CAT + Caterpillar 3608 Marine Auxiliary Operation & Maintenance Manual by Heavy Equipment Manual

Product:MARINEAUXILIARY

Model:3608MARINEAUXILIARY1ZD

Configuration:3608MarineAuxiliaryEngineMilitary1ZD00001-UP

OperationandMaintenanceManual 3608Engine

MediaNumber-SEBU7312-03PublicationDate-01/03/2014DateUpdated-18/03/2014 s00037353

Foreword

LiteratureInformation

Thismanualcontainssafety,operationinstructions,lubricationandmaintenanceinformation.This manualshouldbestoredinorneartheengineareainaliteratureholderorliteraturestoragearea. Read,studyandkeepitwiththeliteratureandengineinformation.

EnglishistheprimarylanguageforallCatpublications.TheEnglishusedfacilitatestranslation andconsistencyinelectronicmediadelivery.

Somephotographsorillustrationsinthismanualshowdetailsorattachmentsthatmaybedifferent fromyourengine.Guardsandcoversmayhavebeenremovedforillustrativepurposes. Continuingimprovementandadvancementofproductdesignmayhavecausedchangestoyour enginewhicharenotincludedinthismanual.Wheneveraquestionarisesregardingyourengine, orthismanual,pleaseconsultwithyourCatdealerforthelatestavailableinformation.

Safety

Thissafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifieshazardous, warningsituations.Readandunderstandthebasicprecautionslistedinthesafetysectionbefore operatingorperforminglubrication,maintenanceandrepaironthisproduct.

Operation

Operatingtechniquesoutlinedinthismanualarebasic.Theyassistwithdevelopingtheskillsand techniquesrequiredtooperatetheenginemoreefficientlyandeconomically.Skillandtechniques developastheoperatorgainsknowledgeoftheengineanditscapabilities.

Theoperationsectionisareferenceforoperators.Photographsandillustrationsguidetheoperator throughproceduresofinspecting,starting,operatingandstoppingtheengine.Thissectionalso includesadiscussionofelectronicdiagnosticinformation.

Maintenance

Themaintenancesectionisaguidetoenginecare.Theillustrated,step-by-stepinstructionsare groupedbyfuelconsumption,servicehoursand/orcalendartimemaintenanceintervals.Itemsin themaintenanceschedulearereferencedtodetailedinstructionsthatfollow.

Usefuelconsumptionorservicehourstodetermineintervals.Calendarintervalsshown(daily, annually,etc.)maybeusedinsteadofservicemeterintervalsiftheyprovidemoreconvenient schedulesandapproximatetheindicatedservicemeterreading.

Recommendedserviceshouldbeperformedattheappropriateintervalsasindicatedinthe MaintenanceIntervalSchedule.Theactualoperatingenvironmentoftheenginealsogovernsthe MaintenanceIntervalSchedule.Therefore,underextremelysevere,dusty,wetorfreezingcold operatingconditions,morefrequentlubricationandmaintenancethanisspecifiedinthe MaintenanceIntervalSchedulemaybenecessary.

Themaintenancescheduleitemsareorganizedforapreventivemaintenancemanagement program.Ifthepreventivemaintenanceprogramisfollowed,aperiodictune-upisnotrequired. Theimplementationofapreventivemaintenancemanagementprogramshouldminimize operatingcoststhroughcostavoidancesresultingfromreductionsinunscheduleddowntimeand failures.

MaintenanceIntervals

Performmaintenanceonitemsatmultiplesoftheoriginalrequirement.Eachleveland/or individualitemsineachlevelshouldbeshiftedaheadorbackdependinguponyourspecific maintenancepractices,operationandapplication.Werecommendthatthemaintenanceschedules bereproducedanddisplayedneartheengineasaconvenientreminder.Wealsorecommendthata maintenancerecordbemaintainedaspartoftheengine'spermanentrecord.

SeethesectionintheOperationandMaintenanceManual,"MaintenanceRecords"forinformation regardingdocumentsthataregenerallyacceptedasproofofmaintenanceorrepair.Your authorizedCatdealercanassistyouinadjustingyourmaintenancescheduletomeettheneedsof youroperatingenvironment.

Overhaul

MajorengineoverhauldetailsarenotcoveredintheOperationandMaintenanceManualexcept fortheintervalandthemaintenanceitemsinthatinterval.Majorrepairsarebestlefttotrained personneloranauthorizedCatdealer.YourCatdealeroffersavarietyofoptionsregarding overhaulprograms.Ifyouexperienceamajorenginefailure,therearealsonumerousafterfailure overhauloptionsavailablefromyourCatdealer.Consultwithyourdealerforinformation regardingtheseoptions.

CaliforniaProposition65Warning

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.

Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhands afterhandling.

FriMay2411:50:08UTC+05302024

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Product:MARINEAUXILIARY

Model:3608MARINEAUXILIARY1ZD

Configuration:3608MarineAuxiliaryEngineMilitary1ZD00001-UP

OperationandMaintenanceManual 3608Engine

MediaNumber-SEBU7312-03PublicationDate-01/03/2014DateUpdated-18/03/2014 i01222871

AftercoolerCondensation-Drain

SMCS-1063

Theaftercoolerissimilartoaradiator.Coolantpassesthroughthetubesintheaftercoolercore. Inletairthatiswarmedbytheturbochargercompressorisdirectedthroughtheaftercoolercore. Theairiscooledintheaftercooler.

Condensationcanforminthepassagesoftheaftercoolersystem.Adrainplugisprovidedfor drainingthemoisture.

Thedrainplugislocatedontheleftsideneartherearoftheengine. (1)Plug

1.Removeplug(1).

2.Drainthemoistureintoasuitablecontainer.

3.Installtheplug.

FriMay2411:59:28UTC+05302024

Product:MARINEAUXILIARY

Model:3608MARINEAUXILIARY1ZD

Configuration:3608MarineAuxiliaryEngineMilitary1ZD00001-UP

OperationandMaintenanceManual

3608Engine

MediaNumber-SEBU7312-03PublicationDate-01/03/2014DateUpdated-18/03/2014

AftercoolerCore-Clean/Test

SMCS-1064-081;1064-070

i05253323

Beforecleaningtheaftercoolercore,determineiftheaftercoolerrequirescleaning.Usethe1522067DifferentialPressureGaugetomeasurethedifferentialpressureoftheairsideofthe aftercooler.Whentheairsidedifferentialpressurereaches7kPa(1.0psi)atfullratedpower, cleantheaftercoolercore.

CleaningtheAftercooler

SeetheServiceManual,"DisassemblyandAssembly"moduleforinstructionsonremoval, disassembly,assembly,andinstallation.

Note:Thefollowingproceduremaybeusedforcleaningboththeaftercoolercoreandtheoil coolercore.

1.Removethecore.Disassemblethecore.

2.Turnthecoreupside-downinordertoremovedebris.

NOTICE

Donotuseahighpressuresprayforcleaningthefinsofthecore.A highpressurespraycandamagethesurfaceofthefinsandreducethe flowofairthroughthecore.

NOTICE

Donotuseahighconcentrationofcausticcleanertocleanthecore.A highconcentrationofcausticcleanercanattacktheinternalmetalsof

thecoreandcauseleakage.Onlyusetherecommendedconcentration ofcleaner.

3.Backflushthecorewithcleaner.

CaterpillarrecommendstheuseofHydrosolvliquidcleaner.ConsultyourCatdealerforthe partnumbersandquantitiesthatareavailable.

Usea2to5percentconcentrationofthecleanerattemperaturesupto93°C(200°F).

4.Steam-cleanthecoreinordertoremoveanyresidue.Flushthefinsoftheaftercoolercore. Removeanyothertrappeddebris.

5.Washthecorewithhot,soapywater.Rinsethecorethoroughlywithcleanwater.

Personalinjurycanresultfromairpressure.

Personalinjurycanresultwithoutfollowingproperprocedure.When usingpressureair,wearaprotectivefaceshieldandprotectiveclothing.

Maximumairpressureatthenozzlemustbelessthan205kPa(30psi) forcleaningpurposes.

6.Drythecorewithcompressedair.Directtheairinthereversedirectionofthenormalflow.

7.Inspectthecoreinordertoensurecleanliness.Pressure-testthecore.Manyshopsthat serviceradiatorsareequippedtoperformpressuretests.Ifnecessary,repairthecore.

8.Installthecore.

Formoreinformationoncleaningthecore,consultyourCatdealer.

FriMay2411:59:44UTC+05302024

Product:MARINEAUXILIARY

Model:3608MARINEAUXILIARY1ZD

Configuration:3608MarineAuxiliaryEngineMilitary1ZD00001-UP

OperationandMaintenanceManual 3608Engine

MediaNumber-SEBU7312-03PublicationDate-01/03/2014DateUpdated-18/03/2014

AirPrelubePumpLubricatorBowl-Clean

SMCS-1319;5507

Personalinjurycanresultfromremovinghosesorfittingsinapressure system.

Failuretorelievepressurecancausepersonalinjury.

Donotdisconnectorremovehosesorfittingsuntilallpressureinthe systemhasbeenrelieved.

NOTICE

Neverallowthelubricatorbowltobecomeempty.Theprelubepump willbedamagedbyalackoflubrication.Ensurethatsufficientoilisin thelubricatorbowl.

1.Shutofftheairsupplytotheprelubesystem.Releasethepressurizedairfromthesystem.

i01357669

Prelubepumplubricator (1)Fillerplug (2)Drainvalve (3)Clamp (4)Retainingring

2.Slowlyremovefillerplug(1)fromtheheadofthelubricatorinordertoreleasethepressure fromthelubricatorbowl.

NOTICE

Caremustbetakentoensurethatfluidsarecontainedduring performanceofinspection,maintenance,testing,adjustingandrepair oftheproduct.Bepreparedtocollectthefluidwithsuitablecontainers beforeopeninganycompartmentordisassemblinganycomponent containingfluids.

RefertoSpecialPublication,NENG2500,"CaterpillarToolsandShop ProductsGuide"fortoolsandsuppliessuitabletocollectandcontain fluidsonCaterpillarproducts.

Disposeofallfluidsaccordingtolocalregulationsandmandates.

3.Placeasuitablecontainerunderthelubricatorbowlandopendrainvalve(2)inorderto drainanyremainingoilfromthebowl.

4.Loosenclamp(3).Toremovethelubricatorbowl,unscrewretainingring(4).

Illustration2g00716538 (4)Retainingring (5)Lubricatorbowl (6)Gasket (7)Wickassembly

5.Removeretainingring(4),lubricatorbowl(5),andgasket(6),andwickassembly(7).

6.Cleanthewickassemblyandthebowlwithnonflammablesolvent.

Note:Theheightofthewickinsidethelubricatorbowldeterminestheamountofoilthatis deliveredbythelubricator.Theheightofthewickforthelubricatorissettothehalf positionatthefactory.Theheightofthewickmustbeadjustedwhenareductioninthe deliveryoftheoilmistisnoticeable.

7.Usethefollowingstepstoadjusttherateoftheoilmist,ifnecessary.

Illustration3g00716721 Wickassembly(7)intheventurioftheheadofthelubricator (8)Wick (9)Locknut (10)Adjustingnut (11)Notch

a.Loosenlocknut(9).

b.Adjusttheheightofwick(8)byturningadjustingnut(10).

Toincreasetheoilmist,raisethewick.Todecreasetheoilmist,lowerthewick.

Notch(11)islocatedontheadjustingnut.Theheightofthewickisvisuallyindicated bytherelativepositionofthenotchtothebottomoflocknut(9).

8.Installwickassembly(7)intolubricatorbowl(5).

9.Inspectgasket(6)forgoodcondition.Ifthegasketisdamaged,obtainanewgasketfor assembly.Installthegasket,lubricatorbowl(7),andretainingring(4).Tightentheretaining ringbyhand.

10.Makesurethatdrainvalve(2)isclosed.Fillthelubricatorbowlthroughtheholeforfiller plug(1)intheheadofthelubricator.

11.InspecttheO-ringsealforfillerplug(1).Ifthesealisdamaged,obtainanewsealfor assembly.Installthesealandthefillerplug.

Product:MARINEAUXILIARY

Model:3608MARINEAUXILIARY1ZD

Configuration:3608MarineAuxiliaryEngineMilitary1ZD00001-UP

OperationandMaintenanceManual

3608Engine

MediaNumber-SEBU7312-03PublicationDate-01/03/2014DateUpdated-18/03/2014 i01358364

AirPrelubePumpLubricatorOilLevel-Check

SMCS-1319;5507

NOTICE

Neverallowthelubricatorbowltobecomeempty.Theprelubepump willbedamagedbyalackoflubrication.Ensurethatsufficientoilisin thelubricatorbowl.

Note:Theheightofthewickinsidethelubricatorbowldeterminestheamountofoilthatis deliveredbythelubricator.Theheightofthewickmustbeadjustedwhenareductioninthe deliveryoftheoilmistisnoticeable.Ifthelubricatorbowlrequiresmorefrequentfilling, theheightofthewickprobablyneedstobeadjusted.Fortheprocedure,seethisOperation andMaintenanceManual,"AirPrelubePumpLubricatorBowl-Clean".

Illustration1g00716875 (1)Sightgauge (2)Fillerplug

1.Observetheoillevelinsightgauge(1).Iftheoillevelislessthan1/2,addoiltothe lubricatorbowl.

Personalinjurycanresultfromremovinghosesorfittingsinapressure system.

Failuretorelievepressurecancausepersonalinjury.

Donotdisconnectorremovehosesorfittingsuntilallpressureinthe systemhasbeenrelieved.

2.EnsurethattheairsupplytothelubricatorisOFF.Slowlyremovefillerplug(2)inorderto releasepressurefromthelubricatorbowl.

3.Removefillerplug(2).Pouroilintotheholeforthefillerplugintheheadofthelubricator. Fillthebowltothetop.

Use"10W"oilfortemperaturesthataregreaterthan0°C(32°F).Useairtooloilfor temperaturesthatarebelow0°C(32°F).

4.InspecttheO-ringsealforthefillerplug.Ifthesealisdamaged,obtainanewsealfor assembly.Installthesealandfillerplug(2).

FriMay2412:00:14UTC+05302024

Product:MARINEAUXILIARY

Model:3608MARINEAUXILIARY1ZD

Configuration:3608MarineAuxiliaryEngineMilitary1ZD00001-UP

OperationandMaintenanceManual

3608Engine

MediaNumber-SEBU7312-03PublicationDate-01/03/2014DateUpdated-18/03/2014 i01223032

AirShutoff-Test

SMCS-1078-081

Theairshutoffmustoperateproperlyincaseanemergencyshutdownisneeded.Testthe operationoftheairshutoff.Itisnotnecessaryfortheenginetobeoperatinginordertotestthe shutoff.

Illustration1g00748151 (1)Knob (2)Resetlever

1.Toactivatetheairshutoff,pullknob(1).

Aplatethatisinsideoftheapparatuswillcovertheairinlet.Thispreventsairfromentering theinletmanifold.

Resetlever(2)shouldmovetothe"CLOSED"position.Ifthisfailstooccur,investigatethe problem.SeetheServiceManual,"DisassemblyandAssembly"topic.

DONOTattempttooperatetheengineiftheairshutoffwillnotactivate.

Note:Theairshutoffmustberesetbeforetheenginecanbestarted.

2.Toresettheairshutoff,moveresetlever(2)tothe"OPEN"position.

FriMay2412:00:48UTC+05302024

Product:MARINEAUXILIARY

Model:3608MARINEAUXILIARY1ZD

Configuration:3608MarineAuxiliaryEngineMilitary1ZD00001-UP

OperationandMaintenanceManual

3608Engine

MediaNumber-SEBU7312-03PublicationDate-01/03/2014DateUpdated-18/03/2014

AirStartingMotorLinesScreen-Clean

SMCS-1451-070-LI

Illustration1g00716268 (1)Plug (2)Screen

1.EnsurethattheairsupplytotheairlinesisOFF.Purgethepressurizedairfromthesystem.

2.Removeplug(1).

3.Carefullyremovescreen(2).Cleanthescreenwithnonflammablesolvent.Inspectthe screenfordamage.Ifthescreenisdamaged,replacethedamagedscreenwithanewscreen.

4.Installclean,dryscreen(2).Cleanplug(1).Installtheplug.

FriMay2412:00:59UTC+05302024

Product:MARINEAUXILIARY

Model:3608MARINEAUXILIARY1ZD

Configuration:3608MarineAuxiliaryEngineMilitary1ZD00001-UP

OperationandMaintenanceManual 3608Engine

MediaNumber-SEBU7312-03PublicationDate-01/03/2014DateUpdated-18/03/2014

AirStartingMotorLubricatorBowl-Clean

SMCS-1451-070

Iftheengineisequippedwithanairstartingmotor,usethefollowingprocedure:

Personalinjurycanresultfromremovinghosesorfittingsinapressure system.

Failuretorelievepressurecancausepersonalinjury.

Donotdisconnectorremovehosesorfittingsuntilallpressureinthe systemhasbeenrelieved.

1.EnsurethattheairsupplytothelubricatorisOFF.

i06049302

Illustration1g03789898

(1)Fillerplug

(2)Bowl

(3)Drainvalve

2.Slowlyloosenfillerplug(1)inordertoreleasethepressurefromthelubricator.

NOTICE

Caremustbetakentoensurethatfluidsarecontainedduring performanceofinspection,maintenance,testing,adjusting,andrepair oftheproduct.Bepreparedtocollectthefluidwithsuitablecontainers beforeopeninganycompartmentordisassemblinganycomponent containingfluids.

RefertoSpecialPublication,NENG2500,"DealerServiceTool Catalog"fortoolsandsuppliessuitabletocollectandcontainfluidson Catproducts.

Disposeofallfluidsaccordingtolocalregulationsandmandates.

3.Placeasuitablecontainerunderbowl(2)andopendrainvalve(3)inordertodraintheoil fromthebowl.

4.Removebowl(2).Cleanthebowlwithwarmwater.

5.Drythebowl.Inspectthebowlforcracks.Ifthebowliscracked,replacethedamagedbowl withanewbowl.Inspectthegasket.Ifthegasketisdamaged,replacethegasket.

6.Installthebowl.

7.Makesurethatdrainvalve(3)isclosed.

8.Forinstructionsonfillingthelubricator,seethisOperationandMaintenanceManual,"Air StartingMotorLubricatorOilLevel-Check"topic.

FriMay2412:01:11UTC+05302024

Product:MARINEAUXILIARY

Model:3608MARINEAUXILIARY1ZD

Configuration:3608MarineAuxiliaryEngineMilitary1ZD00001-UP

OperationandMaintenanceManual 3608Engine

MediaNumber-SEBU7312-03PublicationDate-01/03/2014DateUpdated-18/03/2014 i06049122

AirStartingMotorLubricatorOilLevel-Check

SMCS-1451-535

NOTICE

Neverallowthelubricatorbowltobecomeempty.Theairstarting motorwillbedamagedbyalackoflubrication.Ensurethatsufficient oilisinthelubricatorbowl.

Illustration1g03789862

1.Observetheoillevelinsightgauge(3).Iftheoillevelislessthan1/2,addoiltothe lubricatorbowl.

Personalinjurycanresultfromremovinghosesorfittingsinapressure system.

Failuretorelievepressurecancausepersonalinjury.

Donotdisconnectorremovehosesorfittingsuntilallpressureinthe systemhasbeenrelieved.

2.EnsurethattheairsupplytothelubricatorisOFF.Slowlyloosenfillerplug(4)inorderto releasepressurefromthelubricatorbowl.

3.Removefillerplug(4).Pouroilintothelubricatorbowl.UsenondetergentSAE10Woil fortemperaturesthataregreaterthan0°C(32°F).Useairtooloilfortemperaturesthatare below0°C(32°F).

4.Installfillerplug(4).

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