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Service TrainingMALAGA
3600 Engines - Basic
STUDENTBOOK
ThorbenMARCH 1998
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DESCRIPTION
CONTENTS
AUDIENCE
PREREQUISITE
EQUIPMENT
COURSE ACTIVITIES
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 basicoperation of the engine systems and goes through disassembly,
assembly and adjusting procedures for the major areas of theengine.
The practical part of the class will be held on a 3612 engine (non-running).
The Student book contents 5 chapters and is covering:- Introduction to 3600 engines
- Lubrication system- Air intake & exhaust system- Fuel system- Cooling system
This course is designed for dealer and customer personnel who willbe servicing 3600 engines.
Good theoretical and practical understanding of diesel engines andcorrect mechanical procedures.
Safety glasses and safety shoes (or hard leather shoes) are
required.Work clothing is suggested because of hands-on exercises on theengine.
During the course the students will participate following tasks:
1. Locate all engine components.2. Utilize hydraulic assembly and disassembly tooling.
3. Remove and install a cylinder head.4. Remove and install a piston, connecting rod and cylinder liner.5. Remove and install a main bearing.6. Remove and install a camshaft segment and time the
camshaft(s) to the crankshaft.
COURSE OBJECTIVES
CHAPTER : Description
3600 Engines - Basic
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LITERATURE
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.
SENR3593-01 SYSTEM OPERATIONTESTING & ADJUSTING (3612 & 3616)
SENR3594-03 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 halfday 3 hours.
COURSE OBJECTIVES
CHAPTER : Description
3600 Engines - Basic
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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..............................................................................................................
CHAPTER : Description
3600 Engines - Basic
4Page:
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Service TrainingMALAGA
3600 Engines - Basic
ThorbenMARCH 1998
I. INTRODUCTION
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3600 engine specifications
CHAPTER : Introduction
3600 Engines - Basic
2Page:
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 engine specifications
CHAPTER : Introduction
3600 Engines - Basic
3Page:
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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Engine components
CHAPTER : Introduction
3600 Engines - Basic
4Page:
The picture above shows a 3616 engine.
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Engine components
CHAPTER : Introduction
3600 Engines - Basic
5Page:
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 havebeen shown on page 4.
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Engine components
CHAPTER : Introduction
3600 Engines - Basic
6Page:
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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CHAPTER : Introduction
3600 Engines - Basic
7Page:
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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CHAPTER : Introduction
3600 Engines - Basic
8Page:
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 themlocate the different components and fill out page 7.
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OIL
Service TrainingMALAGA
3600 Engines - Basic
ThorbenMARCH 1998
II. LUBRICATION SYSTEM
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CHAPTER : Lubrication system
3600 Engines - Basic
2Page:
Oil coolers
Oil coolers
Oil temp. reg.
Inlet water
3 Filter elements
3 Filter elements
Filter changevalve
Return water
Vent
Vent
By-pass valve Relief valve63 psi 145 psi
Oilpan
Priority valve
Coolin jetflow 20 psi
Main oilmanifold &bearings
Oilpan
Centrifugal filterNo flow under 15 psi
Check valve
Prelubepump
Mainoilpump
StrainerOil pan
Breather
Oil flow
Unfiltered oil
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CHAPTER : Lubrication system
3600 Engines - Basic
3Page:
Instructor notes
Oil system
Priority valve
Suction screen
Temperatureregulators
Oil filters
Prelubrication
Two methods ofprelubing
Continuous
Intermittent
Let students make the qiuz (see transparencysection). Give them about 5 min. and then showthem how the system should look like. Explain lubesystem and the function of the differentcomponents.
Oil system provides a constant supply of 85 C (185F) filtered oil at 430 kPa (62.4 psi) pressure.
An oil priority valve regulates oil preesure at thecylinder block oil manifold rather than at the oilpump. This makes the oil manifold pressureindependent of oil filter and oil cooler pressuredrops.
Oil to the oil pump passes through a 650 micron(0.025 in.) screen located between the suction belland the suction tube.
Oil temperature regulators direct the oil to coolersat oil temperatures above 85 C ( 185 F).
From the 20 microns (0.78 mils) final filters the oilflows through the priority valve to drilled oilpassages in the cylinder block.
Prelubrication is required for all 3600 enginesbefore each start.
Two methods are available: intermittent andcontinuous.
Continuous prelubrication occurs in stand-bysituations.
Intermittent prelubrication occurs for a shortinterval preceding engine start and provides oil to
all the engine bearings. A pressure switch andstarter interlock prevent starter operation with lessthan 10 kPa (1.5 psi) lube system pressure.
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CHAPTER : Lubrication system
3600 Engines - Basic
4Page:
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CHAPTER : Lubrication system
3600 Engines - Basic
5Page:
Priority valve
The priority valve senses filtered oil pressure and bypasses or dumps unfilteredoil back to the oil sump to control the engine oil pressure.
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Centrifugal filters
CHAPTER : Lubrication system
3600 Engines - Basic
6Page:
The centrifugal oil filters extend the life of the oil filter elements and remove someparticles 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.
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CHAPTER : Lubrication system
3600 Engines - Basic
7Page:
Slides
LEGV0928 - #19
Show slides and explain the functions of thedifferent components of the lube system.
Oil pump - the oil pump is driven approximately 1.5times engine speed. The components of the pumpare the same for both standard and reverserotation. An oil pump can not be removed from astandard rotation engine and installed directly to areverse rotation engine or visa versa. A single
dowel pin in the mounting flange prevents thepump from being rotated 1800 degrees andinstalled.
Oil pump - standrad rotation.
Oil pump - reverse rotation.
Air operated prelube pump.
Electric prelube pump - pumps can be providedwith 115/230 VAC, 50/60 Hz single phase motor.They also can be equipped with 24 VDC or 60/70VDC motors. Higher voltage 3 phase motors areavailable for continuous prelubrication systems.
Oil temperature regulators.
Oil filters - (Duplex filters) There are two oil filterhousings on all 3600 engines with three replaceablefilter elements in each housing. An oil filter changevalve allows the filter elements for each filterhousing to be changed separatly while the engine isoperating. The maximum change period is 1000hours or when the oil filter pressure drop reaches104 kPa (15 psi).
Oil filter elements.
Priority valve.
LEGV3823 - #90
LEGV3823 - #91
LEGV0928 - #20
LEGV0928 - #20
LEGV0928 - #22
LEGV0928 - #23
LEGV0928 - #27
LEGV0928 - #30
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CHAPTER : Introduction
3600 Engines - Basic
8Page:
Slides
LEGV0928 - #34 Vee engine cylinder block - Three oil manifolds. Theone at the center supplies the main and camshaftbearings. The two outer manifolds supply thepiston cooling spray jets.
Piston cooling jet.
Inlet valve lube metering pump - injects a smallamount of oil into the inlet manifold where it is
mixed with the intake air to lubricate the inlet valvesand valve seats to reduce wear.
Disassembled centrifugal oil filter.
Show students the flow of the oil and the lubsystem components on the engine.
Do lab exercises with students (page 9)
LEGV0928 - #36
LEGV0928 - #37
LEGV0928 - #44
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Lab exercises
CHAPTER : Lubrication system
3600 Engines - Basic
9Page:
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 TrainingMALAGA
3600 Engines - Basic
ThorbenMARCH 1998
III. AIR INTAKE & EXHAUSTSYSTEM
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CHAPTER : Intake & exhaust system
3600 Engines - Basic
2Page:
Instructor notes
LEGV0928 - #59
Explain general air flow of the engine and showslides about engine aftercooler.
For optimum engine performance and low fuelconsumption, two exhaust manifold designs areused on the 3600 family of engines.
A divided or split exhaust manifold system isinstalled on the 3606 and 3612 diesel engines. Theturbocharger(s) used with this manifold design hasa double entry inlet.
A single larger diameter exhaust manifold designwith single inlet into the turbocharger is used with3608, 3616 and all spark ignited (gas) engines.
In-line aftercooler core - mounted on theleft side ofthe engine.
In-line cylinder block - with cast-in inlet manifold.
Vee engine aftercooler core - mounted above thecenter of the vee.
Location of vee engine aftercooler & air shutoff. Anair shutoff is available for installation at theaftercooler inlet. The air shutoff is closed only whenan overspeed occurs or when an emergencyshutdown is initiated.
LEGV0928 - #60
LEGV0928 - #62
LEGV0928 - #61
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Camshaft 3612 engine
CHAPTER : Intake & exhaust system
3600 Engines - Basic
3Page:
C A BBC
Rear end
C A BBC
Install the camshaft journals with the annular groove toward the front of theengine for both standard (CCW) rotation and reverse (CW) rotation engines.
Install the camshaft segments with the groove toward the front of the engine forstandard (CCW) rotation engines.
Install the camshaft segments with the groove toward the rear of the engine forreverse (CW) rotation engines.
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CHAPTER : Intake & exhaust system
3600 Engines - Basic
4Page:
Instructor notes
Camshaft
Talk about camshaft segments and journals.
The camshaft is running half the speed of thecrankshaft. The camshaft is with the help of pushrods and rocker arms activating the air inlet andexhaust valves and the unit injector.
The camshafts in all 3600 engines are segmented.Each cylinder has its own segment but all the
segments are the same. On Vee engines thesegments in the left side are different than those inthe right side.
The segments in the in-line engine will be the sameas the segments in the left or rigth of the Veeengine, depending on whether it is a standard orreverse rotation engine. Therefor there are basicallytwo camshaft part numbers to service both in-line
and Vee distillate fuel engines. Heavy fuel enginecamshafts may be different.
Camshaft segments installed on diesel enginesbefore mid-1990 have thinner flanges and spacers.The bolts are also smaller.
Camshaftsegmented
In-line uses samepart as Vee
Earlier camsegments
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Cam segment trim
CHAPTER : Intake & exhaust system
3600 Engines - Basic
5Page:
E
C
A
B
D
G F
Annular groove
Dowel
Dowel holelocations
Dowel hole
locations
Dowel
At present there are three different kinds of camshaft segments. The differencebetween them is the number and the location of the dowel holes.
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CHAPTER : Intake & exhaust system
3600 Engines - Basic
6Page:
Instructor notes
Cam journals
Explain trimming of camshaft journals.
There are three different kinds of cam journals: onewith 5 dowel holes, one with 3 dowel holes and onewith 2 dowel holes.
When you order a camshaft journal you will get aplain journal and two dowels.
Show slides about camshaft segments, journals,their removal and about rocker arm assembly andvalves.
Camshaft segment, two spacers and camshaft rearjournal.
Camshaft journal - with 5 dowel holes.
Camshaft segment removal tool.
Camshaft segment removal.
Valve lifter group.
Cylinder head - shows air intake and rocker armassembly.
Bottom side of cylinder head - shows intake &exhaust valves.
Let students remove two cam segments, three camjournals and one cam bearing.
Journal trimming
LEGV0928 - #65
LEGV0928 - #66
LEGV0928 - #67
LEGV0928 - #69
LEGV0928 - #71
SESV1535 - #49
LEGV0928 - #80
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Lab exercises
CHAPTER : Intake & exhaust system
3600 Engines - Basic
7Page:
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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CHAPTER : Intake & exhaust system
3600 Engines - Basic
8Page:
Cylinder head removal
Pedestall
Hydrauliccylinder
Collar
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CHAPTER : Intake & exhaust system
3600 Engines - Basic
9Page:
Cylinder head removal
Piston
CylinderStud
Pedestall
Nut
Washer
Cylinder head
CollarCover
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CHAPTER : Intake & exhaust system
3600 Engines - Basic
10Page:
Instructor notes
LEGV0928 - #94
Explain removal of cylinder head. Show followingslides:
Cylinder head removal tool - hydraulic cylinder.
Hydraulic hoses.
Hydraulic cylinders installed on cylinder head.
Hydraulic pump.
Loosening procedure of cylinder head nut.
Lifting device for cylinder head.
Cylinder head - with Kiney valve. The Kiney valve isfor manual relief of cylinder pressure.
Explain removal of unit injector and valve springsand explain messure method of combustion ringand valve springs for reusebility. Show followingslides:
Unit injector removal.
Combustion ring.
Let students remove a cylinder head and
disassemble / assemble it. Let them also check thecombustion ring and the valve springs.
LEGV0928 - #96
LEGV0928 - #95
LEGV0928 - #97
LEGV0928 - #98
LEGV0928 - #101
LEGV0928 - #81
LEGV0928 - #85
8097 - #50
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Lab exercises
CHAPTER : Intake & exhaust system
3600 Engines - Basic
11Page:
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 TrainingMALAGA
3600 Engines - Basic
ThorbenMARCH 1998
IV. COOLING SYSTEM
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CHAPTER : Cooling system
3600 Engines - Basic
2Page:
Instructor notes
Two coolingsystems
Caterpillar is providing two cooling systems:Combined circuit cooling & separate circuit cooling.
Temperatures in the two systems are the same.
50 C (122 F) nominal water temperature to the ACand OC (DFE).
32 C (90 F) nominal water temperature to the AC
and OC (HFE).
90 C (194 F) nominal jacket water temperature to thecylinder block circuit (DFE).
93 C (199 F) nominal jacket water temperature to thecylinder block circuit (HFE).
85 C (185 F) nominal oil to bearing temperature.
Over time, as the performance of the heatexchanger decreases due to fouling, the watertemperature to the AC will increase. At higherambient conditions, the water to the AC and OC isallowed to rise to 65 C (149 F) for DFE or 38 C (100F) for HFE maximumbefore engine deration isrequired.
System temeratures
Basic operatingparameters
Max. temperatures
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CHAPTER : Cooling system
3600 Engines - Basic
3Page:
AC/OCPump
Cylinder Block,Head & Turbo
Heat
Exchanger
ExpansionTank
JWPump
A
B
C
C
D
D
D
(3612/3616)(3606/3608)
E
E
Oil Cooler
Aftercooler
D
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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CHAPTER : Cooling system
3600 Engines - Basic
4Page:
Instructor notes
Advantagecombined system
The combined circuit system is also known as thesingle circuit - two pump system.
The main advantage of the combined circuit systemis that it requires only one external cooling circuitwith only one heat exchanger or radiator. There isless coolant and cooling system piping can berelatively simple.
Combined system
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3600 Engines - Basic
5Page:
CHAPTER : Cooling system
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CHAPTER : Cooling system
3600 Engines - Basic
6Page:
H
eat
E
xchanger
(A
C/OCCircuit)
C
AC/OCPump
C
ExpansionTank
Cylinder Block,Head & Turbo
D
D
F
JWPump
F
Oil Cooler
Aftercooler
D
Heat
Exchanger
(JWC
ircuit)
E
E
VentLine
MakeupLine
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
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CHAPTER : Cooling system
3600 Engines - Basic
7Page:
Instructor notes
Makeup line(separate circuit)
The only connection between the AC / OC circuitand the engine jacket water circuit is a makeup linethat goes from the expansion tank to the waterpump supply line. This line keeps the AC / OCcircuit filled when it shares the expansion tank withthe jacket water circuit. There is no active flowbetween the circuits.
The total radiator surface area may be 20 % less at45 C (110 F) ambient and up to 30 % less at higherambients, when compared to a combined circuit.
Maintains nominal water temperature to the AC andOC while rejecting heat from the cylinder block andheads at higher temperatures.
The total external flow is approximately twice theexternal flow of the single circuit system. Half of the
flow (high temperature circuit) must be cooled tonominal jacket water temperature and the lowtemperature circuit cooled to nominal AC / OCwater temperature.
Advantage separatesystem
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CHAPTER : Cooling system
3600 Engines - Basic
8Page:
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CHAPTER : Cooling system
3600 Engines - Basic
9Page:
Instructor notes
LEGV0928 - #109
Explain combined and separate circuit coolingsystems.
Show slides about piston and liner removal andpiston assembly disassembling.
Connecting rod cap bolts.
Lower the connecting rod cap.
Install crank protectors.
Piston $ connecting rod assembly.
Removal of piston retaining rings.
Piston pin guide.
Piston ring removal.
Measure piston and rings.
Cylinder liner removal tool.
Installation of liner removal tool.
Remove piston and liner and disassemble pistonassembly.
Show and explain the three kinds of different liners.
LEGV0928 - #110
LEGV0928 - #111
LEGV0928 - #115
LEGV0928 - #117
LEGV0928 - #118
LEGV0928 - #119
LEGV0928 - #120
LEGV0928 - #121
LEGV0928 - #123
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Lab exercises
CHAPTER : Cooling system
3600 Engines - Basic
10Page:
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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DIESEL
Service TrainingMALAGA
3600 Engines - Basic
ThorbenMARCH 1998
V. FUEL SYSTEM
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CHAPTER : Fuel system
3600 Engines - Basic
2Page:
Secondaryfuel filterelements
Secondaryfuel filterelements
Filterchangevalve
Pressurereliefvalve
Relief valve
Handprimingpump
Checkvalve
Mainfuelpump
Mainfuel tank
PrimaryFuel filters
Checkvalve
Checkvalve
Checkvalve
Checkvalve
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CHAPTER : Fuel system
3600 Engines - Basic
3Page:
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CHAPTER : Fuel system
3600 Engines - Basic
4Page:
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CHAPTER : Fuel system
3600 Engines - Basic
5Page:
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CHAPTER : Fuel system
3600 Engines - Basic
6Page:
Storage forzero-ing pin
Power settingscrew underthis cover
Install zero-ing
pin here
Location fordial gage
See detailbelow
Link togovernor
Rack
Adjustment screwfor rack zero settinginside
Spring loadedlink
To otherinjectors
Control bar
Bolted anddoweled
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Injector synchronization
CHAPTER : Fuel system
3600 Engines - Basic
7Page:
A
B
C
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 thegauge 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. DONT DO THIS !!
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LAB EXERCISES
CHAPTER : Fuel system
3600 Engines - Basic
8Page:
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 TrainingMALAGA
3600 Engines - Basic
ThorbenMARCH 1998
PRE-/POSTTEST
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CHAPTER : PRE-TEST
3600 Engines - Basic
2Page:
1. When is the Caterpillar Dinner this week ?
2. When the engine is at top center #1 cylindercompression stroke, how many injectors can be timedwithout turning the crankshaft ?
___ALL
___1/2
___NONE
___NONE OF THE ABOVE
3. The fuel linkage has to be set in the reference positionfor ALL limkage adjustments.
(T or F)
4. The valve bridges need to be adjusted every time thevalve lash is adjusted.
(T or F)
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CHAPTER : PRE-TEST
3600 Engines - Basic
3Page:
5. Why must the linkage be adjusted between the governorand 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 rotatingthe crankshaft.
(T or F)
7. Holes have to be drilled and tapped in the top of a pistonbefore it can be removed.
(T or F)
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CHAPTER : PRE-TEST
3600 Engines - Basic
4Page:
8. When installing a piston, a V(or X) mark on thepiston must be aligned with a V (or X) mark stampedon 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 headsis:
___30,000 kPa (4350 psi)
___35,000 kPa (5075 psi)
___40,000 kPa (5800 psi)
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CHAPTER : PRE-TEST
3600 Engines - Basic
5Page:
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 enginerunning, 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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CHAPTER : PRE-TEST
3600 Engines - Basic
6Page:
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 oilpressure 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 cannot be made to work on a standard rotation engine.
(T or F)
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CHAPTER : PRE-TEST
3600 Engines - Basic
17. The gauges in the oil filter covers measure oil filterdifferential 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 sideare different than those in the right side.
(T or F)
20. The camshaft segments in the in-line engine will be thesame as the segments in the left or right side of the Veeengine, depending on whether it is a standard or reverse
rotation engine.
(T or F)
21 H li t d C t ill id ?