AftercoolerCondensation-Drain
SMCS-1063
i08173093
Theaftercoolercoolsthecompressedair/fuelmixturefromtheturbocharger.Coolantpasses throughthetubesintheaftercoolercore.Theair/fuelmixturethatiscompressedandwarmedby theturbochargercompressorisdirectedthroughtheaftercoolercore.Theair/fuelmixtureis cooledintheaftercooler.
Condensationcanforminthehousingoftheaftercooler.Adrainplugisprovidedfordrainingthe condensation.
Note:Anautomaticdrainisavailableforusewith32°C(90°F)separatecircuitaftercoolers. ConsultyourCatdealerfordetails.
Illustration1g00786820 (1)Plug
Removeplug(1).Drainthemoistureintoasuitablecontainer.Installtheplug.
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Product:GASENGINE
Model:G3516GASENGINEWPW
Configuration:G3516EngineWPW00001-UP
OperationandMaintenanceManual G3500Engines
MediaNumber-SEBU8099-08PublicationDate-01/07/2014DateUpdated-01/05/2019
AirStartingMotorLubricatorBowl-Clean
SMCS-1451-070
Iftheengineisequippedwithanairstartingmotor,usethefollowingprocedure:
Personalinjurycanresultfromremovinghosesorfittingsinapressure system.
Failuretorelievepressurecancausepersonalinjury.
Donotdisconnectorremovehosesorfittingsuntilallpressureinthe systemhasbeenrelieved.
1.EnsurethattheairsupplytothelubricatorisOFF.
i08272007
Illustration1g06610184 (1)Fillerplug (2)Bowl (3)Drainvalve
2.Slowlyloosenfillerplug(1)toreleasethepressurefromthelubricator.
NOTICE
Caremustbetakentoensurethatfluidsarecontainedduring performanceofinspection,maintenance,testing,adjusting,andrepair oftheproduct.Bepreparedtocollectthefluidwithsuitablecontainers beforeopeninganycompartmentordisassemblinganycomponent containingfluids.
RefertoSpecialPublication,PERJ1017,"DealerServiceTool Catalog"fortoolsandsuppliessuitabletocollectandcontainfluidson Cat®products.
Disposeofallfluidsaccordingtolocalregulationsandmandates.
3.Placeasuitablecontainerunderbowl(2)andopendrainvalve(3)todraintheoilfromthe bowl.
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.
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Product:GASENGINE
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OperationandMaintenanceManual
G3500Engines
MediaNumber-SEBU8099-08PublicationDate-01/07/2014DateUpdated-01/05/2019
AdjusttheLubricator
Note:Adjustthelubricatorwithaconstantrateofairflow.Aftertheadjustment,thelubricator willreleaseoilinproportiontovariationsoftheairflow.
1.EnsurethatthefuelsupplytotheengineisOFF.
NOTICE
Donotcranktheenginecontinuouslyformorethan30seconds.Allow thestartingmotortocoolfortwominutesbeforecrankingtheengine again.
2.Operatetheairstartingmotor.Observethedropsofoilthatarereleasedindome(1).
Note:Somelubricatorshaveanadjustmentscrewratherthanaknob.
3.Ifnecessary,adjustthelubricatortoreleasefrom1to3dropsofoilpersecond.Toincrease therate,turnknob(2)counterclockwise.Todecreasetherate,turntheknobclockwise.
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OperationandMaintenanceManual G3500Engines
MediaNumber-SEBU8099-08PublicationDate-01/07/2014DateUpdated-01/05/2019 i08233915
AirTankMoistureandSediment-Drain
SMCS-1466-543-M&S
Moistureandsedimentintheairstartingsystemcancausethefollowingconditions:
•Freezing
•Corrosionofinternalparts
•Malfunctionoftheairstartingsystem
Whenopeningthedrainvalve,wearprotectivegloves,aprotectiveface shield,protectiveclothing,andprotectiveshoes.Pressurizedaircould causedebristobeblownandresultinpersonalinjury.
NOTICE
Caremustbetakentoensurethatfluidsarecontainedduring performanceofinspection,maintenance,testing,adjusting,andrepair oftheproduct.Bepreparedtocollectthefluidwithsuitablecontainers beforeopeninganycompartmentordisassemblinganycomponent containingfluids.
RefertoSpecialPublication,NENG2500,"CatDealerServiceTool Catalog"orrefertoSpecialPublication,PECJ0003,"CatShop SuppliesandToolsCatalog"fortoolsandsuppliessuitabletocollect andcontainfluidsonCatproducts.
Disposeofallfluidsaccordingtolocalregulationsandmandates.
1.Openthedrainvalvethatisonthebottomoftheairtank.Allowthemoistureandsediment todrain.
2.Closethedrainvalve.
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Product:GASENGINE
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OperationandMaintenanceManual G3500Engines
MediaNumber-SEBU8099-08PublicationDate-01/07/2014DateUpdated-01/05/2019
Alternator-Inspect
SMCS-1405-040
Inspectthealternatorforthefollowingconditions:
•Properconnections
•Cleanportsforcoolingairflow
•Properchargingofthebattery
i08233932
Observetheammeterduringengineoperationtoensureproperbatteryperformanceand/orproper performanceoftheelectricalsystem.
Makerepairs,ifnecessary.SeetheServiceManualforserviceprocedures.ConsultyourCat dealerforassistance.
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OperationandMaintenanceManual G3500Engines
MediaNumber-SEBU8099-08PublicationDate-01/07/2014DateUpdated-01/05/2019
BatteryElectrolyteLevel-Check
SMCS-1401-535-FLV
Whentheenginehasnotrunforlongorshortperiodsoftime,thebatteriesmaynotfullyrecharge. Ensureafullchargetohelppreventthebatteryfromfreezing.
Inwarmerclimates,checktheelectrolytelevelmorefrequently.
Ensurethattheelectrolytelevelis13mm(0.5inch)abovethetopoftheseparators.
Alllead-acidbatteriescontainsulfuricacidwhichcanburntheskinand clothing.Alwayswearafaceshieldandprotectiveclothingwhen workingonornearbatteries.
1.Removethefillercaps.Maintaintheelectrolyteleveltothe"FULL"markonthebattery.
Iftheadditionofwaterisnecessary,usedistilledwater.Ifdistilledwaterisnotavailable, usecleanwaterthatislowinminerals.Donotuseartificiallysoftenedwater.
2.Checktheconditionoftheelectrolytewiththe245-5829CoolantBatteryTester Refractometer.
3.Keepthebatteriesclean.
Cleanthebatterycasewithoneofthefollowingcleaningsolutions:
Amixtureof0.1kg(0.2lb)ofbakingsodaand1L(1qt)ofcleanwater
Amixtureof0.1L(0.11qt)ofammoniaand1L(1qt)ofcleanwater
Thoroughlyrinsethebatterycasewithcleanwater.
i08265744
Usethe1U-9921BatteryServiceTooltocleanthebatteryterminals.Useawirebrushto cleanthecableclamps.Cleantheitemsuntilthesurfacesarebrightorshiny.DONOT removematerialexcessively.Excessiveremovalofmaterialcancausetheclampstofit improperly.CoattheclampsandtheterminalswiththeLoctite®productlistedbelow, petroleumjellyorMPGM.
ForAmericasNorth-LoctiteLB8632
ForEuropeandAfrica,MiddleEast,CIS(AMEC)-LoctiteLB8104
ForAsiaPacific-LoctiteLB8801
ForAmericasSouth-LoctiteLBSuperlube
Fororderingtheproductslistedabove,gotothefollowingaddress. http://www.loctite.com/en/meta/meta-nav/location-selector.html
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OperationandMaintenanceManual
G3500Engines
MediaNumber-SEBU8099-08PublicationDate-01/07/2014DateUpdated-01/05/2019
Belts-Inspect/Adjust/Replace
SMCS-1357-025;1357-040;1357-510
Inspection
i08259812
Inspectthealternatorbeltandthefandrivebeltsforwearandforcracking.Replacethebeltsifthe beltsarenotingoodcondition.
CheckthebelttensionaccordingtotheinformationintheServiceManual,"Specifications".
Slippageofloosebeltscanreducetheefficiencyofthedrivencomponents.Vibrationofloose beltscancauseunnecessarywearonthefollowingcomponents:
•Belts
•Pulleys
•Bearings
Ifthebeltsaretootight,unnecessarystressisplacedonthecomponents.Beltsthataretootight reducestheservicelifeofthecomponents.
AdjustingtheAlternatorBelt
Typicalalternator
(1)Mountingbolt
(2)Adjustingnuts (3)Mountingbolt
1.Loosenmountingbolt(1),adjustingnuts(2),andmountingbolt(3).
2.Turnadjustingnuts(2)toincreaseordecreasethedrivebelttension.
3.Tightenadjustingnuts(2).Tightenmountingbolt(3).Tightenmountingbolt(1).Forthe propertorque,seetheServiceManual,"Specifications"module.
Note:Ifnewdrivebeltsareinstalled,checkthedrivebelttensionagainafter30minutesof engineoperationattheratedrpm.
4.Stoptheengine.
5.Usethe491-2178Belttensionmetertooltocheckthetensionwiththealternatorguard installed.
Note:Thecurrentguarddesignallowsforinspectionofthebelttensionwithoutremovalof theguard.
AdjustingtheFanDriveBelt
1.Loosenthemountingboltforthepulley.
2.Loosentheadjustingnutforthepulley.
3.Movethepulleytoadjustthebelttension.
4.Tightentheadjustingnuttothepropertorque.
5.Tightenthemountingbolttothepropertorque.
Forthepropertorquespecifications,refertotheServiceManual,"Specifications"module.
Replacement
Forapplicationsthatrequiremultipledrivebelts,replacethedrivebeltsinmatchedsets. Replacingonedrivebeltofamatchedsetwillcausethenewdrivebelttocarrymoreloadbecause theolderdrivebeltsarestretched.Theadditionalloadonthenewdrivebeltcouldcausethenew drivebelttofail.
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Product:GASENGINE
Model:G3516GASENGINEWPW
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OperationandMaintenanceManual
G3500Engines
MediaNumber-SEBU8099-08PublicationDate-01/07/2014DateUpdated-01/05/2019
CarburetorAir/FuelRatio-Check/Adjust
SMCS-1266-535;1266
i02754415
Anenginefailuremayoccuriftheair/fuelratioisnotappropriateforthefuelandfortheoperating conditions.Theservicelifeoftheturbocharger,ofthevalves,andoftheothercomponentsmaybe reduced.
Ensurethatthecarburetorisadjustedproperlysothattheair/fuelratioiscorrect.Anemissions analyzermustbeusedinordertomeasureexhaustemissions.Anemissionsanalyzerthatis capableofmeasuringNOandNO2separatelymustbeusedinordertochecktheair/fuelratio.An emissionsanalyzerthatiscapableofmeasuringNOandNO2separatelymustbeusedinorderto analyzetheair/fuelratio.Theemissionsanalyzerthatisusedforcalibrationoftheenginemustbe accuratewithintenpercentofastandardwhiletheengineisrunningatthedesiredemissionslevel forNOx.CalibratetheemissionsanalyzerfortheNOandfortheNO2inordertomaintainthis accuracylevel.Ifanychangesaremadetotheenginetimingortothesettingsofthewastegate, theratioofairtofuelmustbechecked.Theratioofairtofuelmustthenbeadjustedwithan emissionsanalyzer.
Inordertomaintaintheproperemissions,recalibratetheO2sensororrecalibratetheNOxsensor.
Forinformationonadjustingthecarburetor,refertotheServiceManual,"Systems Operation/TestingandAdjusting",orrefertotheSpecialInstruction,"InstallationandInitialStartUpProcedure".
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OperationandMaintenanceManual G3500Engines
MediaNumber-SEBU8099-08PublicationDate-01/07/2014DateUpdated-01/05/2019 i02209116
CoolingSystemCoolant(NGEC)-Change
SMCS-1350-044
Cleanthecoolingsystembeforetherecommendedmaintenanceintervalifthefollowing conditionsexist:
•Theengineoverheatsfrequently.
•Foamingisobserved.
•Engineoilhasenteredthecoolingsystemandthecoolantiscontaminated.
NOTICE
Useofcommerciallyavailablecoolingsystemcleanersmaycause damagetocoolingsystemcomponents.Useonlycoolingsystem cleanersthatareapprovedforCaterpillarengines.
CleantheCoolingSystem
1.Afterthecoolingsystemhasbeendrained,flushthecoolingsystemwithcleanwaterin ordertoremoveanydebris.
2.Closethecoolingsystemdrainvalves(ifequipped).Cleanthedrainplugsandinstallthe drainplugs.
NOTICE
Fillthecoolingsystemnofasterthan19L(5USgal)perminuteto avoidairlocks.
NOTICE
Iftheaftercoolercircuithasbeendrained,theventplugmustbe openedtoallowtheaftercoolertofillproperly.Failuretodothiswill causeanairlockresultinginenginedamage.
Ventplug
Theventlineoftheebullientcooledenginewillbeinstalledbythecustomer. Ifacustomerhasnotinstalledtheventlines,loosentheventcapfromthetee.
3.Removeventplug(4)fortheaftercooler.
4.FillthecoolingsystemwithamixtureofcleanwaterandCaterpillarFastActingCooling SystemCleaner.Add.5L(1pint)ofcleanerper15L(4USgal)ofthecoolingsystem capacity.Installthecoolingsystemfillercap.Installventplug(4).
5.Starttheengine.Operatetheengineforaminimumof30minuteswithacoolant temperatureofatleast82°C(180°F).
6.Stoptheengineandallowtheenginetocool.Loosenthecoolingsystemfillercapslowlyin ordertorelieveanypressure.Removethecoolingsystemfillercap.Openthecooling systemdrainvalves(ifequipped)orremovedrainplugs(1),(2),and(3).SeeIllustration1.
NOTICE
Improperorincompleterinsingofthecoolingsystemcanresultin damagetocopperandothermetalcomponents.
Toavoiddamagetothecoolingsystem,makesuretocompletelyflush thecoolingsystemwithclearwater.Continuetoflushthesystemuntil allsignsofthecleaningagentaregone.
Note:Thecleanerhasasmellofammonia.Continuetoflushthecoolingsystemuntilthe smellisgone.
7.Allowthewatertodrain.Flushthecoolingsystemwithcleanwateruntilthewaterthat drainsisclean.Closethecoolingsystemdrainvalves(ifequipped).Cleanthedrainplugs andinstallthedrainplugs.
CleaningaCoolingSystemthathasHeavyDepositsor Plugging
Note:Forthefollowingproceduretobeeffective,theremustbeanactiveflowthroughthe coolingsystemcomponents.
1.Afterthecoolingsystemhasbeendrained,flushthecoolingsystemwithcleanwaterin ordertoremoveanydebris.
2.Closethecoolingsystemdrainvalves(ifequipped).Cleandrainplugsandinstalldrain plugs(1),(2),and(3).SeeIllustration1.
NOTICE
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