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Service Training MALAGA
3600 Engines - Basic
STUDENT BOOK Thorben MARCH 1998
3600 Engines - Basic CHAPTER : Description
COURSE OBJECTIVES DESCRIPTION
This book is designed to provide necessary information to the instructor to prepare for class and to conduct the training course. The material in this book identifies components, covers the basic operation of the engine systems and goes through disassembly, assembly and adjusting procedures for the major areas of the engine. The practical part of the class will be held on a 3612 engine (nonrunning).
CONTENTS
The Student book contents 5 chapters and is covering: - Introduction to 3600 engines - Lubrication system - Air intake & exhaust system - Fuel system - Cooling system
AUDIENCE
This course is designed for dealer and customer personnel who will be servicing 3600 engines.
PREREQUISITE
Good theoretical and practical understanding of diesel engines and correct mechanical procedures.
EQUIPMENT
Safety glasses and safety shoes (or hard leather shoes) are required. Work clothing is suggested because of “hands-on” exercises on the engine.
COURSE ACTIVITIES
During the course the students will participate following tasks: 1. 2. 3. 4. 5. 6.
Locate all engine components. Utilize hydraulic assembly and disassembly tooling. Remove and install a cylinder head. Remove and install a piston, connecting rod and cylinder liner. Remove and install a main bearing. Remove and install a camshaft segment and time the camshaft(s) to the crankshaft.
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3600 Engines - Basic CHAPTER : Description
COURSE OBJECTIVES 7. Adjust the valves and valve bridges. 8. Synchronize and time the unit injectors, set the fuel limit. 10. Service the main and centrifugal oil filters.
LITERATURE
SENR3593-01 SENR3594-03
SYSTEM OPERATION TESTING & ADJUSTING (3612 & 3616) DISASSEMBLY & ASSEMBLY (3612 & 3616)
Service manual and other literature are for course use only.
NOTE: The course is designed for a 4.5 days at 6 hours a day plus half day 3 hours.
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3600 Engines - Basic CHAPTER : Description
TABLE OF CONTENTS INTRODUCTION ........................................................................................................ 3600 engine specifications.......................................................................................... Engine components .................................................................................................... Lab exercises .............................................................................................................. LUBRICATION SYSTEM............................................................................................ Lubrication system schematic ..................................................................................... Lubrication flow ........................................................................................................... Priority valve ............................................................................................................... Centrifugal oil filters .................................................................................................... Lab exercises .............................................................................................................. AIR INTAKE & EXHAUST SYSTEM .......................................................................... Engine air flow ............................................................................................................ Cam segment trim....................................................................................................... Lab exercises .............................................................................................................. FUEL SYSTEM ........................................................................................................... Fuel system schematic ............................................................................................... Fuel flow...................................................................................................................... Unit injector ................................................................................................................. Injector control linkage ................................................................................................ Injector synchronization .............................................................................................. Lab exercises .............................................................................................................. COOLING SYSTEM ................................................................................................... Combined circuit cooling system ................................................................................ Coolant flow schematic ............................................................................................... Separate circuit cooling system .................................................................................. Coolant flow schematic ............................................................................................... Lab exercises ..............................................................................................................
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Service Training MALAGA
3600 Engines - Basic
I. INTRODUCTION
Thorben MARCH 1998
3600 Engines - Basic CHAPTER : Introduction
3600 engine specifications The 3600 engine family contains 4 models: - 6 & 8 cylinder engines (in-line engines) - 12 & 16 cylinder engines (“vee” engines)
At the end of 1997 Caterpillar will bring out an 18 cylinder engine (3618), which will be produced in Spain.
Bore x stroke
280 x 300 mm (11.0 x 11.8 in)
Rated speed
720 to 1000 rpm
Low idle speed
280 to 400 rpm
Output
280 kW/cyl (375 hp/cyl) @ 1000 rpm
Compression ratio
13:1
Combustion system
Direct Injection
Peak cylinder pressure
New 2350 psi (16190 kPa) Former 2200 psi (15160 kPa)
Rotation
CCW standard Cw optional
Mean piston velocity
10 m/s (33 ft/s) @ 1000 rpm
BMEP
18.2 bar (264 psi) @ 1000rpm
Displacement/cyl.
18.5 L
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3600 Engines - Basic CHAPTER : Introduction
3600 engine specifications
Weight of serviceable parts (kg)
Cylinder head assembly
196
Liner
101
Piston assembly
35
Piston pin
19
Connecting rod
57
Turbocharger
400
Unit injector
11.3
Front housing
258
Camshaft segment
29.5
Camshaft journal
10.4
3606
3608
3612
3616
Block & bearing caps
4638
6476
6810
9625
Crankshaft
1782
2288
2091
3630
Flywheel assembly
491
491
474
463
Damper
190
249
496
496
Rear housing
222
222
350
350
Aftercooler core
42
42
94
125
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3600 Engines - Basic CHAPTER : Introduction
Engine components
The picture above shows a 3616 engine.
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3600 Engines - Basic CHAPTER : Introduction
Engine components
The picture above shows a 3616 marine engine. On the following page write down the names of the components referring to the numbers on the picture. It is allowed to use the Caterpillar service literature. On this picture there are shown some additional components, which not have been shown on page 4.
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3600 Engines - Basic CHAPTER : Introduction
Engine components 1._________________________
22.________________________
2._________________________
23.________________________
3._________________________
24.________________________
4._________________________
25.________________________
5._________________________
26.________________________
6._________________________
27.________________________
7._________________________
28.________________________
8._________________________
29.________________________
9._________________________
30.________________________
10.________________________
31.________________________
11.________________________
32.________________________
12.________________________
33.________________________
13.________________________
34.________________________
14.________________________
35.________________________
15.________________________
36.________________________
16.________________________ 17.________________________ 18.________________________ 19.________________________ 20.________________________ 21.________________________
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3600 Engines - Basic CHAPTER : Introduction
Engine components
1. Jacket water emergency circuit outlet
19. Mounting foot
2. Jacket water emergency circuit inlet
20. Explosion relief valves
3. Lifting eye
21. Combined circuit outlet
4. Crankcase breather outlet
22. Jacket water circuit outlet
5. Governor
23. Oil circuit thermostat housing
6. Exhaust
24. JAcket water pump inlet
7. Air inlet
25. AC/OC water pump inlet
8. Thermostat housing
26. Flywheel
9. Air intake shutoff
27. Optional water pump inlet
10. AC/OC emergency circuit inlet
28. Optional water pump outlet
11. Air starter inlet
29. Fuel filters
12. Jacket water heater connection
30. Oil coolers
13. AC/OC emergency circuit outlet
31. Oil filters
14. Solenoid shutoff
32. Manual barring device
15. Emergency oil circuit inlet
33. Centrifugal oil filters
16. Emergency oil circuit outlet
34. Oil filler
17. Oil sump drain
35. Dipstick
18. Fuel transfer pump
36. Manual fuel priming pump
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3600 Engines - Basic CHAPTER : Introduction
Instructor notes Show overhead of page 2-4 and talk about them. Show slides: LEGV0928 - #11 (engine left side) LEGV0928 - #12(engine right side) LEGV0928 - #04 (engine rigth side) LEGV0928 - #13 (engine top view) LEGV0928 - #14 (engine rear view) LEGV0928 - #15 (engine front view)
Take students down to the engine and let them locate the different components and fill out page 7.
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Service Training MALAGA
O
IL
3600 Engines - Basic
II. LUBRICATION SYSTEM
Thorben MARCH 1998
3600 Engines - Basic CHAPTER : Lubrication system
Inlet water
Oil coolers
Oil flow
Oil temp. reg.
Return water Oil coolers Vent
3 Filter elements Filter change valve
Vent 3 Filter elements
Priority valve By-pass valve 63 psi
Coolin jet flow 20 psi
Oil pan
Relief valve 145 psi
Oil pan Unfiltered oil
Main oil manifold & bearings
Check valve Centrifugal filter No flow under 15 psi Prelube pump
Breather Oil pan
Main oil pump
Strainer
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3600 Engines - Basic CHAPTER : Lubrication system
Instructor notes Let students make the qiuz (see transparency section). Give them about 5 min. and then show them how the system should look like. Explain lube system and the function of the different components. Oil system
Oil system provides a constant supply of 85 C (185 F) filtered oil at 430 kPa (62.4 psi) pressure.
Priority valve
An oil priority valve regulates oil preesure at the cylinder block oil manifold rather than at the oil pump. This makes the oil manifold pressure independent of oil filter and oil cooler pressure drops.
Suction screen
Oil to the oil pump passes through a 650 micron (0.025 in.) screen located between the suction bell and the suction tube.
Temperature regulators
Oil filters
Oil temperature regulators direct the oil to coolers at oil temperatures above 85 C ( 185 F). From the 20 microns (0.78 mils) final filters the oil flows through the priority valve to drilled oil passages in the cylinder block.
Prelubrication
Prelubrication is required for all 3600 engines before each start.
Two methods of prelubing
Two methods are available: intermittent and continuous.
Continuous
Continuous prelubrication occurs in stand-by situations.
Intermittent
Intermittent prelubrication occurs for a short interval preceding engine start and provides oil to all the engine bearings. A pressure switch and starter interlock prevent starter operation with less than 10 kPa (1.5 psi) lube system pressure. Page:
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3600 Engines - Basic CHAPTER : Lubrication system
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3600 Engines - Basic CHAPTER : Lubrication system
Priority valve
The priority valve senses filtered oil pressure and bypasses or dumps unfiltered oil back to the oil sump to control the engine oil pressure.
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3600 Engines - Basic CHAPTER : Lubrication system
Centrifugal filters
The centrifugal oil filters extend the life of the oil filter elements and remove some particles smaller than the oil filters will normally take out. The centrifugal filters receive 3-4 % of the oil pump flow. The flow of oil through the jets causes the rotor assembly to rotate at about 4000 rpm. Oil flow through each filter is 17 L/min. (5.5 gpm) and the dirt capacity is 3.6 kg (8 lbs.). The centrifugal filters should normally be cleaned every 1000 hours. Page:
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3600 Engines - Basic CHAPTER : Lubrication system
Slides Show slides and explain the functions of the different components of the lube system. LEGV0928 - #19
Oil pump - the oil pump is driven approximately 1.5 times engine speed. The components of the pump are the same for both standard and reverse rotation. An oil pump can not be removed from a standard rotation engine and installed directly to a reverse rotation engine or visa versa. A single dowel pin in the mounting flange prevents the pump from being rotated 1800 degrees and installed.
LEGV3823 - #90
Oil pump - standrad rotation.
LEGV3823 - #91
Oil pump - reverse rotation.
LEGV0928 - #20
Air operated prelube pump.
LEGV0928 - #20
Electric prelube pump - pumps can be provided with 115/230 VAC, 50/60 Hz single phase motor. They also can be equipped with 24 VDC or 60/70 VDC motors. Higher voltage 3 phase motors are available for continuous prelubrication systems.
LEGV0928 - #22
Oil temperature regulators.
LEGV0928 - #23
Oil filters - (Duplex filters) There are two oil filter housings on all 3600 engines with three replaceable filter elements in each housing. An oil filter change valve allows the filter elements for each filter housing to be changed separatly while the engine is operating. The maximum change period is 1000 hours or when the oil filter pressure drop reaches 104 kPa (15 psi).
LEGV0928 - #27
Oil filter elements.
LEGV0928 - #30
Priority valve. Page:
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3600 Engines - Basic CHAPTER : Introduction
Slides LEGV0928 - #34
Vee engine cylinder block - Three oil manifolds. The one at the center supplies the main and camshaft bearings. The two outer manifolds supply the piston cooling spray jets.
LEGV0928 - #36
Piston cooling jet.
LEGV0928 - #37
Inlet valve lube metering pump - injects a small amount of oil into the inlet manifold where it is mixed with the intake air to lubricate the inlet valves and valve seats to reduce wear.
LEGV0928 - #44
Disassembled centrifugal oil filter. Show students the flow of the oil and the lub system components on the engine. Do lab exercises with students (page 9)
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3600 Engines - Basic CHAPTER : Lubrication system
Lab exercises
1) Removal of oil filter elements. Disassembly & Assembly (SENR3594-03) page 119.
2) Removal, disassembly & assembly of centrifugal filter. Disassembly & Assembly (SENR3594-03) page 127.
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Service Training MALAGA
3600 Engines - Basic
III. AIR INTAKE & EXHAUST SYSTEM
Thorben MARCH 1998
3600 Engines - Basic CHAPTER :
Intake & exhaust system
Instructor notes Explain general air flow of the engine and show slides about engine aftercooler.
For optimum engine performance and low fuel consumption, two exhaust manifold designs are used on the 3600 family of engines. A divided or split exhaust manifold system is installed on the 3606 and 3612 diesel engines. The turbocharger(s) used with this manifold design has a double entry inlet. A single larger diameter exhaust manifold design with single inlet into the turbocharger is used with 3608, 3616 and all spark ignited (gas) engines.
LEGV0928 - #59
In-line aftercooler core - mounted on theleft side of the engine.
LEGV0928 - #60
In-line cylinder block - with cast-in inlet manifold.
LEGV0928 - #62
Vee engine aftercooler core - mounted above the center of the vee.
LEGV0928 - #61
Location of vee engine aftercooler & air shutoff. An air shutoff is available for installation at the aftercooler inlet. The air shutoff is closed only when an overspeed occurs or when an emergency shutdown is initiated.
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3600 Engines - Basic CHAPTER : Intake & exhaust system
Camshaft 3612 engine
C
C
A
B
B
C
C
A
B
B
Rear end
Install the camshaft journals with the annular groove toward the front of the engine for both standard (CCW) rotation and reverse (CW) rotation engines. Install the camshaft segments with the groove toward the front of the engine for standard (CCW) rotation engines. Install the camshaft segments with the groove toward the rear of the engine for reverse (CW) rotation engines.
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3600 Engines - Basic CHAPTER : Intake & exhaust system
Instructor notes Talk about camshaft segments and journals. Camshaft
The camshaft is running half the speed of the crankshaft. The camshaft is with the help of push rods and rocker arms activating the air inlet and exhaust valves and the unit injector.
Camshaft segmented
The camshafts in all 3600 engines are segmented. Each cylinder has it’s own segment but all the segments are the same. On Vee engines the segments in the left side are different than those in the right side.
In-line uses same part as Vee
The segments in the in-line engine will be the same as the segments in the left or rigth of the Vee engine, depending on whether it is a standard or reverse rotation engine. Therefor there are basically two camshaft part numbers to service both in-line and Vee distillate fuel engines. Heavy fuel engine camshafts may be different.
Earlier cam segments
Camshaft segments installed on diesel engines before mid-1990 have thinner flanges and spacers. The bolts are also smaller.
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3600 Engines - Basic CHAPTER : Intake & exhaust system
Cam segment trim
Dowel
D
E C
B A
Annular groove
Dowel hole locations
Dowel
G
F
Dowel hole locations
At present there are three different kinds of camshaft segments. The difference between them is the number and the location of the dowel holes.
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3600 Engines - Basic CHAPTER : Intake & exhaust system
Instructor notes Explain trimming of camshaft journals. Cam journals
There are three different kinds of cam journals: one with 5 dowel holes, one with 3 dowel holes and one with 2 dowel holes.
Journal trimming
When you order a camshaft journal you will get a plain journal and two dowels. Show slides about camshaft segments, journals, their removal and about rocker arm assembly and valves.
LEGV0928 - #65
Camshaft segment, two spacers and camshaft rear journal.
LEGV0928 - #66
Camshaft journal - with 5 dowel holes.
LEGV0928 - #67
Camshaft segment removal tool.
LEGV0928 - #69
Camshaft segment removal.
LEGV0928 - #71
Valve lifter group.
SESV1535 - #49
Cylinder head - shows air intake and rocker arm assembly.
LEGV0928 - #80
Bottom side of cylinder head - shows intake & exhaust valves. Let students remove two cam segments, three cam journals and one cam bearing.
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3600 Engines - Basic CHAPTER :
Intake & exhaust system
Lab exercises
1) Removal of camshaft segment and journal. Disassembly & Assembly (SENR3594-03) page 213
2) Removal of camshaft bearing. Disassembly & Assembly (SENR3594-03) page 220.
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3600 Engines - Basic CHAPTER : Intake & exhaust system
Cylinder head removal
Collar
Hydraulic cylinder
Pedestall
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3600 Engines - Basic CHAPTER :
Intake & exhaust system
Cylinder head removal
Collar
Cover Piston
Cylinder Stud Pedestall
Nut Washer
Cylinder head
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3600 Engines - Basic CHAPTER : Intake & exhaust system
Instructor notes Explain removal of cylinder head. Show following slides: LEGV0928 - #94
Cylinder head removal tool - hydraulic cylinder.
LEGV0928 - #96
Hydraulic hoses.
LEGV0928 - #95
Hydraulic cylinders installed on cylinder head.
LEGV0928 - #97
Hydraulic pump.
LEGV0928 - #98
Loosening procedure of cylinder head nut.
LEGV0928 - #101
Lifting device for cylinder head.
LEGV0928 - #81
Cylinder head - with Kiney valve. The Kiney valve is for manual relief of cylinder pressure. Explain removal of unit injector and valve springs and explain messure method of combustion ring and valve springs for reusebility. Show following slides:
LEGV0928 - #85
Unit injector removal.
8097 - #50
Combustion ring. Let students remove a cylinder head and disassemble / assemble it. Let them also check the combustion ring and the valve springs.
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3600 Engines - Basic CHAPTER : Intake & exhaust system
Lab exercises
1) Removal of cylinder head. Disassembly & Assembly (SENR3594-03) page 183. Note before starting to remove the cylinder head : a) Drain the engine coolant to a level below the cylinder heads. b) Shut off the fuel supply and return, drain the fuel system and remove the fuel lines that connect the fuel manifolds to the cylinder head. c) Install plugs in the fuel lines and caps over the fittings on the cylinder head to keep dirt out of the fuel system.
2) Disassembling of the cylinder head. Disassembly & Assembly (SENR3594-03) page 191
3) Measurement of combustion gasket thickness. Disassembly & Assembly (SENR3594-03) page 187.
4) Measurement of valve springs. Spcifications (SENR3592-01) page 17.
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Service Training MALAGA
3600 Engines - Basic
IV. COOLING SYSTEM
Thorben MARCH 1998
3600 Engines - Basic CHAPTER : Cooling system
Instructor notes Two cooling systems
Caterpillar is providing two cooling systems: Combined circuit cooling & separate circuit cooling.
System temeratures
Temperatures in the two systems are the same.
Basic operating parameters
50 C (122 F) nominal water temperature to the AC and OC (DFE). 32 C (90 F) nominal water temperature to the AC and OC (HFE). 90 C (194 F) nominal jacket water temperature to the cylinder block circuit (DFE). 93 C (199 F) nominal jacket water temperature to the cylinder block circuit (HFE). 85 C (185 F) nominal oil to bearing temperature.
Max. temperatures
Over time, as the performance of the heat exchanger decreases due to fouling, the water temperature to the AC will increase. At higher ambient conditions, the water to the AC and OC is allowed to rise to 65 C (149 F) for DFE or 38 C (100 F) for HFE maximum before engine deration is required.
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3600 Engines - Basic CHAPTER : Cooling system
D A
Cylinder Block, Head & Turbo
JW Pump
C
B
D (3612/3616)
D (3606/3608) Oil Cooler
E D
Heat Exchanger
Aftercooler
E
AC/OC Pump
Expansion Tank
C
A - Mixed temp. from engine and coolers B - Mixing chamber from AC & OC C - Regulator D - Factory orifices E - Factory or customer orifices Coolant going to Expansion Tank - 50C for DO & 32C for HFO Coolant going to Cylindeer Block etc. - 90C for DO & 93 C for HFO
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3600 Engines - Basic CHAPTER : Cooling system
Instructor notes Combined system
The combined circuit system is also known as the single circuit - two pump system.
Advantage combined system
The main advantage of the combined circuit system is that it requires only one external cooling circuit with only one heat exchanger or radiator. There is less coolant and cooling system piping can be relatively simple.
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3600 Engines - Basic CHAPTER : Cooling system
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3600 Engines - Basic CHAPTER : Cooling system
E
Cylinder Block, Head & Turbo
Heat Exchanger (JW Circuit)
D E JW Pump
Expansion Tank
Vent Line
C
Makeup Line F
D Oil Cooler
Heat Exchanger (AC/OC Circuit)
D Aftercooler
F AC/OC Pump
C
A - Mixed temp. from engine and coolers B - Mixing chamber from AC & OC C - Regulator D - Factory orifices E - Factory or customer orifices F - Customer orifices Coolant going to AC/OC - 50C for DO & 32C for HFO Coolant going to Cylindeer Block etc. - 90C for DO & 93 C for HFO Page:
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3600 Engines - Basic CHAPTER : Cooling system
Instructor notes Makeup line (separate circuit)
The only connection between the AC / OC circuit and the engine jacket water circuit is a makeup line that goes from the expansion tank to the water pump supply line. This line keeps the AC / OC circuit filled when it shares the expansion tank with the jacket water circuit. There is no active flow between the circuits.
Advantage separate system
The total radiator surface area may be 20 % less at 45 C (110 F) ambient and up to 30 % less at higher ambients, when compared to a combined circuit. Maintains nominal water temperature to the AC and OC while rejecting heat from the cylinder block and heads at higher temperatures. The total external flow is approximately twice the external flow of the single circuit system. Half of the flow (high temperature circuit) must be cooled to nominal jacket water temperature and the low temperature circuit cooled to nominal AC / OC water temperature.
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3600 Engines - Basic CHAPTER : Cooling system
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3600 Engines - Basic CHAPTER : Cooling system
Instructor notes Explain combined and separate circuit cooling systems. Show slides about piston and liner removal and piston assembly disassembling. LEGV0928 - #109
Connecting rod cap bolts.
LEGV0928 - #110
Lower the connecting rod cap.
LEGV0928 - #111
Install crank protectors.
LEGV0928 - #115
Piston $ connecting rod assembly.
LEGV0928 - #117
Removal of piston retaining rings.
LEGV0928 - #118
Piston pin guide.
LEGV0928 - #119
Piston ring removal.
LEGV0928 - #120
Measure piston and rings.
LEGV0928 - #121
Cylinder liner removal tool.
LEGV0928 - #123
Installation of liner removal tool. Remove piston and liner and disassemble piston assembly. Show and explain the three kinds of different liners.
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3600 Engines - Basic CHAPTER : Cooling system
Lab exercises
1) Removal of piston & connecting rod assemblies. Disassembly & Assembly (SENR3594-03) page 203 2) Removal of cylinder liner. Disassembly & Assembly (SENR3594-03) page 210. 3) Measurement of piston rings. Guideline for reusable parts (SEBF8107). 4) Removal and installation of crankshaft main bearings. Disassembly & Assembly (SENR3594-03) page 222 5)Installation of cylinder liner. Disassembly & Assembly (SENR3594-03) page 211 6) Installation of piston & connecting rod assemblies. Disassembly & Assembly (SENR3594-03) page 205 7) Installation of cylinder head. Disassembly & Assembly (SENR3594-03) page 187
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Service Training MALAGA
3600 Engines - Basic
DIESEL
V. FUEL SYSTEM
Thorben MARCH 1998
3600 Engines - Basic CHAPTER : Fuel system
Pressure relief valve
Check valve
Secondary fuel filter elements Filter change valve
Check valve
Secondary fuel filter elements
Relief valve
Main fuel pump
Check valve Check valve
Check valve
Main fuel tank
Hand priming pump
Primary Fuel filters Page:
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3600 Engines - Basic CHAPTER : Fuel system
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3600 Engines - Basic CHAPTER : Fuel system
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3600 Engines - Basic CHAPTER : Fuel system
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3600 Engines - Basic CHAPTER : Fuel system
Adjustment screw for rack zero setting inside Link to governor Spring loaded link
See detail below
Rack
Control bar
Bolted and doweled
To other injectors Storage for zero-ing pin
Power setting screw under this cover
Location for dial gage
Install zero-ing pin here
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3600 Engines - Basic CHAPTER : Fuel system
Injector synchronization
C
B A
A) Rack B) Rack synchronization distance C) Trim bolt
For injector synchronization slide the rack synchronization gauge (6V9057) between shoulder on rack and head of trim bolt. During the injector synchronization the synchronization gauge is touching the trim bolt. As a result the gauge might not be completely straight between the rack and the injector body. There have been some cases where the service man has grinded a piece out of the gauge to make it fit perfectly. DON’T DO THIS !!
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3600 Engines - Basic CHAPTER : Fuel system
LAB EXERCISES 1) Installation of camshaft bearing. Disassembly & Assembly (SENR3594-3) page 220 2) Installation of camshaft segment and journal. Disassembly & Assembly (SENR3594-3) page 213 3) Timing the camshaft(s) to the crankshaft. Disassembly & Assembly (SENR3594-03) page 148. System Operation Testing & Adjustment (SENR3593-01) page 48 4) Timing of unit injector. Systems Operation Testing & Adjusting (SENR3593-01) page 53. 5) Fuel setting. Systems Operation Testing & Adjusting (SENR3593-01) page 68. 6) Injector synchronization. Systems Operation Testing & Adjusting (SENR3593-01) page 55. 7) Check valve clearance. System Operation Testing & Adjustment (SENR3593-01) page 73
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Service Training MALAGA
3600 Engines - Basic
PRE-/POSTTEST
Thorben MARCH 1998
3600 Engines - Basic CHAPTER : PRE-TEST
1. When is the Caterpillar Dinner this week ?
2. When the engine is at top center #1 cylinder compression stroke, how many injectors can be timed without turning the crankshaft ? ___ALL ___1/2 ___NONE ___NONE OF THE ABOVE
3. The fuel linkage has to be set in the reference position for ALL limkage adjustments. (T or F)
4. The valve bridges need to be adjusted every time the valve lash is adjusted. (T or F)
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3600 Engines - Basic CHAPTER : PRE-TEST
5. Why must the linkage be adjusted between the governor and the control house ? ___To reduce linkage deadband in the governor shutoff position ___To synchronize the air-fuel ratio control to the engine ___To prevent engine overspeed on startup ___To improve governor stability at low idle ___All of above
6. All the valve bridges can be adjusted without rotating the crankshaft. (T or F)
7. Holes have to be drilled and tapped in the top of a piston before it can be removed. (T or F)
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3600 Engines - Basic CHAPTER : PRE-TEST
8. When installing a piston, a “V”(or “X”) mark on the piston must be aligned with a “V” (or “X”) mark stamped on the engine block to: ___Prevent piston interference with the crankshaft ___Prevent piston interference with the piston cooling jet ___Make installation easier ___Permit installation of the piston and liner as a kit
9. The unit injector must be removed with a pry bar. (T or F)
10. The proper tensioning pressure for all cylinder heads is: ___30,000 kPa (4350 psi) ___35,000 kPa (5075 psi) ___40,000 kPa (5800 psi)
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3600 Engines - Basic CHAPTER : PRE-TEST
11. The priority valve controls engine oil pressure by: ___Bypassing lube oil to the pump inlet ___Bypassing filtered oil into the sump ___Bypassing unfiltered oil into the sump ___Bypassing both filtered & unfiltered oil to the sump
12. When changing oil filter elements with the engine running, which statement is true: ___The filter change valve can be rotated directly from the service position to the run position ___ The oil filters will drain completely if given enough time with the drain valve open ___The filter change valve must be rotated to the fill position and the pressure in both filters equalized before it can be rotated to the run position
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3600 Engines - Basic CHAPTER : PRE-TEST
13. The inlet valve faces are lubricated: ___By natural oil flow past the valve stems guide ___By spray nozzles in the manifold connected directly to the lube oil supply ___By a low volume metering pump and lines that inject a small amount of oil into the inlet manifold ___All of the above
14. A pressure relief valve in the lube system priority valve gives the priority valve additional bypass capability if oil pressure exceeds 150 psi (1035 kPa). (T or F)
15. The oil pump is driven at approximately 1.5 times engine speed. (T or F)
16. The engine oil pump from a reverse rotation engine can not be made to work on a standard rotation engine. (T or F) Page:
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3600 Engines - Basic CHAPTER : PRE-TEST
17. The gauges in the oil filter covers measure oil filter differential pressure. (T or F)
18. The centrifugal oil filters are bypass type filters and can only be serviced with the engine stopped. (T or F)
19. On Vee engines the camshaft segments in the left side are different than those in the right side. (T or F)
20. The camshaft segments in the in-line engine will be the same as the segments in the left or right side of the Vee engine, depending on whether it is a standard or reverse rotation engine. (T or F)
21. How many cooling systems does Caterpillar provide ?
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