3600 Engines - Basic

Service Training
MALAGA
3600 Engines - Basic
STUDENT
BOOK
Thorben
MARCH 1998
CHAPTER : Description
COURSE OBJECTIVES
DESCRIPTION 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).
CONTENTS The Student book contents 5 chapters and is covering:

- Introduction to 3600 engines
- Lubrication system
- Air intake & exhaust system
- Fuel system
- Cooling system
AUDIENCE This course is designed for dealer and customer personnel who will
be servicing 3600 engines.
PREREQUISITE Good theoretical and practical understanding of diesel engines and

correct mechanical procedures.
EQUIPMENT Safety glasses and safety shoes (or hard leather shoes) are
required.
Work clothing is suggested because of “hands-on” exercises on the
engine.
COURSE ACTIVITIES 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.
Page: 2
COURSE OBJECTIVES
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.
LITERATURE 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.
Page: 3
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 ..............................................................................................................
Page: 4
Service Training
MALAGA
I. INTRODUCTION
Thorben
MARCH 1998
CHAPTER : Introduction
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
Displacement/cyl. 18.5 L
Page: 2
3600 engine specifications
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
Page: 3
Engine components
The picture above shows a 3616 engine.
Page: 4
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.
Page: 5
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.________________________
Page: 6
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
Page: 7
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.
Page: 8
Service Training
MALAGA
IL
O
II. LUBRICATION SYSTEM
Thorben
MARCH 1998
CHAPTER : Lubrication system
Inlet water
Oil coolers
Oil flow
Oil temp. reg.
Return water
Oil coolers
Vent
3 Filter elements
Vent Filter change

valve
3 Filter elements
Priority valve
By-pass valve Relief valve
63 psi 145 psi
Oil Oil
Coolin jet pan pan
flow 20 psi Unfiltered oil
Main oil
manifold &
bearings Check valve
Centrifugal filter
No flow under 15 psi Main
oil
Prelube pump
Breather pump
Oil pan Strainer
Page: 2
Instructor notes
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 Oil system provides a constant supply of 85 C (185

F) filtered oil at 430 kPa (62.4 psi) pressure.
Priority valve 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.
Suction screen Oil to the oil pump passes through a 650 micron
(0.025 in.) screen located between the suction bell
and the suction tube.
Temperature
Oil temperature regulators direct the oil to coolers
regulators
at oil temperatures above 85 C ( 185 F).
From the 20 microns (0.78 mils) final filters the oil

Oil filters flows through the priority valve to drilled oil
passages in the cylinder block.
Prelubrication Prelubrication is required for all 3600 engines
before each start.
Two methods of Two methods are available: intermittent and

prelubing continuous.
Continuous Continuous prelubrication occurs in stand-by

situations.
Intermittent prelubrication occurs for a short

Intermittent 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.
Page: 3
Page: 4
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.
Page: 5
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.).
The centrifugal filters should normally be cleaned every 1000 hours.
Page: 6
Slides
Show slides and explain the functions of the
different components of the lube system.
LEGV0928 - #19 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.
LEGV3823 - #90 Oil pump - standrad rotation.
LEGV3823 - #91 Oil pump - reverse rotation.
LEGV0928 - #20 Air operated prelube pump.
LEGV0928 - #20 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.
LEGV0928 - #22 Oil temperature regulators.
LEGV0928 - #23 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).
LEGV0928 - #27 Oil filter elements.
LEGV0928 - #30 Priority valve.
Page: 7
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.
LEGV0928 - #36 Piston cooling jet.
LEGV0928 - #37 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.
LEGV0928 - #44 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)
Page: 8
Lab exercises
1) Removal of oil filter elements.
Disassembly & Assembly (SENR3594-03) page 119.
2) Removal, disassembly & assembly of centrifugal filter.
Page: 9
Service Training
MALAGA
III. AIR INTAKE & EXHAUST

SYSTEM
Thorben
MARCH 1998
CHAPTER : Intake & exhaust system
Instructor notes
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.
LEGV0928 - #59 In-line aftercooler core - mounted on theleft side of

the engine.
LEGV0928 - #60 In-line cylinder block - with cast-in inlet manifold.
Vee engine aftercooler core - mounted above the

LEGV0928 - #62 center of the vee.
Location of vee engine aftercooler & air shutoff. An

LEGV0928 - #61 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.
Page: 2
Camshaft 3612 engine
C C A B B
Rear end
C C A B 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.
Page: 3
Instructor notes
Talk about camshaft segments and journals.
Camshaft 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.
Camshaft The camshafts in all 3600 engines are segmented.

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.
In-line uses same The segments in the in-line engine will be the same
part as Vee 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.
Earlier cam Camshaft segments installed on diesel engines

segments before mid-1990 have thinner flanges and spacers.
The bolts are also smaller.
Page: 4
Cam segment trim
Dowel
E D
C B
Annular groove
Dowel hole
locations
Dowel
G F
Dowel hole
locations
At present there are three different kinds of camshaft segments. The difference
between them is the number and the location of the dowel holes.
Page: 5
Instructor notes
Explain trimming of camshaft journals.
Cam 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.
Journal trimming 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.
LEGV0928 - #65 Camshaft segment, two spacers and camshaft rear

journal.
LEGV0928 - #66 Camshaft journal - with 5 dowel holes.
LEGV0928 - #67 Camshaft segment removal tool.
LEGV0928 - #69 Camshaft segment removal.
LEGV0928 - #71 Valve lifter group.
SESV1535 - #49 Cylinder head - shows air intake and rocker arm
assembly.
LEGV0928 - #80 Bottom side of cylinder head - shows intake &

exhaust valves.
Let students remove two cam segments, three cam

journals and one cam bearing.
Page: 6
Lab exercises
1) Removal of camshaft segment and journal.
Disassembly & Assembly (SENR3594-03) page 213
2) Removal of camshaft bearing.
Page: 7
Cylinder head removal
Collar
Hydraulic
cylinder
Pedestall
Page: 8
Cylinder head removal
Collar
Cover
Piston
Cylinder
Stud
Pedestall
Nut
Washer
Cylinder head
Page: 9
Instructor notes
Explain removal of cylinder head. Show following

slides:
LEGV0928 - #94 Cylinder head removal tool - hydraulic cylinder.
LEGV0928 - #96 Hydraulic hoses.
LEGV0928 - #95 Hydraulic cylinders installed on cylinder head.
LEGV0928 - #97 Hydraulic pump.
LEGV0928 - #98 Loosening procedure of cylinder head nut.
LEGV0928 - #101 Lifting device for cylinder head.
LEGV0928 - #81 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:
LEGV0928 - #85 Unit injector removal.
8097 - #50 Combustion ring.
Let students remove a cylinder head and

disassemble / assemble it. Let them also check the
combustion ring and the valve springs.
Page: 10
Lab exercises
1) Removal of cylinder head.
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.
3) Measurement of combustion gasket thickness.
4) Measurement of valve springs.
Spcifications (SENR3592-01) page 17.
Page: 11
Service Training
MALAGA
IV. COOLING SYSTEM
Thorben
MARCH 1998
CHAPTER : Cooling system
Instructor notes
Two cooling Caterpillar is providing two cooling systems:

systems Combined circuit cooling & separate circuit cooling.
System temeratures Temperatures in the two systems are the same.
Basic operating 50 C (122 F) nominal water temperature to the AC

parameters 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.
Max. temperatures 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.
Page: 2
A
Cylinder Block,
Head & Turbo JW
Pump C B
D D
(3606/3608) (3612/3616)
Oil Cooler
E
D
Aftercooler
Exchanger
E
Heat
AC/OC Expansion
Pump Tank C
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
Page: 3
Instructor notes
Combined system The combined circuit system is also known as the

single circuit - two pump system.
Advantage The main advantage of the combined circuit system

combined 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.
Page: 4
Page: 5
D E
(JW Circuit)
Exchanger
Cylinder Block, E
Head & Turbo JW Expansion
Heat
Pump Tank C
Vent Makeup
Line Line
D F
Oil Cooler
(AC/OC Circuit)
Aftercooler
Exchanger
Heat
F
AC/OC C
Pump
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
Page: 6
Instructor notes
Makeup line The only connection between the AC / OC circuit

(separate 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.
Advantage separate The total radiator surface area may be 20 % less at

system 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.
Page: 7
Page: 8
Instructor notes
Explain combined and separate circuit cooling

systems.
Show slides about piston and liner removal and

piston assembly disassembling.
LEGV0928 - #109 Connecting rod cap bolts.
LEGV0928 - #110 Lower the connecting rod cap.
LEGV0928 - #111 Install crank protectors.
LEGV0928 - #115 Piston $ connecting rod assembly.
LEGV0928 - #117 Removal of piston retaining rings.
LEGV0928 - #118 Piston pin guide.
LEGV0928 - #119 Piston ring removal.
LEGV0928 - #120 Measure piston and rings.
LEGV0928 - #121 Cylinder liner removal tool.
LEGV0928 - #123 Installation of liner removal tool.
Remove piston and liner and disassemble piston

assembly.
Show and explain the three kinds of different liners.
Page: 9
Lab exercises
1) Removal of piston & connecting rod assemblies.
2) Removal of cylinder liner.
3) Measurement of piston rings.
Guideline for reusable parts (SEBF8107).
4) Removal and installation of crankshaft main bearings.
5)Installation of cylinder liner.
6) Installation of piston & connecting rod assemblies.
7) Installation of cylinder head.
Page: 10
Service Training
MALAGA
DIESEL
V. FUEL SYSTEM
Thorben
MARCH 1998
CHAPTER : Fuel system
Pressure
relief
valve Secondary
Check fuel filter
valve elements
Filter
change
valve
Check Secondary
valve fuel filter
elements
Relief valve
Main
fuel Check
pump valve
Check
valve
Hand
Check priming
valve pump
Main Primary
fuel tank Fuel filters
Page: 2
Page: 3
Page: 4
Page: 5
Adjustment screw
for rack zero setting
inside
Link to
governor
Spring loaded
See detail link
below
Rack
Bolted and
Control bar doweled
To other
injectors
Storage for
zero-ing pin
Power setting
screw under
this cover
Location for
dial gage
Install zero-ing
pin here
Page: 6
Injector synchronization
C
B
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 !!
Page: 7
LAB EXERCISES
1) Installation of camshaft bearing.
2) Installation of camshaft segment and journal.
3) Timing the camshaft(s) to the crankshaft.
System Operation Testing & Adjustment (SENR3593-01)
page 48
4) Timing of unit injector.
Systems Operation Testing & Adjusting (SENR3593-01)
page 53.
5) Fuel setting.
page 68.
6) Injector synchronization.
page 55.
7) Check valve clearance.
System Operation Testing & Adjustment (SENR3593-01)
page 73
Page: 8
Service Training
MALAGA
PRE-/POSTTEST
Thorben
MARCH 1998
CHAPTER : PRE-TEST
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.
(T or F)
Page: 2
CHAPTER : PRE-TEST
5. Why must the linkage be adjusted between the governor

and 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 rotating

the crankshaft.
(T or F)
7. Holes have to be drilled and tapped in the top of a piston

before it can be removed.
(T or F)
Page: 3
CHAPTER : PRE-TEST
8. When installing a piston, a “V”(or “X”) mark on the

piston must be aligned with a “V” (or “X”) mark stamped
on 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 heads

is:
___30,000 kPa (4350 psi)
___35,000 kPa (5075 psi)
___40,000 kPa (5800 psi)
Page: 4
CHAPTER : PRE-TEST
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 engine

running, 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
Page: 5
CHAPTER : PRE-TEST
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 oil
pressure 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 can
not be made to work on a standard rotation engine.
(T or F)
Page: 6
CHAPTER : PRE-TEST
17. The gauges in the oil filter covers measure oil filter
differential 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 side

are different than those in the right side.
(T or F)
20. The camshaft segments in the in-line engine will be the

same as the segments in the left or right side of the Vee
engine, depending on whether it is a standard or reverse
rotation engine.
(T or F)
21. How many cooling systems does Caterpillar provide ?
Page: 7

3600 Engines - Basic

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3600 Engines - Basic

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Service Training

CONTENTS The Student book contents 5 chapters and is covering:

PREREQUISITE Good theoretical and practical understanding of diesel engines and

1. Locate all engine components.

LITERATURE SENR3593-01 SYSTEM OPERATION

3600 Engines - Basic

3600 engine specifications

The 3600 engine family contains 4 models:

- 6 & 8 cylinder engines (in-line engines)

- 12 & 16 cylinder engines (“vee” engines)

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

Mean piston velocity 10 m/s (33 ft/s) @ 1000 rpm

BMEP 18.2 bar (264 psi) @ 1000rpm

3600 engine specifications

Weight of serviceable parts (kg)

Cylinder head assembly 196

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

The picture above shows a 3616 engine.

The picture above shows a 3616 marine engine.

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

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

Show overhead of page 2-4 and talk about them.

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

3600 Engines - Basic