the offset voltage is very low. Therefore, the value of the "Generator Output Power Sensor Offset" parameter must be set to zero. The offset voltage must be measured before you change this parameter from zero. To measure the offset voltage, refer to Troubleshooting, "Generator Output Power Readings Do Not Match". If the offset voltage is less than 0.01 VDC, the value of the "Generator Output Power Sensor Offset" must be set to zero. The value of this parameter is in units of ekW. The minimum programmable value for this parameter is 327 ekW. The maximum programmable value for this parameter is 200 ekW. The ECM adds the value of the "Generator Output Power Sensor Offset" parameter to the value that is determined by the "Generator Output Power Sensor Scale Factor" parameter. This refines the electronic control module's calculation of the generator's actual output. The electronic control module's final determination of the generator's actual output is displayed on Cat ET as the "Generator Real kW" parameter in Status Group 1. If the value of this parameter is within one percent of the generator's actual power output, the ECM will accurately control the air/fuel ratio.

"Engine Output Power" The value of the "Engine Output Power" parameter is the engine's full load rating in ekW. The rating is stamped on the engine's Information Plate. During operation, the ECM uses this value to determine the engine's load as a percentage of the maximum load.

"Engine Driven Accessory Load Configuration" The value of this parameter is the rated load of the auxiliary equipment such as a radiator fan that is directly driven by the engine. The value is in units of ekW. The ECM adds this load to the calculated value of the generator's actual output in order to determine the total load on the engine.

Information for the ECM "Engine Serial Number" The engine serial number is programmed into the ECM at the factory. The number is stamped on the engine Information Plate.

"Equipment ID" The customer can assign an "Equipment ID" for the purpose of identification.

Customer Passwords Two customer passwords can be entered. The passwords are used to protect certain configuration parameters from unauthorized changes. Note: Factory level security passwords are required for clearing certain logged events and for changing certain programmable parameters. Because of the passwords, only authorized personnel can make changes to some of the programmable items in the ECM. When the correct passwords are entered, the changes are programmed into the ECM.

"Total Tattletale"

This item displays the number of changes that have been made to the configuration parameters.

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Engine Sensors The information from the sensors enables the Electronic Control Module (ECM) to control the engine as efficiently as possible over a wide range of operating conditions. The sensors also enable the module to activate alarms, impending shutdowns, and shutdowns in response to abnormal operation. The functions of the sensors are described below.

Illustration 1

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Right side view (1) Engine oil temperature sensor (2) Pressure switch for the coolant pump (inlet) (3) Pressure sensor for unfiltered oil (4) Pressure sensor for filtered oil

Engine oil temperature sensor (1) - An oil temperature sensor measures the engine oil temperature. A high oil temperature will activate an alarm or a shutdown. The trip points can be programmed with the Caterpillar Electronic Technician (Cat ET). To observe the output value of the sensor, use Cat ET to view the "Engine Oil Temperature" parameter. Pressure switch for the coolant pump (inlet) (2) - A pressure switch is located at the inlet for the engine jacket water. If the inlet pressure is too high, the switch will activate a shutdown. To observe the status of the switch, use the Caterpillar Electronic Technician (Cat ET) to view the "Engine Coolant Pump Pressure" parameter. Oil pressure sensors (3) and (4) - The engine oil pressure is measured before the oil filters (3) and after the oil filters (4). An alarm or a shutdown can be activated by any of the following occurrences: low filtered oil pressure, low oil filter differential pressure and high oil filter differential pressure. The trip point for the activation of a warning or a shutdown for oil filter differential pressure can be programmed with Cat ET. To observe the value of the output of the sensor, use Cat ET to view the "Engine Oil Pressure" or the "Unfiltered Engine Oil Pressure" parameter.

Illustration 2

g01442420

Typical front and left side (5) Compressor discharge pressure sensor (if equipped with ASM) (6) Air inlet pressure sensor (optional location) (7) Detonation sensor

Compressor discharge pressure sensor (5) - This sensor only applies to engines that are equipped with an Auxiliary Sensing Module (ASM). The sensor is located at the top of the duct between the compressor outlet and the inlet to the throttle. The ASM uses the signal from this sensor to rapidly respond to changes in engine load. Air inlet pressure sensor (6) - This sensor is connected to the inlet manifold. If the engine is equipped with an ASM, the sensor is located at the rear of the manifold. Otherwise, this sensor is located at the front of the manifold. The sensor monitors the absolute manifold pressure. This is the atmospheric pressure plus the gauge pressure. The information is used by the ECM to calculate the air flow. To observe the output value of the sensor, use Cat ET to view the "Inlet Manifold Air Pressure (abs)".

Detonation sensors (7) - The detonation sensors monitor the engine for mechanical vibrations. Each sensor monitors two cylinders. The sensor produces a voltage signal that is proportional to the engine detonation. This information is processed by the ECM in order to determine detonation levels. To eliminate detonation, the ECM retards the timing of the cylinder. If detonation continues, the ECM will shut down the engine. To observe the value of the output of the sensors, use Cat ET to view the "Cylinder #X Detonation Level". The "X" is the number for the particular cylinder.

Illustration 3

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(6) Air manifold inlet pressure sensor (with ASM) (8) Engine coolant pressure sensor (outlet) (9) Engine coolant temperature sensor (10) Inlet manifold air temperature sensor (11) Speed/timing sensor

Engine coolant pressure sensor (outlet) (8) - A pressure switch is located at the outlet for the engine jacket water. If the outlet pressure is too low, the ECM will activate a shutdown.

Engine coolant temperature sensor (9) - The temperature sensor is located in the water temperature regulator housing. To monitor the coolant temperature, the element must be in contact with the coolant. Otherwise, the sensor will not function properly. A high coolant temperature will activate an alarm or a shutdown. A low coolant temperature will only activate an alarm. The trip points for the activation can be programmed with Cat ET. The engine can be restarted after a shutdown due to high engine coolant temperature. However, another shutdown will occur after one minute if the temperature remains high. To observe the value of the output of the sensor, use Cat ET to view the "Engine Coolant Temperature" parameter. Inlet manifold air temperature sensor (10) - A sensor for monitoring the inlet air temperature is located in the inlet elbow for the number twenty cylinder. Excessive inlet air temperature can activate an alarm or a shutdown during high load or low load operation. The trip points for activation can be programmed with Cat ET. To observe the value of the output of the sensor, use Cat ET to view the "Inlet Air Temperature" parameter. Engine speed/timing sensor (11) - The engine speed/timing sensor is located at the rear end of the left camshaft. The ECM monitors the engine speed/timing sensor in order to determine the position of the crankshaft and the engine rpm. With the position of the crankshaft, the ECM is able to determine the ignition timing. To observe the engine speed in rpm, use Cat ET to view the "Engine Speed" parameter.

Engine speed sensor for the ASM (12) - This sensor only applies to engines that are equipped with an ASM. The ASM uses the signal from this sensor to accurately determine engine speed. In addition, the ASM determines the rate of change of the engine speed. The ASM uses this information to rapidly respond to changes in engine load. The ASM sends information on engine speed to the master ECM via the Cat Data Link. Engine speed sensor for the GSC+ (13) - The GSC+ uses the signal from this sensor to monitor the

engine rpm.

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Electronic Service Tools Caterpillar Electronic Service Tools are designed to help the service technician perform the following functions: l l l l l

Obtain data. Diagnose problems. Read parameters. Program parameters. Calibrate sensors.

The tools that are listed in Table 2 are required in order to enable a service technician to perform the functions. Table 1 Service Tools Pt. No.

Description

Functions

Personal Computer (PC)

The PC is required for the use of the Caterpillar Electronic Technician (ET).

Software

Single user license for Cat ET Use the most recent version of the software.

Software

Data subscription for all engines

Communication Adapter As

This group provides the communication between the PC and the engine.

Communication Adapter Gp

This group provides the communication between the PC and the engine.

7X-1414

Data Link Cable As

This cable connects the communication adapter to the service tool connector on the engine.

237-7547

Adapter Cable As

This cable connects to the USB port on personal computers.

225-5985

Parallel Port Cable (COMMUNICATION ADAPTER)

146-4080

Digital Multimeter

The multimeter is used for the testing and the adjusting of electronic circuits.

156-1060

Emissions Analyzer Gp

The emissions analyzer is use to read emissions from the engine's exhaust.

"JERD2124" "JERD2129" 171-4400

(1)

275-5120

(2)

This cable connects to the parallel port on personal computers.

(1)

This item includes the 171-4401 Communication Adapter As .

(2)

This item includes the 275-5121 Communication Adapter As . The 7X-1700 Communication Adapter Gp may also be used.

Caterpillar Electronic Technician (ET) The Caterpillar Electronic Technician (ET) is designed to run on a personal computer. Cat ET can display the following information: l l l l l l

Parameters Diagnostic codes Event codes Engine configuration Status of the monitoring system Performance data

Cat ET can perform the following functions: l l l l

Diagnostic tests Sensor calibration Flash downloading Set parameters

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Engine Monitoring System The Electronic Control Module (ECM) monitors the operating parameters of the engine. The ECM can initiate a warning or a shutdown if a specific engine parameter exceeds an acceptable range. Use the Caterpillar Electronic Technician (ET) to perform the following activities: l l l

Select the available responses. Program the level for monitoring. Program delay times for each response.

The default settings for the parameters are programmed at the factory. To accommodate unique applications and sites, the parameters may be reprogrammed with Cat ET. The screens of Cat ET provide guidance for the changing of trip points. Note: Some of the parameters are protected by factory passwords. Other parameters can be changed with customer passwords. Refer to the Troubleshooting Manual for the default settings and for instructions on the troubleshooting events.

Monitoring Parameters "Low System Voltage" The trip point for this parameter is set at the factory. The trip point cannot be changed. This parameter is always ON. This parameter cannot be turned off. If the system voltage decreases to the trip point or if the system voltage goes below the trip point, the ECM will generate a warning or a shutdown.

"High Engine Coolant Temperature" The trip points for this parameter can be programmed by the customer. The shutdown response is always ON. The shutdown response cannot be turned off. If the engine coolant temperature exceeds the trip point, the ECM will generate a warning, an impending shutdown, or a shutdown.

"Low Engine Coolant Temperature" The trip point for this parameter can be programmed by the customer. If the engine coolant temperature decreases to the trip point, the ECM will generate a warning.

"Engine Overspeed" The trip point for this parameter is set at the factory. This parameter is always ON. This parameter cannot be turned off. If the engine speed exceeds the trip point, the ECM will activate an engine shutdown. For generator set engines, a typical trip point is 118 percent of the engine's rated speed.

"High Engine Oil Temperature"

The trip point for a warning for this parameter can be programmed by the customer. The trip point for a shutdown is set at the factory. This parameter is always ON. This parameter cannot be turned off. If the engine oil temperature exceeds the trip point, the ECM will generate a warning or a shutdown.

"High Oil Filter Differential Pressure" The trip point for a warning for this parameter can be programmed by the customer. The trip point for a shutdown is set at the factory. This parameter is always ON. This parameter cannot be turned off. If the engine oil filter differential pressure exceeds the trip point, the ECM will generate a warning or a shutdown.

"Low Oil Filter Differential Pressure" The trip point for a warning for this parameter can be programmed by the customer. The trip point for a shutdown for this parameter is set at the factory. This parameter is always ON. This parameter cannot be turned off. If the engine oil filter differential pressure decreases to the trip point, the ECM will generate a warning or a shutdown.

"High Fuel Temperature" The trip point for this parameter can be programmed by the customer. If the fuel temperature exceeds the trip point, the ECM will generate a warning.

"Low Fuel Pressure" The trip point for this parameter can be programmed by the customer. If the fuel pressure decreases to the trip point, the ECM will generate a warning.

"High Eng Oil to Eng Coolant Diff Temp" The trip point for a warning for this parameter can be programmed by the customer. The trip point for a shutdown for this parameter is set at the factory. The shutdown response is always ON. The shutdown response cannot be turned off. If the differential temperature of the engine oil to the jacket water exceeds the trip point, the ECM will generate a warning or a shutdown.

"Low Gas Fuel Differential Pressure" The trip point for this parameter can be programmed by the customer. If the fuel differential pressure decreases to the trip point, the ECM will generate a warning.

"High Gas Fuel Differential Pressure" The trip point for this parameter can be programmed by the customer. If the fuel differential pressure exceeds the trip point, the ECM will generate a warning.

"High System Voltage" The trip point for this parameter is set at the factory. The trip point cannot be changed. This parameter is always ON. This parameter cannot be turned off. If the system voltage exceeds the trip point, the ECM

will generate a warning.

Trip Points of the Engine Load for High Inlet Air Temperature The trip points for this parameter can be programmed by the customer. The shutdown response is always ON. The shutdown response cannot be turned off. This feature provides a trip point between high engine load and low engine load. The trip point is used for events that involve high inlet air temperature. The trip point for the events is based on the engine load. The possible responses of the system include warning, an impending shutdown, and shutdown. If the load is greater than the trip point, the trip point for the "High Inlet Air Temperature at High Engine Load" event is used for the logging of the high inlet air temperature. If the load is less than the trip point, the trip point for the "High Inlet Air Temperature at Low Engine Load" event is used for the logging of the high inlet air temperature.

"High Inlet Air Temperature at Low Engine Load" The "Service/Configuration" screen of Cat ET defines the "High Inlet Air Temp Engine Load Set Point". The ECM can activate a warning, an impending shutdown, or a shutdown if the inlet air temperature exceeds the trip point during the low load operation that is defined.

"High Inlet Air Temperature at High Engine Load" The "Service/Configuration" screen of Cat ET defines the "High Inlet Air Temp Engine Load Set Point". The ECM can activate a warning, a derating, or a shutdown if the inlet air temperature exceeds the trip point during the high load operation that is defined.

"High Fuel Pressure" The trip point for this parameter can be programmed by the customer. The ECM will activate a warning if the fuel pressure exceeds the trip point.

Conditions for Parameters Some of the programmable parameters are dependent on the status of an ECM output before the parameters are allowed to function. Some of the parameters are allowed to function after the crank terminate relay has been energized for more than 30 seconds. Other parameters are allowed to function after the output for the fuel control relay is energized. Some parameters are not dependent upon any conditions. The conditions are designed to eliminate false events during start-up if the customer has programmed a delay time to zero. If the trip point for a shutdown is programmed to activate before the trip point for a warning, the engine will shut down and the warning will not be activated.

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Ignition System The engine is equipped with an electronic ignition system. The system provides dependable firing and low maintenance. The system provides precise control of the spark and of the ignition timing for each cylinder.

Illustration 1 Rear view (1) Electronic Control Module (ECM)

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Illustration 2

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Rear view The engine is equipped with an Auxiliary Sensing Module (ASM). (1) ECM

Each cylinder has an ignition transformer. The ECM controls ignition on the left bank and on the right bank. To initiate combustion, the ECM sends a pulse of approximately 100 volts to the primary coil of each ignition transformer at the appropriate time and for the appropriate duration. The transformers step up the voltage in order to create a spark across the spark plug electrode. Detonation sensors monitor the engine for detonation. The G3516 Engine has eight detonation sensors. Each sensor monitors two adjacent cylinders. The sensors generate data on vibration that is processed by the ECM in order to determine detonation levels. The ECM monitors detonation from 0-30 deg ATDC for each cylinder. If detonation occurs, the ECM retards the ignition timing of the affected cylinder or cylinders up to six degrees. If a cylinder has been fully retarded for 16 combustion cycles and the cylinder is still detonating, the ECM shuts down the engine. During a detonation shutdown request, the ECM retards the detonating cylinder an additional six degrees, not to exceed ten degrees total. The ECM provides diagnostics for the ignition system. Refer to the engine's Troubleshooting manual for more information on the diagnostics of the ignition system.

Ignition Transformers and Spark Plugs

Illustration 3

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Side view of a cylinder head (3) Mounting flange (4) Ignition transformer (5) Primary connection (6) Spark plug (7) Extension

Mounting flange (3) provides a ground for each ignition transformer (4). The ignition harness is connected to primary connection (5). The output from the secondary circuit of the transformer is sent to spark plug (6) through the extension (7) . The spark plug does not have a conventional electrode gap that can be adjusted. The spark plug has a precombustion chamber. During the compression stroke, the air/fuel mixture in the cylinder enters holes in the spark plug's precombustion chamber. The secondary circuit of the transformer provides an initial 8,000 to 32,000 V to the spark plug in order to create a spark. The air/fuel mixture ignites the air/fuel mixture in the cylinder.

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Fuel System Operation The Electronic Control Module (ECM) provides control of the air/fuel mixture to the engine. Illustration 1 is a diagram of the fuel system's main components. The flow of fuel through a typical fuel system is explained below. Refer to the Application and Installation Guide, LEBW5336, "Gaseous Fuel Systems" for more information on fuel system specifications and installation.

Illustration 1

g01442708

The fuel flows from the main gas supply through a knock-down regulator. A knock-down regulator is a second regulator that is needed when the gas supply pressure is to high for a single regulator to manage.

From knock-down regulator, the fuel flows to the fuel filter. Usually, the fuel filter is a component of the design at the particular site. The customer is responsible for supplying clean, dry fuel to the engine. The fuel filter may be supplied by Caterpillar or by the customer. To prevent particles from entering the engine, a one micron filter is recommended. The filter must be properly sized for the required gas pressure. For installation of the fuel filter, the recommended location is close to the engine before the engine's gas pressure regulator. Pressure gauges in the gas lines on each side of the fuel filter are recommended in order to monitor the filter's differential pressure. A manual shutoff valve in the gas line before the fuel filter will facilitate servicing of the filter. The filtered fuel flows to the Gas Shutoff Valve (GSOV). The GSOV may be supplied by Caterpillar or by the customer. The solenoid for the GSOV may be connected to engine's wiring harness or to a harness that is supplied by the customer. In either case, the customer may install a switch that can interrupt the circuit. The control system is configured for a GSOV that is energize-to-run. This means that the GSOV must be energized in order for the engine to run. The GSOV may be energized by the customer's equipment or by the ECM. When the GSOV is energized, the valve opens and the fuel flows to the engine. When the control system shuts down the engine, the voltage is removed from the solenoid. The valve closes and the fuel is shut off. The fuel flows through the GSOV to the gas pressure regulator. The regulator may be supplied by Caterpillar or by the customer. For parallel to utility applications, the required fuel pressure stability is ± 1.7237 kPa (± 0.25 psi). A regulated pressure of 7 to 35 kPa (1 to 5 psi) is recommended. For island mode applications, the minimum fuel pressure is 20 kPa (2.9 psi). Steady state fuel pressure stability requirement of ± 6.9 mbar/sec (1 psi/sec). Transient fuel pressure stability requirement of ± 48.2 mbar/sec (7 psi/sec). Less gas pressure may result in reduced power. More gas pressure may result in instability.

Illustration 2 Top view Flow of fuel through the single turbocharger arrangement (1) Fuel metering valve

g00925714

Illustration 3 Top view Fuel flow through the twin turbocharger arrangement (1) Fuel metering valve

g00925717

Illustration 4

g01442860

Fuel flow through a low BTU arrangement (1) Fuel metering valve

The fuel flows to the electronically controlled fuel metering valve (1) . The ECM issues a command signal to the fuel metering valve via the CAN data link. The fuel metering valve regulates the flow of fuel to the engine.

Illustration 5 Right view Flow of fuel and of air through the single turbocharger arrangement (2) Air inlet elbow's adapter (3) Turbocharger's compressor

g00925730

Illustration 6

g00925767

Right view Flow of fuel and of air through the twin turbocharger arrangement (2) Air inlet elbow's adapter (3) Turbocharger's compressor

The fuel metering valve controls the volume of fuel that flows to adapter (2) for the air inlet elbow. The inlet air that is necessary for combustion also enters the adapter. The air/fuel mixture enters turbocharger compressor (3) .

Illustration 7

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Right view Flow of fuel and of air through the single turbocharger arrangement (4) Throttle (5) Aftercooler

Illustration 8

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Right view Flow of fuel and of air through the twin turbocharger arrangement (4) Throttle (5) Aftercooler

The compressed air/fuel mixture flows to the electronically controlled throttle (4) . The ECM issues a command signal to the throttle's actuator via the CAN data link. The signal is based on the desired engine speed. The throttle controls the volume of the air/fuel mixture that flows through aftercooler (5) . The temperature of the compressed air/fuel mixture is reduced in the aftercooler. This increases the density of the air/fuel mixture. This results in more efficient combustion.

Illustration 9

g01443038

Flow of air and fuel through the air inlet manifold (5) Aftercooler (6) Air inlet manifold (7) Spark arrestor

The air/fuel mixture flows from the aftercooler through air inlet manifold (6) . The manifold distributes the air/fuel mixture through the spark arrestor to the cylinders for combustion.

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Air/Fuel Ratio Control The Electronic Control Module (ECM) provides control of the air/fuel mixture for performance and for efficiency at low emission levels. The system includes the following components: maps in the ECM, output drivers in the ECM, air inlet pressure sensor, inlet manifold air temperature sensor, engine speed/timing sensor, generator output power sensor and fuel metering valve. Additionally, the customer's input via the Caterpillar Electronic Technician (Cat ET) is required. Illustrations 1 and 2 are diagrams of the system's main components and of the inputs for the system. For engines that are equipped with an Auxiliary Sensing Module (ASM), ASM receive inputs from the following sensors: l l l

Generator output power sensor Air inlet pressure sensor Engine speed sensor

The ASM rapidly processes the signals from these sensors and passes the information to the master ECM via the Cat Data Link.

Illustration 1 Diagram of the air/fuel ratio control The engine is not equipped with an ASM.

g01443064

Illustration 2

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Diagram of the air/fuel ratio control The engine is equipped with an ASM.

Cat ET - This software is designed to run on a personal computer. Technicians can use the program to perform many functions. For the air/fuel ratio control, the technician programs configuration parameters into the ECM. Generator output power sensor - The engine's control system requires an input which indicates the generator's output in kilowatts. This input can be from the EMCP II+, from a programmable logic controller (PLC), or from a wattmeter. If the EMCP II+ is not used, the equipment that monitors the generator's output is provided by the customer. The PLC or the wattmeter must provide an analog signal with a range of 0 to 5 VDC. The signal must use as much of this range as possible. The signal must be accurate within 0.5 percent of the generator's actual output. The signal must have a linear relationship with the generator's actual output in electrical kilowatts (ekW). Engines that are equipped with ASM are not compatible with EMCP II+ load signal. Inlet manifold air temperature sensor - This sensor monitors the temperature of the air/fuel mixture in the inlet manifold. Air inlet pressure sensor - This sensor monitors the pressure of the air/fuel mixture in the inlet manifold. Engine speed/timing sensor - This sensor monitors the rotation of a speed-timing wheel in order to provide information on the engine timing and on the engine rpm. Fuel metering valve - This is an electronically controlled actuator and a valve that regulates the flow of fuel. The device monitors the fuel temperature, the fuel pressure, and the valve's differential pressure. The ECM sends a command signal for the fuel flow to the device. The device modulates the valve in order to match the command signal. The ECM communicates with the fuel metering valve via the CAN data link. Optional Fuel Quality Sensor - Some applications support an input for remote fuel quality. These engines can accept an input from a fuel quality sensor that is provided by the customer. The sensor performs continuous analysis of the fuel in order to determine the fuel's LHV. The sensor provides a 4 to 20 mA signal to the ECM which indicates the fuel's LHV. The sensor has a "CONFIG" setting and a "4 to 20 mA" setting. The "CONFIG" setting is only used if the quality of fuel supply is constant. The "4 to 20 mA" setting is used when the quality of the fuel supply is variable. The air/fuel ratio control has two basic modes of operation: l l

Open loop Charge density feedback

The modes of operation are explained below. For proper operation of the air/fuel ratio control, inputs from the customer are necessary.

Inputs from the Customer To accurately control the air/fuel ratio, the control system depends on these inputs from the customer: l l

Fuel Quality Engine Load

Fuel Quality Before the initial start-up, a current gas analysis is required. Data from the gas analysis must be entered into Caterpillar Software, LEKQ6378, "Methane Number Program". The results are programmed into the ECM. Note: It is very important to use the Caterpillar Software, LEKQ6378, "Methane Number Program". Use of only the data from the gas analysis can result in incorrect settings. The ECM must have values for the following parameters. The values are entered via the "Configuration" screen of Cat ET: l l l l l l

"Fuel Quality Input Type Configuration" "Fuel Quality Sensor LHV Lower Setpoint" "Fuel Quality Sensor LHV Upper Setpoint" "Fuel Quality" "Gas Specific Gravity" "Fuel Specific Heat Ratio"

Note: The "Fuel Quality Sensor LHV Lower Setpoint" and the "Fuel Quality Sensor LHV Upper Setpoint" are needed only when using the 4-20 mA signal from a fuel quality sensor. Note: For more details on these parameters, refer to Systems Operation/Testing and Adjusting, "Electronic Control System Parameters". "Fuel Quality Input Type Configuration" - Program this parameter to either "CONFIG" or "4 to 20 mA". The "CONFIG" setting is only used if the quality of fuel supply is constant. If the "CONFIG" setting is used, enter a value under the "Fuel Quality" setting. The "4 to 20 mA" setting is used when the quality of the fuel supply is variable. If the "4 to 20 mA" is used, enter the values for the "Fuel Quality Sensor LHV Lower Setpoint" and for the "Fuel Quality Sensor LHV Upper Setpoint". "Fuel Quality Sensor LHV Lower Setpoint" - The ECM uses the value of this parameter to determine the lower limit of the range of the fuel's LHV. "Fuel Quality Sensor LHV Upper Setpoint" - The ECM uses the value of this parameter to help determine the upper limit of the range of the fuel's LHV. "Fuel Quality" - This is the fuel's Low Heating Value (LHV). The value is obtained from a fuel analysis which is entered into Caterpillar Software, LEKQ6378, "Methane Number Program". Only use this value when the fuel quality sensor is in the "CONFIG" setting. During operation, the ECM uses the LHV to help determine the command signal for the fuel flow. "Gas Specific Gravity" - This is the fuel's specific gravity in relation to the specific gravity of air. The value is obtained from a fuel analysis which is entered into Caterpillar Software, LEKQ6378, "Methane Number Program". "Fuel Specific Heat Ratio" - This is a ratio of the fuel's specific heat at a constant pressure and at a constant volume. The ECM provides the fuel's specific gravity and heat ratio to the fuel metering valve via the CAN data link. The fuel metering valve uses this information to help regulate the fuel flow. In addition to the information on the fuel, the ECM requires information on the engine load.

Engine Load The ECM must have values for the following parameters. The parameters are entered into the ECM via Cat ET. l l l l

"Engine Output Power" "Engine Driven Accessory Load Configuration" "Generator Output Power Sensor Scale Factor" "Generator Output Power Sensor Offset"

"Engine Output Power" - This is the engine's full load rating in ekW. The rating is stamped on the engine's Information Plate. During engine operation, the ECM uses this value to determine the engine's load as a percentage of the maximum load. "Engine Driven Accessory Load Configuration" - This is the load of the auxiliary equipment such as a radiator fan that is directly driven by the engine. The value is in units of ekW. The ECM adds this load to the estimate of the generator's actual output in order to determine the total load on the engine. "Generator Output Power Sensor Scale Factor" - This is a scale for the wattmeter's output. If the generator is equipped with the EMCP II+, information on the generator's electrical power output is provided to the ECM via the Cat Data Link. The value for the "Generator Output Power Sensor Scale Factor" parameter is correctly programmed at the factory. This parameter has no effect when the EMCP II+ provides the information on the generator's power output. If the generator is equipped with a wattmeter, the signal from the power sensor increases as the generator's output increases to the maximum output. Select a wattmeter that provides a full scale output (4.8 VDC) for the generator's maximum power output. The ECM requires a scale factor in order to estimate the generator's output. For further information, refer to Systems Operation, "Electronic Control System Parameters". "Generator Output Power Sensor Offset" - The offset is used to make the scale accurate for the generator output power sensor. If the generator is equipped with the EMCP II+, information on the generator's output is provided to the ECM via the Cat Data Link. The value for the "Generator Output Power Sensor Offset" parameter is correctly programmed at the factory. If the generator is equipped with a power sensor, the power sensor's output may not be zero when the generator's output is zero. When this occurs, the power sensor has an offset voltage. The offset voltage may be positive or negative. In most cases, the offset voltage is very low. All of the above parameters are programmed into the ECM via the "Configuration" screen of Cat ET. For more details, refer to Systems Operation, "Electronic Control System Parameters".

Open Loop Mode Open loop - During operation in this mode, the ECM controls the air/fuel ratio with maps and with calculations for the desired air/fuel ratio. This mode of operation uses no feedback. The air/fuel ratio is controlled in the open loop mode from start-up until the engine load becomes greater than 25 percent. The ECM uses a Fuel Correction Factor (FCF) to help determine the fuel flow. During operation in the open loop mode, the FCF is always 100 percent. This enables the customer programmable "Fuel Quality" or LHV to affect the air/fuel ratio. To richen the air/fuel mixture, reduce the LHV. The ECM will compensate for the reduced LHV by increasing the fuel flow. To lean the air/fuel mixture, increase the LHV. The ECM will compensate for the increased LHV by reducing the fuel flow.

Charge Density Feedback Charge density - This is the density of the air/fuel mixture in the air inlet manifold. The ECM calculates

the charge density from the values of inlet manifold air temperature and air inlet pressure. Charge density feedback - The ECM calculates the actual charge density. The actual charge density is compared to the desired charge density. To achieve the desired charge density, the ECM sends a command signal to the fuel metering valve. This is a continuous process during operation with loads that are greater than 25 percent. The same customer's inputs that are required for operation in the open loop are used for the feedback mode. The following additional configuration parameter must be programmed into the ECM via the "Configuration" screen of Cat ET: "Desired Emissions Gain Adjustment Percentage" - This is an adjustment for the charge density. To richen the air/fuel mixture, increase the gain adjustment. To lean the air/fuel mixture, decrease the gain adjustment. This increases the charge density and lowers NOX. The ECM uses the gain adjustment to help determine the FCF. The FCF varies during operation in the feedback mode. Note: A small change in the "Desired Emissions Gain Adjustment Percentage" causes a large change in the actual exhaust emissions. For example, an adjustment of one percent in the parameter's value will result in a change of 20 to 40 ppm in the actual level of NOx. This parameter should only be adjusted only if the engine is above 50 percent load.

SYSTEMS OPERATION

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G3516E Service manual (GAS)

Media Number -KENR6834-03

Aftercooler

Illustration 1

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Flow of the air/fuel mixture through the aftercooler (1) First stage (2) Second stage

The aftercooler is located on top of the engine. The aftercooler has a two-stage core assembly. Coolant from the jacket water circuit flows through first stage (1) of the aftercooler core. Coolant from the separate circuit flows through second stage (2) of the aftercooler core. Note: For some engines that are used for cogeneration, the aftercooler's first stage may also be separate. The air/fuel mixture from the turbocharger's compressor flows through the throttle into the aftercooler's cover. The air/fuel mixture passes through the fins of the aftercooler core in order to exchange heat with the coolant. The temperature of the compressed air/fuel mixture is reduced in the aftercooler. This increases the density of the air/fuel mixture. This results in more efficient combustion. The temperature of the air/fuel mixture is initially reduced in the first stage. The second stage provides further reduction of the air/fuel mixture's temperature. The air/fuel mixture from the aftercooler is distributed through the air inlet manifold to the cylinders for combustion.

SYSTEMS OPERATION

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G3516E Service manual (GAS)

Media Number -KENR6834-03

Compressor Bypass A rapid reduction in the generator's power output can cause a rapid increase in the engine speed. The increased engine speed causes the turbocharger to produce boost pressures that are greater than the requirement for the engine operation. Turbocharger surge - In response to the excess pressure in the air inlet system, the flow of air across the turbocharger compressor wheel is reversed. This reversal of the air flow is called a turbocharger surge. During a turbocharger surge, the turbocharger overspeeds temporarily. This places a greater axial load on the thrust bearing and higher than normal torque on the shaft. The turbocharger surge can result in severe damage to the turbocharger. The compressor bypass group reduces the opportunity for a turbocharger surge.

Illustration 1

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Flow of the compressed air/fuel mixture during activation of the compressor bypass group (50 Hz arrangement) (1) Actuator for the bypass valve (2) Bypass valve (3) Throttle (4) Throttle actuator (5) Fuel metering valve

The master Electronic Control Module (ECM) monitors the engine speed. The ECM responds to a rapid increase in the engine speed by sending a command signal to actuator (1). This causes the actuator to move a shaft that is connected to a plate inside bypass valve (2). The bypass valve opens. The bypass valve is connected before throttle (3). Tubing is connected from the bypass valve to the inlet for the turbocharger compressor. When the bypass valve is opened, the compressed air/fuel mixture is diverted through the tubing away from the throttle. This reduces the back pressure that is caused by excessive pressure in the air inlet system. Note: The bypass valve for the 60 Hz arrangement is connected to two sets of tubing: one set of tubing is connected to the inlet for the right turbocharger and the other set of tubing is connected to the inlet for the

left turbocharger. Additionally, the ECM sends two other command signals. A command to throttle actuator (4) opens the throttle in order to reduce the resistance that contributes to back pressure. A command to fuel metering valve (5) reduces the fuel supply in order to reduce the engine speed and the turbocharger's speed. The combined effect of these actions reduces the opportunity for a turbocharger surge. The ECM determines a time period that is required for opening of the bypass valve. After the time period has expired, the ECM sends a command signal to actuator (1) in order to close the bypass valve. Normal operation resumes. The compressor bypass group is also operated during engine shutdown. This reduces the opportunity for a turbocharger surge during engine shutdown. Additionally, any air/fuel mixture that may have been trapped in the tubing is purged. Active Bypass The compressor bypass valve is commanded to a wide range of positions if the engine is equipped with an Auxiliary Sensing Module (ASM). This is called active bypass. The ASM uses inputs from the manifold air pressure sensor and the boost pressure sensor in order to determine the pressure drop across the throttle plate. The ASM determines the amount of active bypass that is required in order to maintain the desired pressure drop across the throttle plate. The ASM transfers the information to the master ECM via the Cat Data Link. The master ECM sends a command to the actuator for the bypass valve in order for the bypass valve to move to the desired position.

SYSTEMS OPERATION

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G3516E Service manual (GAS)

Media Number -KENR6834-03

Exhaust Manifold

Illustration 1 Flow of exhaust gas through the exhaust manifolds (50 Hz arrangement) The 50 Hz arrangement has one turbocharger.

g00928158

Illustration 2

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Flow of exhaust gas through the exhaust manifolds (60 Hz arrangement) The 60 Hz arrangement has two turbochargers.

The exhaust manifolds are located on the sides of the engine. Exhaust gas flows from each cylinder head through intermediate exhaust manifolds that are connected by bellows in order to form a passage to the turbocharger turbine. The dry exhaust manifolds provide maximum heat to the turbine. The exhaust manifolds are covered with insulated heat shields in order to retain the heat. The heat shields also help protect the wiring and other components from the heat.

SYSTEMS OPERATION

016

G3516E Service manual (GAS)

Media Number -KENR6834-03

Turbocharger The turbine side of the turbocharger is mounted to the exhaust manifold. The compressor side of the turbocharger is connected by pipes to the aftercooler housing.

Illustration 1

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Turbocharger (typical example) (1) Compressor wheel (2) Bearing (3) Oil inlet (4) Bearing (5) Turbine wheel (6) Exhaust outlet (7) Air inlet (8) Coolant passages (9) Oil outlet (10) Exhaust inlet

The exhaust gases go into the exhaust inlet (10) of the turbine housing. The gases push the blades of turbine wheel (5). The turbine wheel and the compressor wheel turn at speeds up to 90,000 rpm. Air and fuel are pulled through the compressor housing air inlet (7) by the rotation of the compressor wheel (1). The action of the compressor wheel blades causes a compression of the air/fuel mixture. Bearing (2) and bearing (4) in the turbocharger use engine oil under pressure for lubrication. The oil is sent through the oil inlet line to oil inlet (3) at the top. The oil then goes through passages in the center section for lubrication of the bearings. The oil goes out of oil outlet (9) at the bottom. The oil then goes back to the engine block through the drain line. The bearing housing in the turbocharger is also cooled by the jacket water coolant. Coolant from the coolant inlet line enters the side of the center section. The coolant travels through the coolant passages (8) in the bearing housing. The coolant then leaves the turbocharger at the opposite side of the center section.

SYSTEMS OPERATION

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G3516E Service manual (GAS)

Media Number -KENR6834-03

Valve System Components The valve system components control the flow of the inlet air and of the fuel into the cylinders and the flow of exhaust gas out of the cylinders during engine operation.

Illustration 1

g00813876

(1) Rocker arm (2) Valve bridge (3) Valve rotator (4) Valve spring (5) Pushrod (6) Valve (7) Cam follower (8) Camshaft lobe

The crankshaft gear drives the camshaft gears through idler gears. The camshafts must be timed to the

crankshaft in order to get the correct relation between the movement of the piston and movement of the valves. The camshafts have two camshaft lobes (8) for each cylinder. As the camshaft turns, the camshaft lobe causes cam follower (7) and pushrod (5) to move up and down. The pushrod moves rocker arm (1). Movement of the rocker arm causes valve bridge (2) to move up and down on a dowel in the cylinder head. This movement operates valves (6). The valve bridge enables one rocker arm to operate two valves simultaneously. There are two inlet valves and two exhaust valves for each cylinder. Valve rotator (3) turns the valve during engine operation. The rotation of the valves keeps the deposit of carbon on the valves to a minimum. This provides longer service life for the valves. When cam follower (7) moves downward, valve spring (4) closes the valve.

SYSTEMS OPERATION

018

G3516E Service manual (GAS)

Media Number -KENR6834-03

Lubrication System

Illustration 1

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Lubrication system schematic (typical example) (1) Main engine oil gallery (2) Engine oil gallery for the left camshaft (3) Engine oil gallery for the right camshaft (4) Engine oil gallery for the piston cooling jets (5) Piston cooling jet (6) Engine oil supply for the turbochargers (7) Sequence valve (8) Sequence valve (9) Adapter (10) Engine oil filter base (11) Engine oil cooler (12) Bypass valve (13) Relief valve (14) Engine oil pump (15) Elbow (16) Suction bell (17) Engine oil filter

Engine oil pump (14) has three gears that are driven by the front gear train. The engine oil pump pulls engine oil from the pan through suction bell (16) and elbow (15). The suction bell has a screen in order to strain the engine oil.

Relief valve (13) controls the maximum pressure of the engine oil from the engine oil pump. If the pressure from the pump becomes excessive, the relief valve opens and some of the engine oil returns to the engine oil pan. Engine oil cooler (11) reduces the temperature of the engine oil. The engine oil cooler has bypass valve (12) that is designed to open if the cooler becomes restricted.

Illustration 2

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(10) Engine oil filter base (17) Engine oil filter housing

Engine oil filter base (10) provides the mount for engine oil filters (17). The base has an internal bypass valve. The bypass valve will open if there is a restriction in the engine oil cooler or in the engine oil filter. This allows the engine to be lubricated if the engine oil cooler is plugged or if the engine oil filter is dirty. Clean engine oil from the engine oil filters goes through adapter (9) into the block. Part of the engine oil goes to left camshaft oil gallery (2). The remainder of the engine oil goes to main engine oil gallery (1) . Engine oil galleries (2) and (3) supply engine oil through drilled passages to the camshaft bearings. The engine oil circulates around each camshaft journal. The engine oil then flows through the cylinder head and through the rocker arm housing to the rocker arm shaft. Some of the engine oil lubricates the valve stems. The remainder of the engine oil drains from the cylinder head in order to lubricate the pushrods, the valve lifters, the camshaft, and the camshaft bearings. Engine oil from main engine oil gallery (1) is supplied to the main bearings through drilled passages. Drilled holes in the crankshaft supply engine oil from the main bearings to the connecting rod bearings. Engine oil from the rear of the main engine oil gallery goes to the rear of right camshaft oil gallery (3) . Sequence valves (7) and (8) allow engine oil from main engine oil gallery (1) to enter engine oil galleries (4) for piston cooling jets (5). The sequence valves will not allow engine oil into gallery (4) for the piston cooling jets until there is pressure in the main engine oil gallery. This reduces the amount of time that is required for pressure buildup when the engine is started.

Illustration 3

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(5) Piston cooling jet

Piston cooling jet (5) is located in the engine block below each piston. Each piston cooling jet has two tubes with open ends. One tube directs engine oil into an opening in the bottom of the piston for an engine oil gallery in the piston. This gallery provides cooling oil behind the ring band of the piston. The gallery provides engine oil to a slot (groove) in the side of both piston pin bores. The other tube directs engine oil to the center of the piston. This provides lubrication to the piston pin and to the piston undercrown. This also helps cool the piston.

Illustration 4

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Lines for engine oil (6) Supply line (18) Drain line

Supply line (6) provides engine oil for lubrication of the turbocharger bearings. The engine oil flows through drain line (18) into the front housing. Engine oil is provided to the front and rear gear groups through drilled passages in the front housings, in the rear housings, and in the faces of the cylinder block. These passages are connected to engine oil galleries (2) and (3) for the camshafts. After the oil has completed lubrication, the engine oil returns to the engine oil pan.

SYSTEMS OPERATION

019

G3516E Service manual (GAS)

Media Number -KENR6834-03

Cooling System The engine has two cooling systems. The jacket water system cools the following components: engine oil cooler, cylinder block, cylinder heads, turbochargers and aftercooler's first stage. A separate system cools the aftercooler's second stage. Illustration 1 is a diagram of the typical cooling system.

Illustration 1

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The cooling system has two pumps that are driven by the engine. Coolant from the jacket water cools the first stage of the aftercooler. The separate circuit cools the second stage.

Water temperature regulators are used in each circuit in order to maintain correct operating temperatures.

Jacket Water System

The jacket water pump is located on the right front side of the engine. The water pump has a gear that is driven by the lower right front gear group. Coolant from the radiator or the heat exchanger enters the water pump's inlet. The rotation of the impeller in the jacket water pump pushes the coolant through the system. The flow of the coolant is divided. Some of the coolant from the jacket water pump flows through a tube to the front of the cylinder block and into the main distribution manifold for the water jacket of each cylinder. The remainder of the coolant flows through the engine oil cooler. After flowing through the engine oil cooler, this portion of the coolant is divided again. Some of the coolant flows into the water jacket of the right rear cylinder. This coolant is mixed throughout the engine's water jacket with the coolant that flows to the front of the cylinder block. The remainder of the coolant flows through the first stage of the aftercooler. The coolant inside the cylinder block flows around the cylinder liners. The water jacket is smaller near the top of the cylinder liners. This shelf causes the coolant to flow faster for better cooling of the cylinder liner. The coolant is pumped up through water directors into the cylinder heads. The coolant flows through passages around these items in the cylinder head: valves, valve seat inserts, spark plug adapter and exhaust outlets. The coolant exits the cylinder heads through tubes and the coolant flows into the water manifold. Coolant flows through the water manifold into lines for the turbocharger turbine housing. The coolant returns to the water manifold. Air is vented from the high points of the cooling system. The vent line from the connection must be straight and the vent line must have a slight upward slope. The vent must not be obstructed. The water manifold directs the coolant to the water temperature regulator housing. The engine has eight water temperature regulators. The water temperature regulators control the direction of the coolant flow according to the coolant temperature. When the coolant achieves normal operating temperature, the water temperature regulators open and coolant flow is divided. Most of the coolant goes through the radiator or through the heat exchanger. This coolant circulates back to the jacket water pump. The remainder of the coolant goes through a bypass tube to the jacket water pump. Note: The water temperature regulators are necessary to maintain the correct engine temperature. If the water temperature regulators are not installed in the system, there is no mechanical control. Most of the coolant will take the path of least resistance through the bypass tube. This will cause the engine to overheat in hot weather. The small amount of coolant that goes through the radiator in cold weather will not allow the engine to achieve normal operating temperatures. The water temperature regulators control the minimum temperature of the coolant. The radiator or the heat exchanger controls the maximum temperature of the coolant. The bypass tube has another function. When you fill the cooling system the internal bypass allows the coolant to go into the cylinder head and into the cylinder block without going through the water pump. The total system capacity depends on the amount of coolant in the cylinder block, in the piping, and in the radiator or heat exchanger.

Separate Circuit

Illustration 2

g00929351

(1) Auxiliary water pump (2) Tube for the coolant supply to the aftercooler's second stage (3) Aftercooler (4) Tube for the coolant return from the aftercooler to the thermostatic valve (5) Thermostatic valve (6) Outlet for coolant to the radiator or heat exchanger (7) Inlet for coolant from the radiator or heat exchanger

Auxiliary water pump (1) is driven by the engine's auxiliary drive. The coolant is pumped through tube (2) to the aftercooler's second stage (3). The coolant exits the aftercooler through tube (4) that is connected to thermostatic valve (5) . The thermostatic valve has one inlet, two outlets, and a water temperature regulator. When the coolant is cool, the water temperature regulator is closed. The coolant is routed directly back to the auxiliary water pump. The coolant is recirculated through the aftercooler. When the coolant reaches the opening temperature, the water temperature regulator opens. The coolant is to a radiator or to a heat exchanger through outlet (6). The coolant returns to the auxiliary pump through inlet (7) .

SYSTEMS OPERATION

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G3516E Service manual (GAS)

Media Number -KENR6834-03

Cylinder Block, Liners and Heads The cylinders in the left side of the block form a 60 degree angle with the cylinders in the right side.

Illustration 1

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(1) Cylinder liner (2) Filler band (3) O-ring seals (4) Main bearing cap (5) Bolt

Cylinder liners (1) can be removed for replacement. The top surface of the cylinder block is the seat for the cylinder liner flange. Engine coolant flows around the cylinder liners in order to keep the cylinder liners cool. Filler band (2) and three O-ring seals (3) seal the coolant in the cylinder block. Main bearing caps (4) are fastened to the cylinder block with four bolts (5) per cap.

Illustration 2

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(6) Spacer plate (7) Gasket

The engine has a separate cylinder head for each cylinder. An aluminum spacer plate (6) and gasket (7) is between each cylinder head and the cylinder block. The plate and the gasket accommodate the thickness of the cylinder liner flange.

Illustration 3

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(8) Exhaust valves (9) Inlet valves (10) Gasket (11) Water seals

Each cylinder head has four valves. Two exhaust valves (8) and two inlet valves (9) are controlled by a camshaft and pushrods. For information on the operation of the valves, refer to Systems Operation, "Valve System Components". Valve guides are pressed into the cylinder heads. The spark plug is located

between the four valves. Another gasket (10) on top of the spacer plate seals the oil drain passages between the cylinder head and the spacer plate. After the engine oil lubricates the components in the cylinder head, the engine oil drains back into the engine block. Coolant flows from the cylinder block into the cylinder head through water seals (11). The coolant flows through passages in the cylinder head. The coolant exits the cylinder head and flows into the water manifold.

Illustration 4

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(12) Camshaft cover (13) Crankcase cover

Camshaft covers (12) allow access to the camshaft and valve lifters. Crankcase covers (13) allow access to the crankshaft connecting rods, main bearings, and piston cooling jets.

SYSTEMS OPERATION

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Pistons, Rings and Connecting Rods

Illustration 1

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(1) Piston (2) Compression rings (3) Oil ring (4) Connecting rod (5) Piston pin (6) Pin retainer (7) Bolt (8) Connecting rod cap (9) Connecting rod bearing

Aluminum pistons (1) have three rings. The rings include two compression rings (2) and one oil ring (3). All the rings are located above the piston pin bore. The top two compression rings are rectangular. The oil ring is a two-piece ring. Engine oil returns to the crankcase through holes in the oil ring groove. The piston is attached to connecting rod (4) with piston pin (5) and with two pin retainers (6). The connecting rod has a taper on the pin bore end. This taper gives the connecting rod and the piston more strength in the areas with the most load. Four bolts (7), which are set at a small angle, hold connecting rod cap (8) to the connecting rod. This design keeps the connecting rod width to a minimum, so that a larger connecting rod bearing (9) can be used and the connecting rod can still be removed through the cylinder liner.

SYSTEMS OPERATION

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G3516E Service manual (GAS)

Media Number -KENR6834-03

Crankshaft

Illustration 1

g01393753

Crankshaft

The crankshaft changes the reciprocating motion of the pistons into usable rotating torque. The crankshaft drives a group of gears on the front and on the rear of the engine. The front gear group drives the engine oil pump, the jacket water pump, and the accessory drives. The rear gear group drives the camshafts. Pressurized engine oil is supplied to the crankshaft's main bearings through drilled passages in the webs of the cylinder block. The engine oil then flows through drilled passages in the crankshaft in order to provide lubrication to the connecting rod bearings. The engine has nine main bearings. Two thrust plates on the sides of the center main bearing control the end play of the crankshaft.

Illustration 2

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Cross sections of the crankshaft seals and wear sleeves

Seals and wear sleeves are used at both ends of the crankshaft. Engine oil is sealed by the lip seals and the wear sleeves help prevent wear on the crankshaft.

Illustration 3 Side view of the vibration damper

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A vibration damper is bolted to the front of the crankshaft in order to reduce torsional vibrations that can cause damage to the engine.

SYSTEMS OPERATION

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G3516E Service manual (GAS)

Media Number -KENR6834-03

Camshaft The engine has two camshafts. The camshafts are driven by the gears at the rear of the engine.

Illustration 1

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Connections for the two-piece camshaft (1) Dowel (2) Spacer (3) Bolt

The engine has two-piece camshafts. Dowel (1) in one section of the camshaft goes through spacer (2) into the other section of the camshaft. The sections are joined by bolts (3). Each camshaft is supported by nine bearings. As the camshaft turns, each lobe moves a lifter assembly. There are two lifter assemblies for each cylinder. Each lifter assembly moves a pushrod and two inlet valves or two exhaust valves. The camshafts must be timed with the crankshaft. The relation of the camshaft lobes to the crankshaft position cause the valves in each cylinder to operate at the correct time.

SYSTEMS OPERATION

024

G3516E Service manual (GAS)

Media Number -KENR6834-03

Air Starting System

Illustration 1

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Air starting system (typical example) (1) Relay valve (2) Hose (3) Starting motor solenoid (4) Hose (5) Air starting motor

Illustration 2

Air starting motor

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(6) Air inlet (7) Vanes (8) Rotor (9) Pinion (10) Reduction gears (11) Piston (12) Piston spring

When the main supply of pressurized air is ON, pressurized air is provided to relay valve (1). The main supply of pressurized air is blocked by the relay valve. The relay valve allows some control air pressure to flow through hose (2) from the bottom of the relay valve to another valve that is connected to starting motor solenoid (3) . When the normally closed starting motor solenoid is activated for start-up, the solenoid opens the connected valve. The valve allows the control air pressure to flow behind piston (11) inside air starting motor (5) . The control air pressure pushes the piston. The piston compresses piston spring (12) and the piston moves the drive shaft for pinion (9) outward in order to engage the pinion with the flywheel ring gear. The starting motor does not crank the engine yet. After the pinion is engaged with the flywheel ring gear, a port in the starting motor is opened in order to allow the control air pressure to flow through hose (4) to the top of relay valve (1). The relay valve opens in order to allow the main supply of pressurized air to flow through the starting motor's air inlet (6) . The pressurized air causes vanes (7) and rotor (8) to rotate. The rotor uses reduction gears (10) to rotate the drive shaft for the pinion and the pinion rotates the flywheel in order to crank the engine. When the engine starts to run, the flywheel will begin to rotate faster than the pinion. The design of the drive shaft for the pinion allows the pinion to move away from the flywheel. This prevents damage to the air starting motor, to the pinion, and to the flywheel ring gear. When the engine control senses the crank terminate speed, starting motor solenoid (3) is de-energized. The solenoid closes the attached valve and the control air pressure is removed from piston (11). Piston spring (12) retracts the piston, the drive shaft, and pinion (9) . The retraction of piston (11) closes the passage for the control air pressure to relay valve (1). The relay valve closes in order to shut off the main supply of pressurized air to the starting motor.

SYSTEMS OPERATION

025

G3516E Service manual (GAS)

Media Number -KENR6834-03

Electric Starting System

Illustration 1

g01114061

Components for the electrical starting system (1) Terminal box (2) Magnetic switches (3) Circuit breaker for the start command from the Electronic Control Module (ECM) (4) Starting motor solenoids (5) Starting motors

When the ECM in terminal box (1) receives an input for start-up, the ECM supplies +Battery voltage to two magnetic switches (2). The magnetic switches are located in a power distribution box on the side of the engine. The start command from the ECM is protected by circuit breaker (3) . The two magnetic switches are connected in a secondary electrical circuit to two starting motor solenoids (4). The start command closes the contacts of the magnetic switches in order to complete the secondary electrical circuit. This energizes the starting motor solenoids. The energizing of the starting motor solenoids causes the starting motors' pinions to engage with the flywheel ring gear. The starting motor solenoids are also connected in another electrical circuit between the starting motors and a source of +24 VDC for cranking the starting motors. After the starting motor's pinions are engaged with the flywheel ring gear, the starting motor solenoids' contacts complete the other electrical circuit for cranking of the starting motors. The starting motors crank the engine until the ECM detects the crank terminate speed. Then, the ECM removes the +Battery voltage from the magnetic switches. The contacts of the magnetic switches open and the +Battery voltage is removed from the starting motor solenoids. The starting motor solenoids' contacts open and the +24 VDC for cranking is removed from the starting motors. The starting motors' pinions are disengaged from the flywheel ring gear. Illustration 2 is a schematic of the electrical starting circuit.

Illustration 2 Schematic for the electrical starting circuit

g01114064

SYSTEMS OPERATION

026

G3516E Service manual (GAS)

Media Number -KENR6834-03

Power Supply Requirements for the Control System The engine control system requires a clean 24 VDC power supply that is capable of supplying 30 amperes of continuous power. The maximum allowable AC ripple voltage is 150 millivolts AC peak to peak. For the wiring, the maximum allowable voltage drop is 1 VDC from the power supply to the master Electronic Control Module (ECM) in the engine mounted terminal box. Actuators on the engine draw current in all modes for the engine control. A auxiliary charging system is recommended in order to maintain battery power while the engine is not running. If an auxiliary charging system is not at the engine's site the battery power should be disconnected through the 35 Amp breaker in the junction box when the engine is not running. Separate the power supply for the engine control from the power supply for the starting motor. From the factory, the engine's power supply for the engine control is also the power supply for the starter.

SYSTEMS OPERATION

027

G3516E Service manual (GAS)

Media Number -KENR6834-03

Grounding Practices Proper grounding is necessary for optimum engine performance and reliability. Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths. Uncontrolled electrical circuit paths can result in damage to main bearings, to connecting rod bearing journal surfaces, and to aluminum components. Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the engine electronics and communications. Ensure that all grounds are secure and free of corrosion. The engine alternator must be grounded to the negative "-" battery terminal with a wire that is adequate to carry the full charging current of the alternator. For the starting motor, do not attach the battery negative terminal to the engine block.

NOTICE This engine is equipped with a 24 volt starting system. Use only equal voltage for boost starting. The use of a welder or higher voltage will damage the electrical system.

Ground the engine block with a ground strap that is furnished by the customer. Connect this ground strap to the ground plane. Use a separate ground strap to ground the negative "-" battery terminal for the control system to the ground plane. Disconnect the power when you are working on the engine's electronics. If rubber couplings are used to connect the steel piping of the cooling system and the radiator, the piping and the radiator can be electrically isolated. Ensure that the piping and the radiator are continuously grounded to the engine. Use ground straps that bypass the rubber couplings.

SYSTEMS OPERATION

028

G3516E Service manual (GAS)

Media Number -KENR6834-03

Alternator

NOTICE Never operate the alternator without the battery in the circuit. Making or breaking an alternator connection with heavy load on the circuit can cause damage to the regulator.

Illustration 1

g00285111

Alternator components (typical example) (1) Regulator (2) Roller bearing (3) Stator winding (4) Ball bearing (5) Rectifier bridge (6) Field winding (7) Rotor assembly (8) Fan

The alternator is driven by a belt from an auxiliary drive at the front right corner of the engine. This alternator is a three-phase, self-rectifying charging unit, and regulator (1) is part of the alternator. This alternator design has no need for slip rings or brushes, and the only part that has movement is rotor assembly (7). All conductors that carry current are stationary. The conductors are field winding (6), stator windings (3), six rectifying diodes, and the regulator circuit components. Rotor assembly (7) has many magnetic poles. Air space is between the opposite poles. The poles have residual magnetism that produces a small amount of magnetic lines of force between the poles. As rotor assembly (7) begins to turn between field windings (6) and stator windings (3), a small amount of alternating current (AC) is produced in stator windings (3). This current is from the small, magnetic lines of force that are made by the residual magnetism of the poles. This alternating current (AC) is changed to a direct current (DC). The change occurs when the current passes through the diodes

of rectifier bridge (5). Most of this current completes two functions. The functions are charging the battery and supplying the low amperage circuit. The remainder of the current is sent to field windings (6). The DC current flow through field windings (6) (wires around an iron core) now increases the strength of the magnetic lines of force. These stronger lines of force increase the amount of AC current that is produced in stator windings (3). The increased speed of rotor assembly (7) also increases the current and voltage output of the alternator. Voltage regulator (1) is a solid-state, electronic switch. The regulator feels the voltage in the system. The regulator will start and the regulator will stop many times in one second in order to control the field current to the alternator. The output voltage from the alternator will now supply the needs of the battery and the other components in the electrical system. No adjustment can be made in order to change the rate of charge on these alternator regulators.

SYSTEMS OPERATION

029

G3516E Service manual (GAS)

Media Number -KENR6834-03

Starting Solenoid A solenoid is an electromagnetic switch that does two basic operations. l l

The solenoid closes the high current starting motor circuit with a low current start switch circuit. The solenoid engages the starter motor pinion with the ring gear.

Illustration 1

g00285112

Typical solenoid schematic

The solenoid has windings (one or two sets) around a hollow cylinder. The cylinder contains a spring loaded plunger. The plunger can move forward and backward. When the start switch is closed and the electricity is sent through the windings, a magnetic field is made. The magnetic field pulls the plunger forward in the cylinder. This moves the shift lever in order to engage the pinion drive gear with the ring gear. The front end of the plunger makes contact across the battery and the motor terminals of the solenoid. The starting motor begins to turn the flywheel of the engine. When the start switch is opened, current no longer flows through the windings. The spring pushes the plunger back to the original position. The spring simultaneously moves the pinion gear away from the flywheel. When two sets of windings in the solenoid are used, the windings are called the hold-in windings and the pull-in windings. Both of the windings have the same number of turns around the cylinder. However, the pull-in winding uses a wire with a larger diameter in order to produce a greater magnetic field. When the start switch is closed, part of the current flows from the battery through the hold-in windings. The rest of the current flows through the pull-in windings to the motor terminal. The current then goes through the motor to the ground. When the solenoid is fully activated, current is shut off through the pull-in windings. Only the smaller hold-in windings are in operation for the extended period of time. This period of time is the amount of time that is needed for the engine to start. The solenoid will now take less current from the battery. The heat that is made by the solenoid will be kept at an acceptable level.

SYSTEMS OPERATION

030

G3516E Service manual (GAS)

Media Number -KENR6834-03

Starting Motor The starting motor is used to turn the engine flywheel in order to start the engine.

Illustration 1

g00285113

Cross section of the starting motor (typical example) (1) Field winding (2) Solenoid (3) Clutch (4) Pinion (5) Commutator (6) Brush assembly (7) Armature

The starting motor has a solenoid (2). When the start switch is activated, electricity will flow through the windings of the solenoid. The solenoid core will move in order to push pinion (4) with a mechanical linkage. This will engage with the ring gear on the flywheel of the engine. Pinion (4) will engage with the ring gear before the electric contacts in solenoid (2) close the circuit between the battery and the starting motor. When the circuit between the battery and the starting motor is complete, pinion (4) will turn the engine flywheel. A clutch gives protection to the starting motor. The engine can not turn the starting motor too fast. When the start switch is released, pinion (4) will move away from the flywheel ring gear.

Starting Motor Protection The starting motor is protected from damage in two ways: l

l

The starting motor is protected from engagement with the engine when the engine is running. The control feature will not allow the starting motor to engage if the speed is above 0 rpm. The starting motor is protected from continuous starting. For example, if an operator is holding the key in the Start position after the engine starts, the starting motor solenoid will disengage after engine speed reaches 300 rpm.

SYSTEMS OPERATION

031

G3516E Service manual (GAS)

Media Number -KENR6834-03

Circuit Breaker The circuit breaker is a sealed electromagnetic switch that opens the electrical circuit if the current exceeds the rating of the circuit breaker. The circuit breaker has a coil that operates as an electromagnet. As the current that flows through the coil increases, the coil's magnetic field becomes stronger. If the current exceeds the trip point, the mechanism that normally closes the electrical circuit is pulled toward the coil's magnetic field and the electrical circuit is opened.

NOTICE Find and correct the problem that causes the circuit breaker to open. This will help prevent damage to the circuit components from too much current.

The circuit breaker is designed to operate in a temperature range of -40 to 85 °C (-40 to 185 °F). Because the circuit breaker uses an electromagnet rather than a metal element that responds to heat, the circuit breaker is not affected by changes in the ambient temperature. Also, the electromagnet operates faster than a metal element. The circuit breaker is reset with a toggle switch. If the current continues to exceed the circuit breaker's rating, the electrical circuit will remain open even when the toggle switch is held in the ON position. The power distribution box has four circuit breakers that are identified in Illustration 1.

Illustration 1 The power distribution box is located on left side of the engine. (1) Power distribution box

g00927512

(2) 2.5 amp circuit breaker for the engine control (3) 10 amp circuit breaker for the customer (4) 35 amp circuit breaker for the engine (5) 2.5 amp circuit breaker for the start command from the master ECM (6) Positive terminal for the connection of the engine's power supply (7) Negative terminal for the connection of the engine's power supply

Media Number -KENR6834-03

G3516E Service manual (GAS) Testing and Adjusting General Information (Electronic Control System) Connecting the Caterpillar Electronic Technician (Cat ET) to the Electronic Recommendations for Programming the System Configuration Parameters Changing the Settings of the Monitoring System Engine Governing - Adjust Governor Type Manifold Air Pressure Sensor Detonation Sensor Engine Speed/Timing Sensor Timing Calibration Ignition Transformer Spark Plug Landfill Applications Ignition Timing - Adjust General Information (Fuel System) Air/Fuel Ratio Control - Adjust Finding the Top Center Position for the No. 1 Piston Camshaft Timing Timing Check Timing Adjustment Restriction of Air Inlet and Exhaust Air Inlet Restriction Aftercooler Differential Pressure Exhaust Restriction Measuring Inlet Manifold Temperature Compressor Bypass - Adjust Measuring Exhaust Temperature Compression Crankshaft Position for Valve Lash Setting Valve Lash and Valve Bridge Adjustment Valve Bridge Adjustment Valve Lash Adjustment General Information (Lubrication System) Excessive Bearing Wear - Inspect Excessive Engine Oil Consumption - Inspect Engine Oil Leaks on the Outside of the Engine Engine Oil Leaks into the Combustion Area of the Cylinders Increased Engine Oil Temperature - Inspect Measuring Engine Oil Pressure General Information (Cooling System) Visual Inspection Test Tools for the Cooling System Testing the Cooling System Testing for Freeze Protection Making the Correct Antifreeze Mixtures Testing the Supplemental Coolant Additive and the Glycol Testing for Air and/or Exhaust Gas in the Coolant Testing the Radiator Fan (If Equipped) Testing the Cooling System for Leaks Cylinder Block Piston Rings

INDEX 001

002 003 004 005 006

007 008 009 010 011

012

013 014 015 016 017 018

019 020 021

022 023 024 025 026 027

028

Connecting Rod Bearings Main Bearings Cylinder Liner Projection Flywheel - Inspect Face Runout (Axial Eccentricity) of the Flywheel Bore Runout (Radial Eccentricity) of the Flywheel Flywheel Housing - Inspect Face Runout (Axial Eccentricity) of the Flywheel Housing Bore Runout (Radial Eccentricity) of the Flywheel Housing Vibration Damper - Check General Information (Air/Electric Starting System) Electrical Side Of The Air System Air Side Of The Air System Test Tools for the Electrical System 4C-4911 Battery Load Tester 271-8590 Starting/Charging Analyzer Gp 225-8266 Ammeter Tool Gp 146-4080 Digital Multimeter Gp Battery

029 030

031

032 033

034

035

TESTING AND ADJUSTING

001

G3516E Service manual (GAS)

Media Number -KENR6834-03

General Information (Electronic Control System) Certain programmable parameters must be entered in order for the electronic control system to operate properly. Other programmable parameters are adjusted according to the customer's preferences for the installation. Caterpillar Electronic Service Tools are designed to help the service technician perform the following functions: l l l l l

Obtain data. Diagnose problems. Read parameters. Program parameters. Calibrate sensors.

The tools that are listed in Table 1 are required in order to enable a service technician to perform the procedures.

Connecting the Caterpillar Electronic Technician (Cat ET) to the Electronic Control Module (ECM) Table 1 Tools Needed

Qty

Personal Computer (PC)

1

Single user license for Cat ET Use the most recent version of this software. "JERD2124"

1

Software Data subscription for all engines "JERD2129"

1

171-4400 Communication Adapter Gp

(1)

1

275-5120 Communication Adapter Gp (2) 7X-1414 Adapter Cable As

1

237-7547 Adapter Cable As (3)

1

225-5985 Parallel Port Cable (COMMUNICATION ADAPTER)

1

(1)

This item includes the 171-4401 Communication Adapter As .

(2)

This item includes the 275-5121 Communication Adapter As. The 7X-1700 Communication Adapter Gp may also be used.

(3)

This cable connects to the USB port on computers that are not equipped with a serial port.

For more information regarding the use of Cat ET and the PC requirements for Cat ET, refer to the documentation that accompanies your Cat ET software. The engine's power supply provides the communication adapter with 24 VDC. Use the following

procedure to connect Cat ET and the communication adapter to the engine.

Illustration 1

g01299558

Connecting Cat ET to the service tool connector The service tool connector is on the left rear corner of the engine. (1) Service tool connector (2) Personal Computer (PC) (3) 237-7547 Adapter Cable As (4) 196-0055 Adapter Cable As (5) 225-5985 Parallel Port Cable (COMMUNICATION ADAPTER) (6) 171-4401 Communication Adapter As (6) 275-5121 Communication Adapter As (7) 207-6845 Adapter Cable As

Refer to Illustration 1. The location of the service tool connector depends on the configuration of the control system. The engine's power supply supplies the communication adapter with 24 VDC. Use the following procedure to connect Cat ET and the communication adapter to the engine. 1. Set the engine control to the OFF/RESET mode. 2. Connect communications adapter (6) to a communications port on the PC by using one of the following methods: a. Connect cable (5) between the "COMPUTER" end of communications adapter (6) and the parallel port of PC (2). Be sure to configure Cat ET for the parallel port. This configuration provides the fastest connection. b. Connect cable (4) between the "COMPUTER" end of communication adapter (6) and the serial port of PC (2) . c. Connect cables (3) and (4) between the "COMPUTER" end of communication adapter (6) and the USB port of PC (2) . 3. Connect cable (7) to communication adapter (6) . 4. Connect cable (7) to the service tool connector.

5. Verify that the "POWER" indicator on the communication adapter is illuminated. 6. Set the engine control to the STOP mode. Establish communication between Cat ET and an ECM. If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, "Electronic Service Tool Does Not Communicate". If Cat ET displays "Duplicate Type on data link. Unable to Service", check the harness code for the electronic control modules. The harness inside the terminal box has jumper wires (harness codes) for the slave ECM and the optional Auxiliary Sensing Module (ASM). The ECM that is connected to the harness reads the harness code. This provides the ECM with a unique identifier on the Cat Data Link. The jumper wires must be connected in order for the Cat ET to communicate with the modules. The jumper wires must be connected in order for the engine to crank. The jumper wires must remain connected in order for the engine to run. The jumper wire for the slave ECM connects terminals P3-60 and P3-29. The jumper wire for ASM connects terminals P5-60 and P5-68. Check the continuity between the terminals. Verify that the jumper wires are in good condition. Make repairs, as needed.

Recommendations for Programming the System Configuration Parameters For descriptions of the parameters, refer to Systems Operation, "Electronic Control System Parameters". The values of the parameters can be viewed on the "Configuration" screen of Cat ET. Programmable parameters enable the engine to be configured in order to meet the requirements of the application. The system configuration parameters must be programmed when the application is installed. Perform this programming before the initial engine start-up. Data from a gas analysis is required in order to determine the correct settings for the air/fuel ratio control. The data must be entered into Caterpillar Software, LEKQ6378, "Methane Number Program". Incorrect programming of parameters may lead to complaints about performance and/or to engine damage. If an ECM is replaced, the appropriate parameters must be copied from the original ECM. This can be done with the "Copy Configuration" feature of Cat ET. Alternatively, the settings can be recorded on paper and then programmed into the new module.

NOTICE Changing the parameters during engine operation can cause the engine to operate erratically. This can cause engine damage. Only change the settings of the parameters when the engine is STOPPED.

Changing the Settings of the Monitoring System For descriptions of the monitoring system parameters, refer to Systems Operation, "Engine Monitoring System". To change the settings of the parameters, use Cat ET and select the "Service/Monitoring System" screen. Use care when you program the trip points and the delay times. Ensure that the response of the ECM is correct for the application. The monitoring system will accept any settings within the ranges. Refer to Troubleshooting for the setpoints and for the password protection.

NOTICE

Changing the parameters during engine operation can cause the engine to operate erratically. This can cause engine damage. Only change the settings of the parameters when the engine is STOPPED.

TESTING AND ADJUSTING

002

G3516E Service manual (GAS)

Media Number -KENR6834-03

Engine Governing - Adjust The response of the throttle actuator can be adjusted with the Caterpillar Electronic Technician (ET). Use Cat ET to change these three parameters: l l l

"Governor Gain Factor" "Governor Stability Factor" "Governor Compensation Factor"

The default values should be sufficient for initial start-up. However, the values may not provide optimum performance. These adjustments are provided in order to obtain optimum responses to changes in the load and in the speed. The adjustments also provide stability during steady state operation. If you have a problem with instability, always investigate other causes before you adjust the governor. For example, diagnostic codes and unstable gas pressure can cause instability. When you adjust the primary governor, make sure that the "Grid Status" parameter is "Off". When you adjust the auxiliary governor, make sure that the "Grid Status" parameter is "On". To change the parameters, use the "Real Time Graphing" feature on the "Information" drop-down menu of Cat ET. The graph provides the best method for observing the effects of your adjustments. For details on these parameters, refer to Systems Operation/Testing and Adjusting, "Electronic Control System Parameters". After you make adjustments, always test the stability by interrupting the engine speed and/or load. Operate the engine through the entire range of speeds and of loads in order to ensure stability. Note: Adjustment of the "Governor Gain Factor" directly affects the speed of the throttle actuator when there is a difference between the actual engine speed and the desired engine speed. An excessive increase of this parameter may amplify instability. To set the "Governor Gain Factor", increase the value until the actuator becomes unstable. Slowly reduce the value in order to stabilize the actuator. Observe that the engine operates properly with little overshoot or undershoot. The adjustment of "Governor Stability Factor" dampens the actuator's response to changes in load and in speed. Increasing this value provides less damping. Decreasing the value provides more damping. To reduce overshoot, decrease the value. To reduce undershoot, increase the value. Note: An increase of the "Governor Stability Factor" may require a decrease of the "Governor Gain Factor" in order to maintain a stable operation. Illustration 1 shows some typical curves for transient responses.

Illustration 1

g01017530

(Y) Engine speed (X) Time (1) The "Governor Gain Factor" is too high and the "Governor Stability Factor" is too low. There is a large overshoot on startup and there are secondary overshoots on transient loads. (2) The "Governor Gain Factor" is slightly high and the "Governor Stability Factor" is slightly low. There is a slight overshoot on start-up but the response to transient loads is optimum. (3) The "Governor Gain Factor" is slightly low and the "Governor Stability Factor" is slightly high. There is optimum performance on start-up but slow response for transient loads. (4) The "Governor Gain Factor" is too low and the "Governor Stability Factor" is too high. The response for transient loads is too slow. (5) The response to transient loads is adjusted for optimum performance.

Decrease the "Governor Compensation Factor" until a slow, periodic instability is observed. Then, slightly increase the value. Repeat the adjustments of the "Governor Gain Factor" and of the "Governor Stability Factor". Continue to increase the "Governor Compensation Factor" and readjust the "Governor Gain Factor" and the "Governor Stability Factor" until stability is achieved and the engine's response to changes in load and in speed is optimized. Illustration 2 is a graphic representation of adjusting the "Governor Compensation Factor".

Illustration 2

g01017541

The increased width of the line for the actuator voltage indicates that the throttle actuator is more active as the "Governor Compensation Factor" increases. (Y) Actuator voltage (X) Time in seconds

Governor Type Use Cat ET to select the "Governor Type Setting" configuration parameter. For generator set applications, there are two sets of responses for the throttle actuator. The "Isochronous Mode" is used to provide "off grid" engine stability for synchronization. The "Droop Operation" is for "on grid" stability. Adjustment to the settings for the throttle actuator relates to both of the responses.

TESTING AND ADJUSTING

003

G3516E Service manual (GAS)

Media Number -KENR6834-03

Manifold Air Pressure Sensor Table 1 Tools Needed

Quantity

1U-5470 Engine Pressure Group

1

Absolute pressure - Absolute pressure is the gauge pressure plus the local barometric pressure. Gauge pressure - Gauge pressure is the absolute pressure minus the local barometric pressure. The manifold air pressure sensor is also called the air inlet pressure sensor. The air inlet pressure sensor measures the absolute inlet manifold air pressure. To verify that the air inlet pressure sensor is accurate, use the Caterpillar Electronic Technician (ET) to read the "Inlet Manifold Air Pressure (abs)" when the engine is stopped. The correct pressure will be the ambient barometric pressure. Use the following procedure to compare the reading from the air inlet pressure sensor with a reading from the 1U-5470 Engine Pressure Group . Note: The air inlet pressure sensor may be installed at either end of the inlet manifold. The actual location depends on the configuration of the control system.

Illustration 1

g00929850

Right view at the rear of the engine Plugs in the air inlet manifold

Remove one of the plugs from the air inlet manifold. Connect a line from the opening to a pressure gauge from the 1U-5470 Engine Pressure Group. Operate the engine under a load. Use Cat ET to read the inlet manifold air pressure. Read the pressure gauge from the 1U-5470 Engine Pressure Group and add the local barometric pressure to the reading. Compare the calculation to the reading from Cat ET.

TESTING AND ADJUSTING

004

G3516E Service manual (GAS)

Media Number -KENR6834-03

Detonation Sensor Detonation is engine knock that occurs after combustion has occurred. The excessive mechanical stress and thermal stress can reduce the service life of the engine. There are several possible causes of detonation. Examples are a rich air/fuel mixture, overload, a high compression ratio, and high inlet manifold air temperature. Combustion of the air/fuel mixture prior to the spark is a premature ignition. This is usually caused by a hot spot in the combustion chamber. Possible sources of premature ignition are an incorrect spark plug, an incorrectly installed spark plug, and deposits in the combustion chamber. Detonation can be the result of premature ignition. The premature ignition has the effect of advanced ignition timing. Although a sensor may indicate the presence of detonation, the problem could be a premature ignition. An indication of detonation can also be caused by excessive mechanical engine noise. To avoid detecting vibrations that are not related to detonation, the Electronic Control Module (ECM) only monitors a detonation sensor when one of the sensor's cylinders is between 5 degrees after top center and 40 degrees after top center. Therefore, the "Block Tap" method of testing the detonation sensors does not work for the G3500C Engines. For information on testing the detonation sensors, refer to the engine's Troubleshooting manual.

TESTING AND ADJUSTING

005

G3516E Service manual (GAS)

Media Number -KENR6834-03

Engine Speed/Timing Sensor If a diagnostic code is generated for the engine speed/timing sensor, refer to the Troubleshooting manual. For proper operation, the condition and installation of the sensor must be correct. If the condition or the installation of the sensor is suspect, use the following procedure.

Illustration 1

g00760464

(1) Engine speed/timing sensor

1. Remove engine speed/timing sensor (1). Inspect the condition of the end of the magnet. Look for wear and contaminants. 2. Clean any debris from the face of the magnet.

Illustration 2

g00909543

(2) Sliphead

3. Check the tension of sliphead (2). Gently extend the sliphead for a minimum of 4 mm (0.16 inch).

Then push back the sliphead. When the sliphead has the correct tension, at least 22 N (5 lb) of force is required to push in the sliphead from the extended position.

NOTICE The sliphead must be fully extended when the speed/timing sensor is installed so that the sensor maintains the correct clearance with the speed-timing wheel. If the correct clearance is not maintained, the signal 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 result. Before installing the sensor, ensure that a tooth of the wheel is visible in the mounting hole for the sensor. 4. Install the engine speed/timing sensor. a. Ensure that a tooth on the speed-timing wheel is visible in the mounting hole for the sensor. b. Extend sliphead (2) by a minimum of 4 mm (0.16 inch). c. Coat the threads of the sensor with 4C-5598 High Temperature Anti-Seize . Note: The sliphead is designed to contact a tooth of the speed-timing wheel. The maximum allowable gap between the sliphead and the tooth is 0.5 mm (0.02 inch). d. Install the sensor. Tighten the locknut to 40 ± 5 N·m (30 ± 4 lb ft).

Timing Calibration Calibration of the timing is required only after the following circumstances: l l l

The master Electronic Control Module (ECM) has been replaced. The speed-timing wheel and/or the rear gear train have been adjusted. The speed-timing wheel and/or the rear gear train have been replaced.

The Caterpillar Electronic Technician (ET) uses the engine speed/timing sensor to help calibrate the engine timing. For instructions on the timing calibration, refer to Troubleshooting, "Timing - Calibrate".

TESTING AND ADJUSTING

006

G3516E Service manual (GAS)

Media Number -KENR6834-03

Ignition Transformer If an ignition transformer is suspect, use the following procedure to check the transformer:

Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the transformers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the transformers are removed during engine operation. 1. Turn the engine control OFF. Switch the engine's circuit breaker OFF.

Illustration 1 (1) Cover (2) Connector (3) Transformer (4) Extension

g00929956

(5) Spark plug (6) Mounting flange for the transformer

2. Remove cover (1) . 3. Disconnect the ignition harness from connector (2) . Remove transformer (3) and extension (4) from the engine. 4. Inspect the body of transformer (3) and extension (4) for corrosion and/or for damage. 5. The extension has an internal O-ring seal for spark plug (5) . Inspect the O-ring seal for damage. 6. The extension has an internal terminal for the spark plug. Inspect the terminal for looseness, for corrosion, and/or for damage. Insert an extra spark plug into the transformer and check the terminal for spring pressure.

NOTICE The extension can be scratched and damaged with a wire brush. Do not use a wire brush on the extension. 7. Clean any deposits from the inside of the extension. Use a 6V-7093 Brush with isopropyl alcohol.

Illustration 2 g00754013 Symbol for a diode

8. Measure the primary circuit by checking the voltage of the diode.

Illustration 3

g00829100

Transformer's connector for the ignition harness (A) Terminal (B) Terminal (C) Unused

a. Set the multimeter to the diode scale. Connect the multimeter's leads to terminals (A) and (B) on the transformer's connector for the ignition harness. The polarity of the leads does not matter. Measure the voltage between the terminals and record the measurement. b. Reverse the polarity of the probe and measure the voltage between the terminals again.

One of the measurements is approximately 0.4 to 0.6 VDC. The other measurement indicates an open circuit. Voltage that is significantly outside of this range could indicate a problem with the transformer. 9. Measure the resistance of the secondary circuit. a. Set the multimeter to the 40,000 Ohm scale. Measure the resistance between the extension's internal terminal for the spark plug and mounting flange (6) for the transformer. If the resistance between the terminal for the spark plug and the mounting flange for the transformer is within the acceptable tolerance, proceed to Step 10. Resistance that is significantly outside of this range could indicate a problem with the transformer or with the extension. Note: The resistance of the secondary coil will vary with the temperature. The resistance depends on the transformer that is used. Illustration 4 shows the connection for the former transformers. Illustration 5 is a graph for the resistance of the former transformers. A reading that is within 1000 Ohms is acceptable.

Illustration 4 Former transformer (2) Connector (6) Mounting flange for the transformer

g01361976

Illustration 5

g00863850

Resistance versus temperature (Y) Resistance in ohms (X) Temperature in degrees Celsius (degree Fahrenheit)

Note: The resistance of the secondary coil will vary with the temperature. The resistance depends on the transformer that is used. Illustration 6 shows the connection for the new transformers. Illustration 7 is a graph for the resistance of the new transformers. A reading that is within 1000 Ohms is acceptable.

Illustration 6 New transformer (2) Connector (6) Mounting flange for the transformer

g01361978

Illustration 7

g01170387

Resistance versus temperature

10. Switch the suspect transformer with a transformer from a different cylinder that is known to be good. Install the transformers. 11. Reset the control system. Clear any logged diagnostic codes. 12. Start the engine and operate the engine in order to generate a diagnostic code. If the problem follows the transformer, replace the transformer. Make sure that you use the correct transformer for the engine. Reset the control system. Clear any logged diagnostic codes. If the problem stays with the cylinder, there is a problem with the spark plug or with the electrical circuit for the transformer. For instructions on the electrical circuit, refer to the engine's Troubleshooting manual.

Spark Plug If a diagnostic code is generated for the ignition transformer's secondary circuit, the spark plug may need to be replaced. Misfire and a cold cylinder are other indications of a worn spark plug. Use the Caterpillar Electronic Technician (ET) to monitor the exhaust port temperatures in order to locate a cold cylinder. There is virtually no maintenance for the spark plug. The electrode gap is not adjustable. The resistance cannot be measured. Unless the holes in the spark plug's precombustion chamber become plugged, no cleaning is required. For instructions on inspection and replacement of the spark plug, refer to the engine's Operation and Maintenance Manual.

Illustration 8

g00837850

Spark plug's precombustion chamber

Landfill Applications There is maintenance for the spark plug. The electrode gap is adjustable. For instructions on inspection, adjustment, and replacement of the spark plug, refer to the following publications: l l

Operation and Maintenance Manual Specifications Manual

Illustration 9 Spark plug's electrode gap

g01114280

TESTING AND ADJUSTING

007

G3516E Service manual (GAS)

Media Number -KENR6834-03

Ignition Timing - Adjust Use the following procedure to adjust the base timing of the engine: Note: Data from a fuel analysis is required for this procedure. 1. Connect the Caterpillar Electronic Technician (ET) to the engine. 2. Verify that the values of the "First Desired Timing" and "Second Desired timing" parameters are correct according to the recommended timing in the Engine Performance"Fuel Usage Guide". Enter the correct values if the existing values are incorrect. Refer to Systems Operation, "Electronic Control System Parameters" for additional information on the "Desired Timing" parameters. 3. Verify that the input for the selection of the base timing is appropriate for the type of gas that is used. ¡ If terminal J1-20 is not connected to ground, the Electronic Control Module (ECM) will use the value of the "First Desired Timing" parameter as the base timing. ¡ If terminal J1-20 is connected to ground, the ECM will use the value of the "Second Desired Timing" parameter as the base timing. If the input is not correct, troubleshoot the circuit for the input. Refer to the electrical schematic for the engine. 4. Start the engine. Run the engine at rated speed and load. 5. Use Cat ET to view the "Actual Engine Ignition Timing" status parameter. This parameter is in "Default Status Group 1". Verify that the actual timing is approximately equal to the desired timing. Note: The actual timing may vary according to the engine's load, speed, and the detonation level.

TESTING AND ADJUSTING

008

G3516E Service manual (GAS)

Media Number -KENR6834-03

General Information (Fuel System) The High Heat Value (HHV) is a measurement of the total heat that is generated by combustion of a fuel. When any hydrocarbon is used as a fuel in an internal combustion engine, water is one of the products of combustion. The water is converted into steam before leaving the engine. The conversion requires heat. The steam removes the heat and the energy is not used by the engine. The HHV minus the heat that is used to vaporize the water equals the Low Heat Value (LHV) of the fuel. The fuel must be mixed with air in order to produce combustion. The amount of air that is required for efficient combustion will vary for different types of fuels because of the fuels' different compositions. For optimum engine operation, the air/fuel ratio must be adjusted properly. The fuel's methane number indicates the tendency of the fuel to detonate. Fuel with a low methane number burns more quickly than fuel with a high methane number. Additionally, the heat that is produced by compression can ignite fuel with a low methane number sooner than fuel with a high methane number. If an engine is using low methane fuel and the timing is too early, detonation will occur. To avoid detonation, the engine timing must be retarded for low methane. The engine may also need a lower compression ratio. An engine with a low compression ratio is able to utilize fuels with low methane. An engine with a high compression ratio can use a more limited range of fuels. However, a higher power output and greater fuel economy can be obtained. Operation without combustion problems and production of the required power from the available fuel depends on the correct engine configuration. For a detailed explanation of methane numbers, see Application and Installation Guide, LEKQ7256, "Fuels/Fuel Systems". Follow the guide for fuel usage that is in the engine's Engine Performance publication. These publications are available from your Caterpillar dealer. For detailed information on gaseous fuels, refer to Engine Data Sheet, LEKQ3105, "Internal Combustion Engine Fuel Gases". For information on acceptable fuels for the engine, refer to the engine's Operation and Maintenance Manual.

TESTING AND ADJUSTING

009

G3516E Service manual (GAS)

Media Number -KENR6834-03

Air/Fuel Ratio Control - Adjust The air/fuel ratio must be adjusted properly in order to comply with the emissions requirements of the site. The correct air/fuel ratio also helps ensure stable operation. To adjust the air/fuel ratio, perform the following procedure. 1. Connect a properly calibrated emissions analyzer to the exhaust stack. 2. Connect the Caterpillar Electronic Technician (Cat ET) to the service tool connector. Refer to Systems Operation/Testing and Adjusting, "General Information (Electronic Control System)". 3. Verify that the "Fuel Quality" and "Gas Specific Gravity" parameters are programmed correctly. Use the values that are obtained from the Caterpillar Software, LEKQ6378, "Methane Number Program". 4. Verify that the value for the "Fuel Specific Heat Ratio" parameter is correct. Enter a value of 1.4 for processed, dry pipeline natural gas. 5. Start the engine. Increase the engine speed to high idle rpm. Verify that the engine is stable. If the engine is unstable, perform the following procedure. a. Record the values for these parameters: n "Governor Gain Factor" n "Governor Stability Factor" n "Governor Compensation Factor" b. Set the values for the "Governor Gain Factor", "Governor Stability Factor", and "Governor Compensation Factor" parameters to zero. c. Adjust the "Fuel Quality" parameter until the engine becomes stable and the exhaust oxygen is approximately four percent. Verify that the exhaust port temperatures are below the setpoint for a warning. d. Adjust the primary governor. Refer to Systems Operation/Testing and Adjusting, "Engine Governing - Adjust". 6. Close the main circuit breaker for the generator in order to engage the generator. Note: When the engine load becomes greater than 25 percent, the air/fuel ratio control will operate in the feedback mode. 7. Slowly ramp the load up to 30 percent. Note: When the air/fuel ratio control is in the feedback mode, the Fuel Correction Factor (FCF) may no longer be 100 percent. The Electronic Control Module may adjust the FCF in order to compensate for the fuel quality and for the ambient conditions. 8. Set the "Desired Emission Gain Adjustment" parameter to a value of "100". 9. Verify that the reading on Cat ET for the generator's power output agrees with the switchgear's reading. If the readings do not agree, adjust the "Generator Output Power Sensor Scale Factor" and/or the "Generator Output Power Sensor Offset" parameters. Also, make sure that the "Engine Output Power Configuration" and the "Engine Driven Accessory Load Configuration" parameters are accurately programmed. Refer to Systems Operation/Testing and Adjusting, "Electronic Control System Parameters". 10. Slowly ramp up to 70 percent load. Verify that the engine is stable.

If the engine is unstable, adjust the auxiliary governor. Refer to Systems Operation/Testing and Adjusting, "Engine Governing - Adjust". 11. Verify that the NOx emissions are above the desired full load setting. 12. Slowly ramp up to 100 percent load. 13. Verify that the reading on Cat ET for the generator's power output agrees with the switchgear's reading. 14. Adjust the "Desired Emission Gain Adjustment" parameter in order to obtain the values of emissions that are required at the site. ¡ To lean the air/fuel mixture, decrease the gain adjustment. ¡ To richen the air/fuel mixture, increase the gain adjustment. A small change in the "Desired Emission Gain Adjustment" causes a large change in the actual exhaust emissions. For example, an adjustment of one percent in the parameter's value will result in a change of 20 to 40 ppm in the actual level of NOx. When you adjust the exhaust emissions, make a small change in the value of the gain. Wait until the system stabilizes. Check the emissions again. Repeat the process until the desired emissions level is achieved. Use the emissions analyzer in order to verify that the values of emissions meet the requirements of the site.

TESTING AND ADJUSTING

010

G3516E Service manual (GAS)

Media Number -KENR6834-03

Finding the Top Center Position for the No. 1 Piston Table 1 Tools Needed

Quantity

9S-9082 Engine Turning Tool

1

Illustration 1

g00284799

Timing bolt location (typical example) (1) Cover (2) Timing bolt (3) Plug

1. Remove cover (1) and plug (3) from the right front side of the flywheel housing.

Illustration 2

g00284800

Timing bolt installation (typical example) (2) Timing bolt (4) 9S-9082 Engine Turning Tool

2. Put timing bolt (2) through the timing hole in the flywheel housing. Use the 9S-9082 Engine Turning Tool (4) and a ratchet wrench with a 1/2 inch drive in order to turn the flywheel in the direction of normal engine rotation. Turn the flywheel until the timing bolt engages with the hole in the flywheel. Note: If the flywheel is turned beyond the point of engagement, the flywheel must be turned in the direction that is opposite of normal engine rotation. Turn the flywheel by approximately 30 degrees. Then turn the flywheel in the direction of normal engine rotation until the timing bolt engages with the threaded hole. This procedure will remove the play from the gears when the No. 1 piston is on the top center. 3. Remove the valve cover for the No. 1 cylinder head. 4. The inlet and exhaust valves for the No. 1 cylinder are fully closed if the No. 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the No. 1 piston is on the exhaust stroke. Find the cylinders that need to be checked or adjusted for the stroke position of the crankshaft after the timing bolt has been installed in the flywheel. Refer to Testing And Adjusting, "Crankshaft Position for Valve Lash Setting". Note: When the actual stroke position is identified and the other stroke position is needed, remove the timing bolt from the flywheel. Turn the flywheel by 360 degrees in the direction of normal engine rotation.

TESTING AND ADJUSTING

011

G3516E Service manual (GAS)

Media Number -KENR6834-03

Camshaft Timing Timing Check Table 1 Tools Needed

Quantity

9S-9082 Engine Turning Tool

1

Illustration 1

g00284801

Location of timing pins (typical example) (1) Timing hole (2) Timing pin

1. Remove rear camshaft covers from both sides of the engine. 2. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston". Note: When the timing bolt is installed in the flywheel, it is not necessary to remove the No. 1 valve cover in order to find the compression stroke. Both rear camshaft covers must be removed in order to check the timing. 3. When the timing bolt is installed in the flywheel, look at the rear end of the camshaft. If the timing ring is visible, then the No. 1 piston is on the compression stroke. If the timing ring is not visible, feel the back of the camshaft for the groove. If the groove is at the back of the camshaft, the flywheel must be turned by 360 degrees in order to put the No. 1 piston on the compression stroke.

Illustration 2

g00284802

Installation of timing pins (typical example) (2) Timing pin (3) RH Camshaft

4. When the timing bolt is installed in the flywheel and the No. 1 piston is on the compression stroke, remove timing pins (2) from the storage positions. 5. Install timing pins (2) through timing holes (1) in the engine block. Install timing pins (2) into the groove in camshaft (3) on each side of the engine. In order to time the engine correctly, the timing pins must fit into the groove of each camshaft. If the timing pins do not engage in the grooves of both camshafts, the engine is not in time, and one or both camshafts must be adjusted. 6. Proceed to the "Timing Adjustment" procedure.

NOTICE If a camshaft is out of time more than 18 degrees (approximately 1/2 the diameter of timing pin out of groove), the valves can make contact with the pistons. This will cause damage that will make engine repair necessary.

Timing Adjustment Table 2 Tools Needed

Quantity

9S-9082 Engine Turning Tool

1

1P-0820 Hydraulic Puller

1

8B-7548 Push-Puller Tool Group

1

8B-7559 Adapter

2

5H-1504 Hard Washer

3

9U-6600 Hand Hydraulic Pump

1

Note: Before any timing adjustments are made, make sure that adjustments are necessary. Refer to "Timing Check". After the timing check procedure is completed, the timing bolt will be engaged in the flywheel with No. 1 piston at the top center (TC) position. 1. Disconnect the ignition harness from all of the ignition transformers on the side of the engine with the camshaft that needs adjustment. Remove the ignition transformers.

Illustration 3

g00930076

(1) Bolt (2) Rocker Shaft

2. Remove all valve covers on the side of the engine with the camshaft that needs adjustment. Loosen bolts (1) that hold rocker shaft (2) to the valve cover bases until all rocker arms are free from the valves. Note: The above procedure must be done before the camshaft drive gear is pulled off the camshaft taper.

Illustration 4

g00662269

Left rear (3) Cover (4) Speed/Timing sensor

3. Remove camshaft gear cover (3) from the rear of the engine. If the left rear camshaft gear must be removed, remove speed/timing sensor (4) first.

Illustration 5

g00662337

Rear gear group (5) Gear (left camshaft drive) (6) Idler gear (7) Speed/Timing ring (8) Gear (right camshaft drive) (9) Washer (10) Bolt (11) Bolt (12) Plate

4. To remove the left camshaft drive gear, remove bolt (10) and washer (9). Remove speed/timing ring (7) from the left camshaft. 5. To remove right camshaft drive gear, remove bolt (11) and plate (12) from the right camshaft.

Illustration 6

g00662446

Removing the camshaft drive gear (A) 1P-0820 Hydraulic Puller (12) Plate

6. Use tooling (A) to remove camshaft drive gears (5) and (8) . 7. Install the three 5H-1504 Hard Washers behind plate (12). This plate holds the camshaft drive gear on the camshaft. Install plate (12) and bolt (11) on the camshaft.

NOTICE Do not apply more than 41,340 kPa (6,000 psi) of pressure to 1P-0820 Hydraulic Puller. 8B-7559 Adapters are rated at 5 ton each and 1P0820 Hydraulic Puller is rated at 17 ton at 68,900 kPa (10,000 psi). If too much pressure is applied, the gear may be damaged. 8. Use the 8B-7559 Adapter and needed parts from the 8B-7548 Push-Puller Tool Group to install the 1P-0820 Hydraulic Puller on the camshaft drive gear. Apply 41,340 kPa (6,000 psi) to the puller and tap the screw until the camshaft drive gear is free of the camshaft taper. Remove the tooling and the camshaft drive gear from the camshaft.

Illustration 7 Camshaft timing

g00662447

(13) Timing pin

9. Remove timing pins (13) from the storage positions which are located under the rear camshaft covers on each side of the engine. 10. Turn the camshafts until timing pins (13) can be installed through timing holes and into the grooves (slots) in the camshaft. 11. Use the following procedure to install camshaft gears (5) and (8) : a. For correct timing, the timing bolt must be installed in the flywheel and all gear clearance (backlash) must be removed. Turn the camshaft drive gears in the same direction as crankshaft rotation and hold in this position. b. Pin both camshafts and put the camshaft drive gears in position in line with idler gears (6) on each camshaft taper. Note: Make sure that the gear tapers and the shaft tapers are clean, dry, and free of lubricants. c. Install speed/timing ring (7), bolt (10) and washer (9) on the left side. Install bolt (11) and plate (12) on the right side in order to hold the camshaft drive gears to each camshaft. d. Remove camshaft timing pins (13). Tighten bolts (10) and (11) to a torque of 360 ± 40 N·m (26 ± 30 lb ft). e. Strike plate (12) or the center of speed/timing ring (7). This will seat the gear on the taper. Then tighten the bolt to a torque of 360 ± 40 N·m (266 ± 30 lb ft). Note: If necessary, repeat Step 11.e until the torque does not change. Make sure that the drive gears are in full contact with the taper on the camshafts. f. Verify the crankshaft in relation to the camshaft by installing camshaft timing pins (13). Loosen bolt (11) and the camshaft drive gear if the timing pins cannot be installed. Repeat the installation procedure of the camshaft drive gear. 12. Install the gasket and the camshaft gear cover on the rear housing. Use two 3/8 inch by 6 inch long guide bolts. 13. Remove timing pins (13) from the camshafts. Install timing pins (13) in the storage positions. Install the covers over the camshafts and timing pins. 14. Remove the timing bolt from the flywheel housing. 15. Install the 5M-6213 Pipe Plug in the flywheel housing timing hole. Remove the engine turning pinion, and install the cover and the gasket. 16. Correctly engage the rocker arms with the pushrods. Tighten the bolts for the rocker shafts to a torque of 120 ± 20 N·m (89 ± 15 lb ft). 17. Adjust the valve lash. Refer to Testing And Adjusting, "Valve Lash and Valve Bridge Adjustment".

012

TESTING AND ADJUSTING

G3516E Service manual (GAS)

Media Number -KENR6834-03

Restriction of Air Inlet and Exhaust The efficiency of the engine and the engine power are reduced if there is restriction in the air inlet and/or the exhaust system. Inspect the air inlet and exhaust system. Make sure that there are no obstructions or leaks in the system. Table 1 Tools Needed

Qty

1U-5470 Engine Pressure Group

1

Illustration 1

g00295554

1U-5470 Engine Pressure Group

The 1U-5470 Engine Pressure Group is used to measure the inlet air restriction and the exhaust back pressure.

Air Inlet Restriction Air inlet restriction is the difference in pressure between the air lines after the air cleaner and the atmospheric air pressure. Use the differential pressure gauge of the 1U-5470 Engine Pressure Group in order to measure the air inlet restriction. Connect the pressure port of the differential pressure gauge to the opening for the air filter service indicator on the air cleaner. For optimum operation, replace the air filter when the air filter restriction reaches the restriction value for your particular engine application. Refer to the applicable Gas Engine Technical Data Sheet for additional information. The maximum air filter restriction is 3.7 kPa (15 inches of H2O).

Aftercooler Differential Pressure

Aftercooler differential pressure is the difference in air pressure between the inlet and the outlet of the aftercooler.

Illustration 2

g01105331

(1) Plug

The maximum differential pressure for the aftercooler is 10 kPa (40 inch of H2O). The 8T-0452 Manometer Gauge is used to measure the differential pressure across the aftercooler. Remove plugs (1) from the aftercooler. Connect the manometer in the location of the plugs. Measure the differential pressure when the engine is operating at full load.

Exhaust Restriction Exhaust restriction (back pressure) is the difference in the pressure between the exhaust at the outlet elbow and the atmospheric air pressure. In addition to the loss of efficiency and power, excessive exhaust restriction will lead to these results: high engine temperatures, reduced service life of the turbocharger and early problems with inlet and exhaust valves. Use the differential pressure gauge of the 1U-5470 Engine Pressure Group in order to measure the exhaust back pressure.

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

Making contact with a running engine can cause burns from hot parts and can cause injury from rotating parts.

When working on an engine that is running, avoid contact with hot parts and rotating parts. Connect the pressure port of the differential pressure gauge to the test location on the exhaust manifold. The test location may be located anywhere along the exhaust piping after the turbocharger but before the muffler. Choose a location that is as close to the engine as possible. Install the probe into a straight pipe that is three to five diameters of the pipe away from the last transition. The maximum exhaust back pressure is 6.7 kPa (27 inches of H2O). If the exhaust restriction reaches this limit, determine the cause of the restriction and correct the condition.

TESTING AND ADJUSTING

013

G3516E Service manual (GAS)

Media Number -KENR6834-03

Measuring Inlet Manifold Temperature Table 1 Tools Needed

Qty

4C-6500 Digital Thermometer

1

The Electronic Control Module (ECM) uses the inlet manifold air temperature to help calculate the density of the air/fuel mixture. Use the Caterpillar Electronic Technician (ET) to monitor the inlet manifold air temperature. The temperature can be verified with the 4C-6500 Digital Thermometer.

Illustration 1

g00929850

Right view at the rear of the engine Plugs in the air inlet manifold

To measure the inlet manifold air temperature, use the 4C-6500 Digital Thermometer. Remove one of the plugs from the air inlet manifold. Insert a temperature probe in place of the plug. Measure the temperature when the engine is operating at full load. If the inlet manifold air temperature is too high, inspect the thermostatic valve and the separate circuit's cooling system.

TESTING AND ADJUSTING

014

G3516E Service manual (GAS)

Media Number -KENR6834-03

Compressor Bypass - Adjust

Illustration 1

g01173633

(1) Shaft (2) Pin (3) Valve assembly (4) Plate (5) Coupling (6) Screw (7) Torsion Spring (8) Shaft (9) Tube (10) Torsion Spring

1. Rotate shaft (1) clockwise until the shaft contacts the internal stop. 2. Orient pin (2) parallel with valve assembly (3) in order to close plate (4) . 3. Assemble shaft (8) , tube (9) and torsion springs (7) and (10) . Attach the assembly to coupling (5) . 4. Before you tighten the coupling assembly, make sure that shaft (1) is in the fully clockwise position and make sure that pin (2) is parallel with the valve assembly. Install screws (6) . (6) Screw Torque ... 15 ± 1 N·m (11 ± 0.7 lb ft)

TESTING AND ADJUSTING

015

G3516E Service manual (GAS)

Media Number -KENR6834-03

Measuring Exhaust Temperature Table 1 Tools Needed

Qty

4C-6090 Temperature Selector Group

1

6V-9130 Temperature Adapter

1

237-5130 Digital Multimeter Gp

1

Use the Caterpillar Electronic Technician (ET) to monitor individual cylinder exhaust temperatures, the exhaust temperature to the turbocharger, and the exhaust temperature after the turbocharger. The temperatures can be verified with the 4C-6090 Temperature Selector Group, with the 6V-9130 Temperature Adapter, and with the 237-5130 Digital Multimeter. Refer to Operating Manual, NEHS0537 for the complete operating instructions for the 4C-6090 Temperature Selector Group.

TESTING AND ADJUSTING

016

G3516E Service manual (GAS)

Media Number -KENR6834-03

Compression Table 1 Tools Needed 193-5859

Cylinder Pressure Gauge Gp (Gas Engine)

Quantity 1

Cylinder pressure can be measured during inspection of the spark plugs. The condition of the following items can be tested by checking the cylinder pressure: valves, valve seats, pistons, piston rings and cylinder liners. A loss of cylinder pressure or a change of pressure in one or more cylinders may indicate the following conditions. These conditions may indicate a problem with lubrication: l l l l l l l

Excessive deposits Guttering of valves A broken valve A piston ring that sticks A broken piston ring Worn piston rings Worn cylinder liners

Measure the cylinder pressure of an engine after approximately 250 hours of operation. Record the data. Continue to periodically measure the cylinder pressure. Comparing the recorded data to the new data provides information about the condition of the engine. Note: Cylinder pressure is one of the three factors that help to determine the in-frame overhaul interval. Refer to Operation and Maintenance Manual, "Overhaul (In-Frame)". If the cylinder pressure has risen by one or more compression ratios, the engine needs a top end overhaul in order to remove deposits. Failure to remove the deposits will increase the chance for detonation. Severe guttering of the valves will occur. To measure the cylinder pressure, use the 193-5859 Cylinder Pressure Gauge Gp (Gas Engine). Use the Special Instruction, NEHS0798 that is included with the gauge. Use the following guidelines: l l l

Remove all of the spark plugs. Fully open the throttle plate. Minimize the cranking time. This will enable a maximum consistent cranking speed for the check. Also, the battery power will be conserved.

Illustration 1 is a graph of typical cylinder pressures for engines with different compression ratios.

Illustration 1 (Y) Cylinder pressure in kPa (X) Compression ratio (1) Normal range for cylinder pressure

g00828960

TESTING AND ADJUSTING

017

G3516E Service manual (GAS)

Media Number -KENR6834-03

Crankshaft Position for Valve Lash Setting The SAE standard engine crankshaft rotation is counterclockwise when the crankshaft is viewed from the flywheel end. Table 1 Crankshaft Positions for Valve Lash Setting Standard Counterclockwise Rotation Engine

G3516

(1)

Stroke for the Number 1 Piston At the Top Center Position (1)

Inlet Valves

Exhaust Valves

Compression Stroke

1-2-5-7-8-12-1314

1-2-3-4-5-6-8-9

Exhaust Stroke

3-4-6-9-10-1115-16

7-10-11-12-13-1415-16

Firing Order

1-2-5-6-3-4-9-10-15-16-11-12-13-14-78

Put the No. 1 Piston at the top center (TC) position and identify the correct stroke. Refer to Testing And Adjusting, "Finding the Top Center Position for the No. 1 Piston". Find the top center (TC) position for a particular stroke and make the adjustment for the correct cylinders. Remove the timing bolt. Turn the flywheel by 360 degrees in the direction of normal engine rotation. This will put the No. 1 piston at the top center (TC) position on the opposite stroke. Install the timing bolt in the flywheel and complete the adjustments for the cylinders that remain.

TESTING AND ADJUSTING

018

G3516E Service manual (GAS)

Media Number -KENR6834-03

Valve Lash and Valve Bridge Adjustment Table 1 Required Tools Pt. No.

Description

147-5482

Valve Lash Gauge Gp

Measure the valve lash between the rocker arm and the valve bridge. Perform the adjustments with the engine stopped. The valves must be fully closed. To determine whether the valves are fully closed, refer to Testing And Adjusting, "Finding the Top Center Position for the No. 1 Piston" and Testing And Adjusting, "Crankshaft Position for Valve Lash Setting".

NOTICE Incorrect adjustment of the valve bridge and/or of the valve lash can result in engine damage from these conditions: excessive exhaust temperatures, incorrect seating of the valves and contact between the valves and the piston.

Valve Bridge Adjustment The valve bridge must be adjusted before the valve lash is adjusted. The valve bridge can be adjusted without removing the rocker arms and shafts. The valves must be fully closed. To determine whether the valves are fully closed, refer to Testing And Adjusting, "Finding the Top Center Position for the No. 1 Piston" and Testing And Adjusting, "Crankshaft Position for Valve Lash Setting". Note: If the cylinder head is disassembled, keep the bridges with the respective valves. Check that the bridge dowels are installed to the correct height. Lubricate the bridge dowel, the bore for the bridge dowel, and the top contact surface of the bridge. Install the bridge on the dowel. Use the following procedure to adjust the valve bridges:

Illustration 1

g00930185

(1) Cover (2) Ignition harness (3) Transformer (4) Extension (5) O-ring seal (6) Valve cover (7) Seal

1. Remove cover (1) . 2. Disconnect ignition harness (2) . 3. Remove transformer (3) and extension (4) as a unit. Inspect the extension's internal O-ring seal for the spark plug and inspect O-ring seal (5). If an O-ring seal is damaged or deteriorated, obtain a new O-ring seal for assembly. 4. Remove valve cover (6). Inspect seal (7). If the seal is damaged or deteriorated, obtain a new seal for assembly.

Illustration 2

g00930186

(8) Locknut (9) Adjustment screw (10) Rocker arm (11) Valve bridge

5. Loosen locknut (8) and adjusting screw (9) . 6. Press straight down on rocker arm (10) at the contact point for valve bridge (11). Turn adjusting screw (9) clockwise until the screw just contacts the valve stem. 7. Tighten adjusting screw (9) for an additional 25 ± 5 degrees in order to straighten the valve bridge onto the dowel. 8. Hold adjusting screw (9) in position and tighten locknut (8) to 30 ± 4 N·m (22 ± 3 lb ft). 9. Make sure that the valve lash is correct. Refer to "Valve Lash Adjustment". 10. Make sure that seal (7) is in good condition. Install valve cover (6) . 11. Make sure that O-ring seal (5) is in good condition. Install extension (4) and transformer (3) as a unit. 12. Connect ignition harness (2) . 13. Install cover (1) .

Valve Lash Adjustment The valve bridge must be adjusted before the valve lash is adjusted. Note: You can use the 147-5482 Valve Lash Gauge Group to measure the valve lash. You will also need the 147-2056 Dial Indicator or the 147-5537 Dial Indicator . 1. Ensure that the No. 1 piston is at the top center (TC) position. Refer to Testing And Adjusting, "Finding the Top Center Position for the No. 1 Piston". 2. Work on the appropriate cylinders that are listed in Testing and Adjusting, "Crankshaft Positions for Valve Lash Setting". 3. Before you perform any adjustments, use a soft hammer to lightly tap each rocker arm at top of the adjustment screw. This will ensure that the lifter roller is seated against the camshaft.

Illustration 3

g00930187

(1) Locknut (2) Adjustment screw (3) Rocker arm (4) Valve bridge

4. Loosen locknut (1) and adjusting screw (2) . 5. Measure the valve lash with the 147-5482 Valve Lash Gauge Gp. Refer to the engine's Specifications, "Valve Mechanism" for the correct specifications for the valve lash. If necessary, adjust the valve lash with adjustment screw (2) .

6. Hold adjusting screw (2) in place and tighten locknut (1) to a torque of 70 ± 15 N·m (52 ± 11 lb ft). 7. Verify that the setting is correct. 8. Remove the timing bolt from the flywheel housing. Rotate the crankshaft for 360 degrees. Install the timing bolt in the flywheel housing. 9. With the No. 1 piston in the top center of the opposite stroke, perform Steps 2 through 7 for the remaining cylinders. 10. Remove the timing bolt from the flywheel housing.

TESTING AND ADJUSTING

019

G3516E Service manual (GAS)

Media Number -KENR6834-03

General Information (Lubrication System) The following problems generally indicate a problem in the engine's lubrication system. l l l l l

Excessive consumption of engine oil Low engine oil pressure High engine oil pressure Excessive bearing wear Increased engine oil temperature

TESTING AND ADJUSTING

020

G3516E Service manual (GAS)

Media Number -KENR6834-03

Excessive Bearing Wear - Inspect When some components of the engine show bearing wear in a short time, the cause can be a restriction in a passage for engine oil. An indicator for the engine oil pressure may show that there is enough engine oil pressure, but a component is worn due to a lack of lubrication. In such a case, look at the passage for the engine oil supply to the component. A restriction in an engine oil supply passage will not allow enough lubrication to reach a component. This will result in early wear.

TESTING AND ADJUSTING

021

G3516E Service manual (GAS)

Media Number -KENR6834-03

Excessive Engine Oil Consumption - Inspect Engine Oil Leaks on the Outside of the Engine Check for leakage at the seals at each end of the crankshaft. Look for leakage at the gasket for the engine oil pan and all lubrication system connections. Look for any engine oil that may be leaking from the crankcase breather. This can be caused by combustion gas leakage around the pistons. A dirty crankcase breather will cause high pressure in the crankcase. A dirty crankcase breather will cause the gaskets and the seals to leak.

Engine Oil Leaks into the Combustion Area of the Cylinders Engine oil that is leaking into the combustion area of the cylinders can be the cause of blue smoke. There are several possible ways for engine oil to leak into the combustion area of the cylinders: l l

l l l l l

Leaks between worn valve guides and valve stems Worn components or damaged components (pistons, piston rings, or dirty return holes for the engine oil) Incorrect installation of the compression ring and/or the intermediate ring Leaks past the seal rings in the turbocharger shaft Overfilling of the crankcase Wrong oil level gauge or guide tube Sustained operation at light loads

Excessive consumption of engine oil can also result if engine oil with the wrong viscosity is used. Engine oil with a thin viscosity can be caused by fuel leakage into the crankcase or by increased engine temperature.

TESTING AND ADJUSTING

022

G3516E Service manual (GAS)

Media Number -KENR6834-03

Increased Engine Oil Temperature - Inspect If the engine oil temperature is higher than normal, the engine oil cooler may have a restriction. Look for a restriction in the passages for engine oil in the engine oil cooler. The engine oil pressure will not necessarily decrease due to a restriction in the engine oil cooler. Determine if the engine oil cooler bypass valve is held in the open position. This condition will allow the engine oil to flow through the valve rather than through the engine oil cooler. The engine oil temperature will increase. Make sure that the cooling system is operating properly. A high coolant temperature in the engine oil cooler will cause high engine oil temperature.

TESTING AND ADJUSTING

023

G3516E Service manual (GAS)

Media Number -KENR6834-03

Measuring Engine Oil Pressure Table 1 Tools Needed

Qty

1U-5470 Engine Pressure Group 1

An incorrect engine oil pressure gauge and an incorrect engine oil pressure sensor will provide false indications of low engine oil pressure or high engine oil pressure. Use the 1U-5470 Engine Pressure Group to measure the engine oil pressure. Follow the instructions in Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure Group " that is included with the tool.

Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury.

Illustration 1

g00285344

Measure the engine oil pressure to the camshaft and main bearings on each side of the cylinder block at oil gallery plug (1). With the engine at operating temperature, the correct minimum engine oil pressure at full load rpm is approximately 280 kPa (40 psi). The correct minimum engine oil pressure at low idle rpm is approximately 140 kPa (20 psi). Compare the results to the engine oil pressure that is indicated on the engine oil pressure gauge and on the electronic service tool. If there is a notable difference between the engine oil pressure readings, determine the cause. If the engine oil pressure is too low or too high, determine the cause and correct the condition. If the engine oil pressure gauge or the engine oil pressure sensor is incorrect, replace the suspect component.

TESTING AND ADJUSTING

024

G3516E Service manual (GAS)

Media Number -KENR6834-03

General Information (Cooling System) This engine has a pressure type cooling system. A pressure type cooling system has two advantages. l l

The pressure helps prevent cavitation. The risk of boiling is reduced.

Cavitation occurs when mechanical forces cause the formation of air bubbles in the coolant. The bubbles can form on the cylinder liners. Collapsing bubbles can remove the oxide film from the cylinder liner. This allows corrosion and pitting to occur. If the pressure of the cooling system is low, the concentration of bubbles increases. The concentration of bubbles is reduced in a pressure type cooling system. The boiling point is affected by three factors: pressure, altitude and concentration of glycol in the coolant. The boiling point of a liquid is increased by pressure. The boiling point of a liquid is decreased by a higher altitude. Illustration 1 shows the effects of pressure and altitude on the boiling point of water.

Illustration 1

g00286266

The boiling point of the coolant also depends on the type of coolant and the concentration of glycol. A greater concentration of glycol has a higher boiling temperature. However, glycol transfers heat less effectively than water. Because of the boiling point and the efficiency of heat transfer, the concentration of glycol is important. Three basic problems can be associated with the cooling system: l l l

Overheating Coolant loss Overcooling

If the cooling system is not properly maintained, solids such as scale and deposits reduce the ability of the cooling system to transfer heat. The engine operating temperature will increase. When the engine is overloaded, the engine will run in the lug condition. When the engine is running in

the lug condition, the engine is operating at a lower engine rpm that reduces the coolant flow. Decreased coolant flow during high load will cause overheating. Coolant can be lost by leaks. Overheated coolant can be lost through the cooling system's pressure relief valve. Lower coolant levels contribute to additional overheating. Overheating can result in conditions such as cracking of the cylinder head and piston seizure. A cracked cylinder head or cylinder liner will force exhaust gas into the cooling system. The additional pressure causes coolant loss, cavitation of the water pump, less circulation of coolant, and further overheating. Overcooling is the result of coolant that bypasses the water temperature regulators and flows directly to the radiator or to the heat exchanger. Low load operation in low ambient temperatures can cause overcooling. Overcooling is caused by water temperature regulators that remain open. Overcooling reduces the efficiency of operation. Overcooling enables more rapid contamination of the engine oil. This results in the formation of sludge in the crankcase and carbon deposits on the valves. Cycles of rapid heating and cooling can result in cracked cylinder heads, gasket failure, accelerated wear, and excessive fuel consumption. If a problem with the cooling system is suspected, perform a visual inspection before you perform any tests on the system.

TESTING AND ADJUSTING

025

G3516E Service manual (GAS)

Media Number -KENR6834-03

Visual Inspection If a problem with the cooling system is suspected, inspect the cooling system before you perform any tests on the cooling system. 1. Check the coolant level in the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant Level - Check". 2. Make sure that the coolant meets the recommendations of the Operation and Maintenance Manual. Also, make sure that the coolant has the following properties: ¡ Color that is similar to new coolant ¡ Odor that is similar to new coolant ¡ Free of dirt and debris 3. Look for leaks in the cooling system. After the engine is stopped, look for coolant or steam from the radiator's overflow. Inspect the hoses and clamps for good condition. If engine oil or coolant is leaking from the joint between the cylinder head and the engine block, there is a problem with the cylinder head gasket. Note: The water pump has a weep hole between the seal for the coolant and the seal for the bearing. The weep hole prevents coolant from entering the lubrication system if there is a problem with a seal in the water pump. A small amount of coolant at the weep hole is normal. 4. Make sure that air flows through the radiator and that there is not a restriction. Look for radiator fins that are bent, damaged, or leaking. Look for dirt and debris that can restrict the flow of air through the fins. 5. Inspect the fan drive belts and pulley grooves. A loose fan drive belt wears at a faster rate than a belt with the proper tension. A loose belt can damage the pulleys. A loose belt can slip. Substances such as oil and grease will cause the belts to slip. 6. Check for damage to the fan blades. Look for damaged baffles on the radiator and for baffles that are missing. Inspect the shroud of the fan for good condition. 7. Inspect the air inlet system. Make sure that the air cleaner, the air inlet, and the exhaust are not restricted. 8. Look for signs of air or combustion gas in the coolant. Air and/or gas in the coolant results in foaming of the coolant.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 9. After the engine is cool, remove the cooling system filler cap slowly in order to release pressure. Inspect the filler cap. Check the condition of the gasket. Check the sealing surface for the cap. The gasket and the sealing surface must be clean and free of gouges, nicks, and grooves.

TESTING AND ADJUSTING

026

G3516E Service manual (GAS)

Media Number -KENR6834-03

Test Tools for the Cooling System Table 1 Tools Needed

Quantity

4C-6500

Digital Thermometer

1

285-0901

Blowby Tool Gp

1

285-0910

Multi-Tool Gp

1

9U-7400

Multitach Tool Gp

1

9S-8140

Pressurizing Pump

1

Making contact with a running engine can cause burns from hot parts and can cause injury from rotating parts. When working on an engine that is running, avoid contact with hot parts and rotating parts.

Illustration 1

g00286267

4C-6500 Digital Thermometer

The 4C-6500 Digital Thermometer is used in the diagnosis of overheating conditions or overcooling problems. This group can be used to check temperatures in several different parts of the cooling system. Refer to the testing procedure in the Operating Manual, NEHS0554.

Illustration 2

g00286276

9U-7400 Multitach

The 9U-7400 Multitach is used to check the fan speed. Refer to the testing procedure in Operator Manual, NEHS0605.

Illustration 3

g00286369

9S-8140 Pressurizing Pump

The 9S-8140 Pressurizing Pump is used to test pressure caps. The 9S-8140 Pressurizing Pump is used to pressure check the cooling system for leaks.

Steam or hot coolant can cause severe burns.

Do not loosen the filler cap or the pressure cap on a hot engine. Allow the engine to cool before removing the filler cap or the pressure cap.

TESTING AND ADJUSTING

027

G3516E Service manual (GAS)

Media Number -KENR6834-03

Testing the Cooling System Testing for Freeze Protection Table 1 Tools Needed

Qty

245-5829 Coolant/Battery Tester Gp

1

Illustration 1

g00439083

245-5829 Coolant/Battery Tester Gp

Check the coolant frequently in cold weather for the proper protection against freezing. Use the 245-5829 Coolant/Battery Tester Gp in order to ensure adequate freeze protection. The tester gives immediate, accurate readings. The tester can be used for antifreeze/coolants that contain ethylene or propylene glycol. The tester is also used to check the condition of batteries (specific gravity). Instructions are provided with the tester.

Making the Correct Antifreeze Mixtures Adding pure antifreeze as a makeup solution for the cooling system top-off is an unacceptable practice. Adding pure antifreeze increases the concentration of antifreeze in the cooling system. This increases the concentration of the dissolved solids and the undissolved chemical inhibitors in the cooling system. Add the antifreeze and water mixture in the same concentration as your cooling system. Refer to the engine's Operation and Maintenance Manual.

Testing the Supplemental Coolant Additive and the Glycol

Refer to the engine's Operation and Maintenance Manual for further information about testing the cooling system.

Testing for Air and/or Exhaust Gas in the Coolant Air and/or exhaust gas in the coolant causes foaming and aeration. Bubbles in the cooling system reduce the heat transfer and the pump flow. Pockets of air or gas can prevent coolant from contacting parts of the engine. The pockets allow hot spots to develop. If the cooling system is not filled to the proper level or if the system is filled too quickly, air can be trapped in the system. Leaks from components such as aftercoolers and hoses can allow air to enter the system. The inlet of the water pump is a potential location for the entry of air. To help prevent air from entering the cooling system, fill the system slowly. Make sure that all of the hoses and pipe connections are secure. If the cylinder head is loose or cracked, exhaust gas can enter the cooling system. Exhaust gas can also enter the cooling system through internal cracks and/or defects in the cylinder head gasket. Air and/or exhaust gas in the cooling system can cause overheating. Use the following test to check for the presence of air and/or exhaust gas in the coolant. 1. Make sure that the cooling system is filled to the proper level.

Illustration 2

g00769076

2. Remove the plug from the radiator (if equipped). Install a hose into the hole for the plug. 3. Fill a glass container with water and place the other end of the hose into the container. 4. Start the engine. Operate the engine until normal operating temperature is reached.

5. Observe the end of the hose in the glass container. A bubble may rise occasionally from the hose. This is normal. If a stream of bubbles rise from the hose, air and/or exhaust gas in the coolant is indicated.

Testing the Radiator Fan (If Equipped) Table 2 Tools Needed

Quantity

9U-7400 Multitach Tool Gp

1

The 9U-7400 Multitach Tool Gp is used to check the fan speed. For instructions, refer to the Operating Manual, NEHS0605 that is supplied with the multitach.

Testing the Cooling System for Leaks Table 3 Tools Needed

Qty

9S-8140 Pressurizing Pump

1

Use the following procedure in order to check the cooling system for leaks:

1. After the engine cools, carefully loosen the filler cap in order to release the pressure from the cooling system. Remove the filler cap. 2. Ensure that the cooling system is filled to the correct level. 3. Install the 9S-8140 Pressurizing Pump onto the radiator's filler tube. 4. Increase the pressure reading on the gauge to 20 kPa (3 psi) more than the pressure on the filler cap. 5. Inspect the radiator, all connection points, and the hoses for leaks. If no leaks are found and the gauge reading remains steady for a minimum of five minutes, the cooling system is not leaking.

If leaking is observed and/or the gauge reading decreases, make repairs, as needed.

TESTING AND ADJUSTING

028

G3516E Service manual (GAS)

Media Number -KENR6834-03

Cylinder Block Table 1 Tools Needed

Quantity

1P-4000 Line Boring Tool Group

1

1P-3537 Dial Bore Gauge Group

1

4C-4519 Piston Ring Groove Gauge Gp

1

If the main bearing caps are installed without bearings, the bore in the block for the main bearings can be checked. Tighten the nuts that hold the caps to the torque that is shown in the Specifications. Alignment error in the bores must not be more than 0.08 mm (0.003 inch). Refer to the Special Instruction, SMHS7606 for the correct procedure for using the 1P-4000 Line Boring Tool Group for the alignment of the main bearing bores. The 1P-3537 Dial Bore Gauge Group can be used to check the size of the bores. The Special Instruction, GMGO0981 is with the group.

Illustration 1

g00285686

1P-3537 Dial Bore Gauge Group

Piston Rings The 4C-4519 Piston Ring Groove Gauge is available for checking the top piston ring groove with straight sides. Refer to Guideline For Reusable Parts, SEBF8049, "Pistons".

Connecting Rod Bearings

The connecting rod bearings fit tightly in the bore in the rod. If the bearing joints are fretted, check the bore size. This can be an indication of wear because of a loose fit. Connecting rod bearings are available with 0.63 mm (0.025 inch) and 1.27 mm (0.050 inch) smaller inside diameter than the original size bearing. These bearings are for crankshafts that have been ground.

Main Bearings Main bearings are available with a larger outside diameter than the original size bearings. These bearings are available for the cylinder blocks with the main bearing bore that is made larger than the bores' original size. The size that is available has a 0.63 mm (0.025 inch) outside diameter that is larger than the original size bearings.

TESTING AND ADJUSTING

029

G3516E Service manual (GAS)

Media Number -KENR6834-03

Cylinder Liner Projection Table 1 Tools Needed

Quantity

1U-9895 Crossblock

1

3H-0465 Push-Puller Plate

2

8F-6123 Bolt

2

3B-1925 Washer (COPPER)

4

0S-1575 Bolt

4

8T-0455 Liner Projection Tool Group

1

1. Make sure that the top surface of the cylinder block, the cylinder liner bores, the cylinder liner flanges, and the spacer plates are clean and dry.

Illustration 1 Measuring the cylinder liner projection

g01192749

(1) 3H-0465 Push-Puller Plate (2) 1P-2403 Dial Indicator (3) 1P-2402 Gauge Body (4) 0S-1575 Bolt and 3B-1925 Washer (COPPER) (5) Spacer plate (6) 1U-9895 Crossblock

2. Install a new gasket and spacer plate (5) on the cylinder block. 3. Install the cylinder liner in the cylinder block without seals or bands. 4. Hold spacer plate (5) and the cylinder liner in position according to the following procedure: a. Install four 3B-1925 Washers (COPPER) and four 0S-1575 Bolts (4) around the spacer plate (5). Tighten the bolts evenly to a torque of 95 N·m (70 lb ft). b. Install the following components: 1U-9895 Crossblock (6), two 3H-0465 Push-Puller Plates (1) and two 8F-6123 Bolts. Ensure that 1U-9895 Crossblock (6) is in position at the center of the cylinder liner. Ensure that the surface of the cylinder liner is clean. Tighten the bolts evenly to a torque of 70 N·m (50 lb ft). c. Check the distance from the bottom edge of 1U-9895 Crossblock (6) to the top edge of spacer plate (5). The vertical distance from both ends of the 1U-9895 Crossblock must be equal. 5. Use 8T-0455 Liner Projection Tool Group (6) to measure the cylinder liner projection. 6. Mount 1P-2403 Dial Indicator (2) in 1P-2402 Gauge Body (3). Use the back of the 1P-5507 Gauge Block to zero dial indicator (2). 7. The cylinder liner projection must be 0.059 to 0.199 mm (0.0023 to 0.0078 inch). Read the measurement on the outer flange of the cylinder liner at four equally distant positions. Do not read the measurement on the inner flange. The maximum allowable difference between the high measurements and the low measurements at four positions around each cylinder liner is 0.05 mm (0.002 inch). The maximum allowable difference between the four measurements must not exceed 0.05 mm (0.002 inch) on the same cylinder liner. Note: If the cylinder liner projection is not within specifications, turn the cylinder liner to a different position within the bore. Measure the projection again. If the cylinder liner projection is not within specifications, move the cylinder liner to a different bore. Inspect the top face of the cylinder block. Note: When the cylinder liner projection is correct, put a temporary mark on the cylinder liner and the spacer plate. Be sure to identify the particular cylinder liner with the corresponding cylinder. When the seals and the filler band are installed, install the cylinder liner in the marked position.

TESTING AND ADJUSTING

030

G3516E Service manual (GAS)

Media Number -KENR6834-03

Flywheel - Inspect Table 1 Tools Needed Part Number

Part Name

Quantity

8T-5096

Dial Indicator Gp

1

Face Runout (Axial Eccentricity) of the Flywheel

Illustration 1

g00286049

Checking face runout of the flywheel

1. Refer to illustration 1 and install the dial indicator. Always put a force on the crankshaft in the same direction before the dial indicator is read. This will remove any crankshaft end clearance. 2. Set the dial indicator to read 0.0 mm (0.00 inch). 3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Take the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This value is the runout. The maximum permissible face runout (axial eccentricity) of the flywheel must not exceed 0.15 mm (0.006 inch).

Bore Runout (Radial Eccentricity) of the Flywheel

Illustration 2

g01193057

Checking bore runout of the flywheel (1) 7H-1945 Holding Rod (2) 7H-1645 Holding Rod (3) 7H-1942 Dial Indicator (4) 7H-1940 Universal Attachment

1. Install the 7H-1942 Dial Indicator (3). Make an adjustment of the 7H-1940 Universal Attachment (4) so that the dial indicator makes contact on the flywheel. 2. Set the dial indicator to read 0.0 mm (0.00 inch). 3. Turn the flywheel at intervals of 90 degrees and read the dial indicator. 4. Take the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This value is the runout. The maximum permissible bore runout (radial eccentricity) of the flywheel must not exceed 0.15 mm (0.006 inch).

Illustration 3

g00286058

Flywheel clutch pilot bearing bore

5. Take the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This value is the runout. The maximum permissible pilot bore runout of the flywheel must not exceed 0.13 mm (0.005 inch).

TESTING AND ADJUSTING

031

G3516E Service manual (GAS)

Media Number -KENR6834-03

Flywheel Housing - Inspect Table 1 Tools Needed 8T-5096

Dial Indicator Gp

Quantity 1

Face Runout (Axial Eccentricity) of the Flywheel Housing

Illustration 1

g00285931

Checking face runout of the flywheel housing

If you use any other method except the method that is given here, always remember that the bearing clearance must be removed in order to receive the correct measurements. 1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the face of the flywheel housing. 2. Put a force on the crankshaft toward the rear before the dial indicator is read at each point.

Illustration 2

g00285932

Checking face runout of the flywheel housing

3. Turn the flywheel while the dial indicator is set at 0.0 mm (0.00 inch) at location (A). Read the dial indicator at locations (B), (C) and (D) . 4. The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than 0.38 mm (0.015 inch), which is the maximum permissible face runout (axial eccentricity) of the flywheel housing.

Bore Runout (Radial Eccentricity) of the Flywheel Housing

Illustration 3

g00285934

Checking bore runout of the flywheel housing

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the bore of the

flywheel housing.

Illustration 4

g00285936

2. While the dial indicator is in the position at location (C) adjust the dial indicator to 0.0 mm (0.00 inch). Push the crankshaft upward against the top of the bearing. Refer to the illustration 4. Write the measurement for bearing clearance on line 1 in column (C) . Note: Write the measurements for the dial indicator with the correct notations. This notation is necessary for making the calculations in the chart correctly. 3. Divide the measurement from Step 2 by two. Write this number on line 1 in columns (B) and (D) . 4. Turn the flywheel in order to put the dial indicator at position (A). Adjust the dial indicator to 0.0 mm (0.00 inch).

Illustration 5

g00285932

Checking bore runout of the flywheel housing

5. Turn the flywheel counterclockwise in order to put the dial indicator at position (B). Write the measurements in the chart. 6. Turn the flywheel counterclockwise in order to put the dial indicator at position (C). Write the measurement in the chart. 7. Turn the flywheel counterclockwise in order to put the dial indicator at position (D). Write the measurement in the chart. 8. Add the lines together in each column. 9. Subtract the smaller number from the larger number in column B and column D. Place this number on line III. The result is the horizontal eccentricity (out of round). Line III in column C is the vertical eccentricity.

Illustration 6

g00286046

Graph for total eccentricity (1) Total vertical eccentricity (2) Total horizontal eccentricity (3) Acceptable value (4) Unacceptable value

10. On the graph for total eccentricity, find the point of intersection of the lines for vertical eccentricity and horizontal eccentricity. 11. The bore is in alignment, if the point of intersection is in the range that is marked "Acceptable". If the point of intersection is in the range that is marked "Not acceptable", the flywheel housing must

be changed.

TESTING AND ADJUSTING

032

G3516E Service manual (GAS)

Media Number -KENR6834-03

Vibration Damper - Check The crankshaft vibration damper limits the torsional vibration of the crankshaft. The visconic damper has a weight that is located inside a fluid filled case. The damper is mounted to the crankshaft on the front of the engine. Damage to the failure or failure of the damper will increase vibrations. The increase in vibrations will result in damage to the crankshaft and to other engine components. A deteriorating damper will cause more gear train noise at variable points in the speed range. A damper that is hot may be the result of excessive friction. This could be due to excessive torsional vibration or misalignment. Use an infrared thermometer to monitor the temperature of the damper during operation. If the temperature reaches 100 °C (212 °F), consult your Caterpillar dealer. Inspect the damper for evidence of dents, cracks, and leaks of the fluid. If a fluid leak is found, determine the type of fluid. The fluid in the damper is silicone. Silicone is transparent, smooth, and viscous. It is difficult to remove silicone from most surfaces. If the fluid leak is engine oil, inspect the crankshaft seals for leaks. If a leak is observed, replace the crankshaft seals. Inspect the damper. Repair the damper or replace the damper for any of the following reasons: l l l l l

The damper is dented, cracked, or leaking. The paint on the damper is discolored from heat. The engine has had a failure because of a broken crankshaft. Analysis of the engine oil has revealed that the front main bearing is badly worn. There is a large amount of gear train wear that is not caused by a lack of engine oil.

For instructions on repairing the damper, refer to Guide for Reusable Parts, SEBF8152, "Procedures to Rebuild Vibration Dampers 3600 Family of Engines". The tools and instructions in the guide for reusable parts are appropriate for G3500 Engines.

TESTING AND ADJUSTING

033

G3516E Service manual (GAS)

Media Number -KENR6834-03

General Information (Air/Electric Starting System) This starting system uses an electric solenoid to position an air valve in order to activate the air starting motor. If the starting motor does not function, do the procedure that follows: 1. Check the indicator reading for the air pressure. 2. If the reading is not acceptable then use a remote source to charge the system. 3. If the reading is acceptable then open the main tank drain valve for a moment. Verify the pressure that is shown on the pressure indicator. Listen for the sound of the high pressure from the discharge.

Electrical Side Of The Air System 1. Move the start control switch in order to activate the starting solenoids. Listen for the sound of the engagement of the air starter motor pinion with the flywheel gear. a. If the sound of the engagement can be heard, the problem is with the Air Side Of The Air System. Proceed to the Air Side Of The Air System. b. If no sound of the engagement can be heard, the problem could be with the Electrical Side Of The Air System.

Illustration 1

g00286936

Control valve (typical example) (1) Control valve (2) Connector

2. Check the electrical system by disconnecting the leads from the control valve (1) at connector (2). Set the multimeter in the "DCV" range. Measure voltage across the disconnected leads that connect to the starting switch. a. A voltage reading shows that the problem is in the control valve (2) or the air starting motor. Go to Step 2 of Air Side Of The Air System. b. A "ZERO" reading shows that the problem is in the control switch or the problem is in the wires for the control switch. 3. Fasten the multimeter lead to the start switch at the terminal for the wire from the battery. Fasten

the other lead to a good ground. a. A "ZERO" reading indicates a broken circuit from the battery. With this condition, check the circuit breaker and wiring. b. The problem is in the control switch if either a voltage reading is found at the control switch or if a voltage reading is found in the wires from the control switch to the control valve.

Air Side Of The Air System

Illustration 2

g00286937

Air starting system (typical example) (1) Control valve (2) Connector (3) Connection (4) Air hose (5) Relay valve

1. Activate the control switch. If the engagement of the air starter motor pinion with the flywheel ring gear can be heard then remove the small air hose (4) from the top of the relay valve (5) . a. Full air pressure comes from the end of the air hose (4) when the control switch is activated. The relay valve (5) is worn or the air starting motor is damaged. b. If no air pressure comes from the end of the air hose (4), then the problem is in the pinion nose housing for the air starting motor. 2. The sound of the air starter motor pinion is not heard when the control switch is activated. Voltage was measured at the control valve. Remove the other small air hose from the connection (3) . a. If no air comes from the end of the removed air hose, the control valve (1) is worn. b. If the air comes from the end of the removed hose, then the problem is in the pinion nose housing for the air starting motor.

TESTING AND ADJUSTING

034

G3516E Service manual (GAS)

Media Number -KENR6834-03

Test Tools for the Electrical System Table 1 Tools Needed

Quantity

4C-4911

Battery Load Tester

1

271-8590

Starting/Charging Analyzer Gp

1

225-8266

Ammeter Tool Gp

1

146-4080 or 257-9140

Digital Multimeter Gp

1

Most of the tests for the electrical system can be done on the engine. First, check that the insulation for the wiring is in good condition. Ensure that the wire connections and cable connections are clean and tight. Check that the battery is fully charged. If the on-engine test shows that a component is not functioning properly, remove the component from the engine for more testing. Refer to Testing And Adjusting Electrical Components, REG00636 for complete specifications and test procedures for the components of the starting circuit and the charging circuit.

4C-4911 Battery Load Tester

Illustration 1

g00283565

4C-4911 Battery Load Tester

The 4C-4911 Battery Load Tester is a portable unit in a metal case. The 4C-4911 Battery Load Tester can be used under field conditions and under high temperatures. The tester can be used to load test all 6, 8, and 12 Volt batteries. This tester has two heavy-duty load cables that can easily be fastened to the battery terminals. A load adjustment knob is located on the top of the tester. The load adjustment knob permits the current that is being drawn from the battery to be adjusted to a maximum of 1000 amperes. The tester is cooled by an internal fan that is automatically activated when a load is applied. The tester has two built-in Liquid Crystal Displays (LCD). During testing, one LCD displays the battery voltage at the battery. This measurement is taken through tracer wires that are buried inside the load cables. The other LCD accurately displays the current that is being drawn from the battery which is being tested. Note: Refer to Operating Manual, SEHS9249 for more complete information for the use of the 4C-4911 Battery Load Tester .

271-8590 Starting/Charging Analyzer Gp

Illustration 2

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271-8590 Starting/Charging Analyzer Gp The 271-8590 Starting/Charging Analyzer Gp is a portable, hand-held tool that is used to test the condition of all 6, 8, and 12 Volt batteries, as well as 6, 8, 12 and 24 Volt battery packs. The tester can also be used to test the starting and the charging system. The analyzer has a multifunction input for use with multimeter probes that are an optional purchase. The analyzer also has a print function that is used with a printer that is an optional purchase. Note: Refer to Operating Manual, NEHS0973 for more complete information for the use of the 271-8590 Starting/Charging Analyzer Gp .

225-8266 Ammeter Tool Gp

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225-8266 Ammeter Tool Gp

The 225-8266 Ammeter Tool Gp is a completely portable, self-contained instrument that allows electrical current measurements to be made without breaking the circuit or without disturbing the insulation of a conductor. A digital display is located on the ammeter for displaying current measurements in a range from 1 to 1200 amperes. A 6V-6014 Cable can be connected between the ammeter and a digital multimeter in order to measure a current of less than 1 ampere. A lever is used to open a jaw on the meter that clamps on any conductor up to 23 mm (0.90 inch) in diameter. The jaw of the meter closes around the conductor for the current measurement. A dial is used to set the appropriate range for the amperage reading. A "HOLD" button on the meter allows the latest reading to be sustained on the display. If a measurement is taken in a limited access area, the meter will retain the measurement data that is on the display until the user clears the data. Batteries are used to power the ammeter. Note: Refer to the ammeter's User's Guide for complete information that is related to the use of the ammeter. This guide is packaged with the unit.

146-4080 Digital Multimeter Gp

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146-4080 Digital Multimeter Gp

The 146-4080 Digital Multimeter Gp is a portable instrument that has a digital display. This multimeter is case hardened with a rubber protector cover that provides extra protection against damage in field applications. The 146-4080 Digital Multimeter Gp can be used to perform the following measurements: l l l l l l l

Amperage Capacitance Frequency Pulse Width Modulation (PWM) Resistance Temperature Voltage

The multimeter has an instant ohms indicator that permits the checking of continuity for fast circuit inspection. Temperature measurements can be taken by using the adapter for type K thermocouples. An RS-232 interface adaptor can be used to interface with other electronic tools and displays. Note: Refer to multimeter's Operator's Manual for complete information that is related to the use of the multimeter. The operator's manual is packaged with the unit.

TESTING AND ADJUSTING

035

G3516E Service manual (GAS)

Media Number -KENR6834-03

Battery

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result. The battery circuit is an electrical load on the charging unit. The load is variable because of the condition of the charge in the battery.

NOTICE The charging unit will be damaged if the connections between the battery and the charging unit are broken while in operation. Damage occurs because the load from the battery is lost and because there is an increase in charging voltage. High voltage will damage the charging unit, the regulator, and other electrical components.

Use the 4C-4911 Battery Load Tester in order to test a battery that does not maintain a charge when the battery is active. Refer to Operating Manual, SEHS9249 for detailed instruction on the use of the 4C4911 Battery Load Tester. See Special Instruction, SEHS7633 for the correct procedure and for the specifications to use when you test the batteries.