_instruct Motor Basico

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MALAGA

3600 Engines - Basic

STUDENT

BOOK

Thorben MARCH 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 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 (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 will be servicing 3600 engines.

Good theoretical and practical understanding of diesel engines and correct mechanical procedures.

Safety glasses and safety shoes (or hard leather shoes) are required.

Work clothing is suggested because of “hands-on” exercises on the engine.

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.

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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 OPERATION

TESTING & 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 half day 3 hours.

COURSE OBJECTIVES

CHAPTER : Description

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MALAGA

3600 Engines - Basic

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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

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3600 engine specifications

CHAPTER : Introduction

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

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Engine components

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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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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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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

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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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OIL

MALAGA

3600 Engines - Basic

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Oil coolers

Oil coolers Oil temp. reg.

Inlet water 3 Filter elements 3 Filter elements Filter change valve Return water Vent Vent

By-pass valve Relief valve

63 psi 145 psi Oil pan Priority valve Coolin jet flow 20 psi Main oil manifold & bearings Oil pan Centrifugal filter No flow under 15 psi

Check valve Prelube pump Main oil pump Strainer Oil pan Breather Oil flow Unfiltered oil

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CHAPTER : Lubrication system

Instructor notes

Oil system Priority valve Suction screen Temperature regulators Oil filters Prelubrication Two methods of prelubing Continuous Intermittent

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 provides a constant supply of 85 C (185 F) filtered oil at 430 kPa (62.4 psi) pressure.

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.

Oil to the oil pump passes through a 650 micron (0.025 in.) screen located between the suction bell and the suction tube.

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 is required for all 3600 engines before each start.

Two methods are available: intermittent and continuous.

Continuous prelubrication occurs in stand-by situations.

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.

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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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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.).

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Slides

LEGV0928 - #19

Show slides and explain the functions of the different components of the lube system.

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.

Oil pump - standrad rotation. Oil pump - reverse rotation. Air operated prelube pump.

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. Oil temperature regulators.

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).

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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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.

Piston cooling jet.

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.

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) LEGV0928 - #36

LEGV0928 - #37

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Lab exercises

1) Removal of oil filter elements.

Disassembly & Assembly (SENR3594-03) page 119.

2) Removal, disassembly & assembly of centrifugal filter.

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3600 Engines - Basic

III. AIR INTAKE & EXHAUST

SYSTEM

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CHAPTER : Intake & exhaust system

Instructor notes

LEGV0928 - #59

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.

In-line aftercooler core - mounted on theleft side of the engine.

In-line cylinder block - with cast-in inlet manifold. Vee engine aftercooler core - mounted above the center of the vee.

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. LEGV0928 - #60

LEGV0928 - #62

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Camshaft 3612 engine

C

A

B

Rear end

C

A

B

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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Instructor notes

Camshaft

Talk about camshaft segments and journals. 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.

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.

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.

Camshaft segments installed on diesel engines before mid-1990 have thinner flanges and spacers. The bolts are also smaller.

Camshaft segmented

In-line uses same part as Vee

Earlier cam segments

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Cam segment trim

E C A B D G F Annular groove Dowel Dowel hole locations Dowel hole locations Dowel

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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Instructor notes

Cam journals

Explain trimming of camshaft 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.

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.

Camshaft segment, two spacers and camshaft rear journal.

Camshaft journal - with 5 dowel holes. Camshaft segment removal tool.

Camshaft segment removal. Valve lifter group.

Cylinder head - shows air intake and rocker arm assembly.

Bottom side of cylinder head - shows intake & exhaust valves.

Let students remove two cam segments, three cam journals 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

1) Removal of camshaft segment and journal.

Disassembly & Assembly (SENR3594-03) page 213

2) Removal of camshaft bearing.

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Cylinder head removal

Pedestall

Hydraulic

cylinder

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Cylinder head removal

Piston Cylinder Stud Pedestall Nut Washer Cylinder head Collar Cover

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Instructor notes

LEGV0928 - #94

Explain removal of cylinder head. Show following slides:

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 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:

Unit injector removal. Combustion ring.

Let students remove a cylinder head and

disassemble / assemble it. Let them also check the combustion 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

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.

4) Measurement of valve springs.

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MALAGA

3600 Engines - Basic

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Instructor notes

Two cooling systems

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 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. 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.

System temeratures Basic operating parameters

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CHAPTER : Cooling system

AC/OC Pump

Cylinder Block, Head & Turbo

Heat Exchanger Expansion Tank JW Pump 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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Instructor notes

Advantage

combined system

The combined circuit system is also known as the single circuit - two pump 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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Heat Exchanger (AC/OC Circuit) C AC/OC Pump C Expansion Tank Cylinder Block,

Head & Turbo

D D F JW Pump F Oil Cooler Aftercooler D

Heat Exchanger (JW Circuit)

E

Vent

Line Makeup_Line

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

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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.

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.

Advantage separate system

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Instructor notes

LEGV0928 - #109

Explain combined and separate circuit cooling systems.

Show slides about piston and liner removal and piston 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 piston assembly.

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

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.

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DIESEL

MALAGA

3600 Engines - Basic

V. FUEL SYSTEM

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Secondary fuel filter elements Secondary fuel filter elements Filter change valve Pressure relief valve Relief valve Hand priming pump Check valve Main fuel pump Main fuel tank Primary Fuel filters Check valve Check valve Check valve Check valve

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Storage for zero-ing pin Power setting screw under this cover Install zero-ing pin here Location for dial gage See detail below Link to governor Rack Adjustment screw for rack zero setting inside Spring loaded link To other injectors Control bar Bolted and doweled

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Injector synchronization

CHAPTER : Fuel system

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 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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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.

_instruct Motor Basico

MALAGA

3600 Engines - Basic

STUDENT

BOOK

COURSE OBJECTIVES

TABLE OF CONTENTS

MALAGA

3600 Engines - Basic

3600 engine specifications

3600 engine specifications

Engine components

Engine components

Engine components

Engine components

Instructor notes

OIL

MALAGA

3600 Engines - Basic

Instructor notes

Priority valve

Centrifugal filters

Slides

Slides

Lab exercises

3600 Engines - Basic

III. AIR INTAKE & EXHAUST

SYSTEM

Instructor notes

Camshaft 3612 engine

C

C

A

B

B

Rear end

C

C

A

B

B

Instructor notes

Cam segment trim

Instructor notes

Lab exercises

Cylinder head removal

Pedestall

Hydraulic

cylinder

Cylinder head removal

Instructor notes

Lab exercises

MALAGA

3600 Engines - Basic

Instructor notes

Instructor notes

Instructor notes

Instructor notes

Lab exercises

DIESEL

MALAGA

3600 Engines - Basic

V. FUEL SYSTEM

Injector synchronization

LAB EXERCISES

MALAGA

3600 Engines - Basic

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.