- Engine: All 3600 Engines
Introduction
Important Safety Information
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| Illustration 1 | g02139237 |
Think Safety | |
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation Section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal
Service Parts Section
The Service Parts Section is a reference for parts identification and available part numbers.
Safety Icon Nomenclature
Personal Protection/Important Information
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| Illustration 2 | g02166423 |
Personal Protection/Important Information | |
Prohibited Action
| No Smoking |
Hazard Avoidance
| Crushing Hazard (foot) |
| Crushing Hazard (hand) |
| Pinch Point |
| Fire Hazard |
| Electrical Shock - Hazard |
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| Fire Hazard |
Safety Section
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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure. |
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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 1-800-542-8665, Option 1
International: 1-309-578-7372
References
Refer to the Operation and Maintenance Manual for your equipment. Additional Information may be found in:
3600 Valve Projection Tools
Introduction
The Valve Projection Tools - 3600 provide a means to clearly and accurately document the amount of valve recession on the diesel and gas 3600 engines. Accurate documentation of valve recession is necessary to determine the appropriate time to service the cylinder head.
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| Illustration 3 | g03879385 |
| 4C2980 Valve Projection Group | |
| Group Part Number Not Serviced Consists of the following serviceable parts: |
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| 1 | 1U8869 Dial Indicator |
| 2 | 9U6272 Screw Nylon (part of 4C2982) |
| 3 | 4C2982 Collet Assembly |
| 4 | 4C2979 Gauge Block, Projection |
| 5 | 5P4160 Contact Point |
| 6 | 4C2981 Base, Valve projection 3600 |
| Not shown: | 6V3073 Case |
| 4C Foam Block Group | |
| NEEG2622 Decal | |
| Additional Tools Needed: | 6V7030 Micrometer Depth Gauge Group (metric) or 6V2012 Micrometer Depth Gauge Group (inches) |
Measure Stem Height
On initial installations, follow this procedure to measure and record stem height baseline.
On service intervals, follow this procedure to measure and record the new reading stem height.
The service interval for diesel engines is in Guideline for Reusable Parts Specifications for Cylinder Head Assemblies, 3600 Family of Engines (Form SEBF8106).
The service interval for spark ignited gas engines is in Maintenance Management Schedules for Industrial and EPG Spark Ignited Gas Engines (Form SEBU6127).
The service interval for residual fuel engines is in Guideline for Reusable Parts and Salvage Operations Specifications to Measure and Salvage Cylinder Head Assemblies and Related Components (Form SEBF8162)
- Remove bolts (2) and rocker cover (1) .
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| Illustration 4 | g03879397 |
Note: Record engine coolant temperature before making any height measurements. If on initial installation, the measurements were made on a cold engine, repeat future measurements on a cold engine. If on initial installation, the measurements were made on a hot engine, repeat future measurements on a hot engine.
- Remove bolts (4) and rocker assembly (3) .
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| Illustration 5 | g03879401 |
- Position base (5) (with indicator installed), around the valve spring. Insure that the indicator contact point is making contact with the top of the valve.
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| Illustration 6 | g03879404 |
- Set indicator (6) to "0" (zero) by pressing the "Zero" button (7) .
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| Illustration 7 | g03879405 |
- Remove base (5) and place it on gauge block (8). Record reading from the indicator. On initial installations, record this reading as the stem height baseline. On service intervals, record this as the new reading stem height.
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| Illustration 8 | g03879411 |
Measure Rotocoil Height
Record engine coolant temperature before making any height measurements. If on initial installation, the measurements were made on a cold engine, repeat future measurements on a cold engine. If on initial installation, the measurements were made on a hot engine, repeat future measurements on a hot engine.
- On initial installations, use a "T-bar" depth gauge (6V2012 Micrometer Depth Gauge Group, inches or 6V7030 Micrometer Depth Gauge Group, metric) to measure and record the dimension from the top of the valve rotocoil assembly to the top of the cylinder head. Use of the micrometer depth gauge does not require removal of the rocker arm assembly. On initial installations, record this reading as the rotocoil height baseline. On service intervals, record this reading as the new reading rotocoil height.
During future service intervals, repeat step 1 of this procedure.
If the micrometer depth gauge readings indicate that the amount of valve recession may be approaching, the "maximum valve recession," repeat "Measure Stem Height" procedure to confirm the amount of valve recession.
Reference
The "maximum valve recession" for diesel engines can be found in Guideline for Reusable Parts, Specifications for Cylinder Head Assemblies, 3600 Family of Engines (Form SEBF8106).
The "maximum valve recession" for spark ignited gas engines can be found in Maintenance Management Schedules for Industrial and EPG Spark Ignited Gas Engines (Form SEBU6127).
The "maximum valve recession" for residual fuel engines, can be found in Guideline for Reusable Parts and Salvage Operations Specifications to Measure and Salvage Cylinder Head Assemblies and Related Components (Form SEBF8162).
Make copies of the following chart as needed to record measurements.
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| Illustration 9 | g03879423 |
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| Illustration 10 | g03879425 |
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| Illustration 11 | g03879440 |
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| Illustration 12 | g03879459 |