Pocket Guide - 3600 (LEXQ7766)

3600 Engine FamilyPocket Guide

POWER WHEREVER YOU ARE

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3600 FamilyWhether your needs are marine, industrial, or electric powergeneration, the Caterpillar 3600 Engine Family will provideyou with proven power to get the job done. The 3600 Enginesare the most powerful and reliable power sources everproduced by Caterpillar. Operating economy and durabilitymake it the logical choice; worldwide product support makesit the only choice.

The 3618 Marine Propulsion Engine is the newest addition tothe 3600 Family. It was specifically designed to meet theneeds of our marine fast ferry customers. For moreinformation on the new Caterpillar 3600 engine, consult yourlocal dealer (see page 48 for publications).

This pocket guide is a quick reference to determine which3600 Engine will best meet your needs. If you should haveany questions, please consult your local Caterpillar dealer. Ifyou need assistance in finding a dealer, consult one of ourCaterpillar offices (pp. 46-47).

Caterpillar Inc.

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.A.

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5

Table of ContentsRatings

Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Distillate and Heavy Fuel. . . . . . . . . . . . . . . . . . . . . . . . . .8-11Fast Vessel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3600 Distillate Fuel Consumption. . . . . . . . . . . . . . . . . . . . . .13Engine and Generator Set Dimensions. . . . . . . . . . . . . . . . . .14Product Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-18Overhaul Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19Overhaul Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21Lube Oil Experience List. . . . . . . . . . . . . . . . . . . . . . . . . . .22-23S•O•SSM Oil and Coolant Analysis. . . . . . . . . . . . . . . . . . .24-25Range of Available Ratings. . . . . . . . . . . . . . . . . . . . . . . . .26-27Distillate Fuel Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . .28Heavy Fuel Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Performance Calculations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

English. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-34SI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35-38BMEP, Piston Speed, Output Factor, Prop Demand. . . . . 39Load Factor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Fuel Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Fuel Consumption Comparison. . . . . . . . . . . . . . . . . . .42-43

Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-45Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46-47Reference Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

6 7

ConditionsThe following engine ratings are based on SAE J1995 January1990 and ISO 3046 standard conditions of 100 kPa (99 kPadry barometric pressure) and 25° C air. Performance and fuelconsumption are based on 35 API, 16° C fuel having an LHVof 42 780 kJ/kg used at 29° C with a density of 838.9 g/L.Tolerances include -0/+5% on specific fuel consumption and±3% on brake kilowatt power at the flywheel demonstrated atthe Caterpillar production test cell. The maximum inlet airtemperature to the turbocharger is 45° C before derating.Engine ratings are net power and include deduction for thefollowing parameters: cooling water pumps, lube oil pumps,fuel pump, typical exhaust restriction, and typical air filterrestriction.

Ratings Generator Set RatingsContinuous Rating: Typical application is base load generatorset, 8000 hrs/year, load factor < = 100%, 10% overload.

Prime Power: Typical application is peak shaving, 6000 hrs/year, load factor < = 60%. Rated load (100%) usageis 1 hour in 12, 10% overload.

Standby: Typical application is emergency generator set, < 200 hrs/year, 100% during emergency outage, no overload.

Marine RatingsContinuous Service Rating (CSR): Typical application is U.S.inland river vessel, continuous engine operation, fuel stoppower equals rated power.

Maximum Continuous Rating (MCR): Typical application istugboat, 1 hour in 12 at rated power, fuel stop power equalsrated power.

3612 Cutaway 3600 CylinderHead

98 9

3608 EPG RATINGSDISTILLATE

RPM 1000 900 750 720

APPL bkW ekW bkW ekW bkW ekW bkW ekW

SB 2980 2860 2790 2660 2400 2290 2320 2220

PP 2710 2600 2530 2420 2180 2080 2110 2020

CN 2460 2350 2300 2200 1980 1890 1920 1830

HEAVY FUELCN 2240 2160 2090 2000 1800 1720 1740 1650

CN = Continuous Generator Set (+10% overload)PP = Prime Power Generator Set (+10% overload)SB = Standby Generator Set (no overload)

3608 MARINE PROPULSION/INDUSTRIAL RATINGSDISTILLATE

RPM 1000 900 800 750

APPL bkW bhp bkW bhp bkW bhp bkW bhp

MCR 2710 3634 2530 3393 2290 3071 2180† 2923†

CSR 2460 3299 2300 3084 2080 2789 1980† 2655†

HEAVY FUELRPM 1000 900 825 750


MCR† 2460 3299 – – – – 1980 2655MCR 2320 3111 2300 3084 1980 2655 – –

CSR† 2240 3004 – – – – 1800 2414

CSR 2110 2830 2090 2803 1800 2414 – –CSR = Marine/Industrial – Continuous Service RatingMCR = Marine only – Maximum Continuous Rating (intermittent)† Marine – Controllable Pitch Propellers onlyNOTE: See Applications and Installation Guide for limit line curves (Powervs. Speed)NOTE: Coolant temperature to the aftercooler is 32° C nom. (38° C worst condition) for all heavy fuel ratings. Altitude < = 200 meters.


RPM 1000 900 750 720


SB 2240 2150 2090 2000 1800 1730 1750 1680

PP 2030 1940 1900 1820 1640 1570 1590 1525

CN 1850 1760 1730 1650 1490 1420 1440 1375

HEAVY FUELCN 1680 1600 1570 1500 1350 1280 1310 1250



RPM 1000 900 800 750


MCR 2030 2722 1900 2548 1720 2307 1640 2199

CSR 1850 2481 1730 2320 1560 2092 1490 1998



MCR 1850 2481 1730 2320 1490 1998 1485 1991CSR 1680 2253 1570 2105 1355 1817 1350 1810CSR = Marine/Industrial – Continuous Service RatingMCR = Marine only – Maximum Continuous Rating (intermittent)† Marine – Controllable Pitch Propellers onlyNOTE: See Applications and Installation Guide for limit line curves (Powervs. Speed)

NOTE: Coolant temperature to the aftercooler is 32° C nom. (38° C worst condition) for all heavy fuel ratings. Altitude < = 200 meters.

1110


RPM 1000 900 750 720


SB 5960 5720 5580 5320 4800 4580 4640 4440

PP 5420 5200 5060 4840 4360 4160 4220 4040

CN 4920 4700 4600 4400 3960 3780 3840 3660

HEAVY FUELCN 4480 4320 4180 4000 3600 3440 3480 3350



RPM 1000 900 800 750


MCR 5420 7268 5060 6785 4580 6142 4360† 5847†

CSR 4920 6598 4600 6169 4160 5579 3960† 5310†



MCR† 4920 6598 – – – – 3960 5310MCR 4640 6222 4600 6169 3960 5310 – –

CSR† 4480 6008 – – – – 3600 4828CSR 4220 5659 4180 5605 3600 4828 – –CSR = Marine/Industrial – Continuous Service RatingMCR = Marine only – Maximum Continuous Rating (intermittent)† Marine – Controllable Pitch Propellers onlyNOTE: See Applications and Installation Guide for limit line curves (Powervs. Speed)NOTE: Coolant temperature to the aftercooler is 32° C nom. (38° C worst condition) for all heavy fuel ratings. Altitude < = 200 meters.


RPM 1000 900 750 720


SB 4480 4300 4180 4000 3600 3460 3500 3360

PP 4060 3880 3800 3640 3280 3140 3180 3050

CN 3700 3520 3460 3300 2980 2840 2880 2750

HEAVY FUELCN 3360 3240 3140 3000 2700 2560 2620 2500



RPM 1000 900 800 750


MCR 4060 5444 3800 5096 3440 4613 3280 4398CSR 3700 4962 3460 4640 3120 4184 2980 3996



MCR 3700 4962 3460 4640 2980 3996 2970 3983CSR 3360 4506 3140 4211 2710 3634 2700 3621CSR = Marine/Industrial – Continuous Service RatingMCR = Marine only – Maximum Continuous Rating (intermittent)† Marine – Controllable Pitch Propellers onlyNOTE: See Applications and Installation Guide for limit line curves (Powervs. Speed)

NOTE: Coolant temperature to the aftercooler is 32° C nom. (38° C worst condition) for all heavy fuel ratings. Altitude < = 200 meters.

1312

3600 DISTILLATE Fuel Consumption(g/bkW•hr)

IN-LINE ENGINES

EPG RATINGS

3606 3608rpm 1000 900 750 720 rpm 1000 900 750 720

PP 190 186.4 183 184.3 PP 191 186.3 185.3 185.4

CN 190.2 186.5 183.4 184.8 CN 189.8 188 184.9 185.3

MARINE PROPULSION/INDUSTRIAL RATINGS

3606 3608rpm 1000 900 800 750 rpm 1000 900 800 750

MCR 190 187.6 185 183 MCR 190.1 190.2 182.7 181.2

CSR 189.1 187.4 183.2 183.4 CSR 189 188.5 181.1 180

VEE ENGINES

EPG RATINGS

3612 3616rpm 1000 900 750 720 rpm 1000 900 750 720

PP 189.7 186.1 184.1 183.9 PP 189.2 187 184.1 183.8

CN 189.9 186.3 183.9 183.4 CN 188.1 186.7 182.9 183.7

MARINE PROPULSION/INDUSTRIAL RATINGS

3612 3616rpm 1000 900 800 750 rpm 1000 900 800 750

MCR 189.1 187.4 186.1 184.1 MCR 191 193.2 191.3 185.4

CSR 188.3 187.2 184.4 183.9 CSR 190 191.6 189.7 184.4

PP = Standard Prime Power Generator Set Rating (+10% overload)CN = Standard Continuous Generator Set Rating (+10% overload)CSR = Standard Marine/Industrial – Continuous Service RatingMCR = Standard Marine only – Maximum Continuous Rating (intermittent)The above fuel consumption is based on SAE J1995 January 1995 andISO 3046 standard conditions of 100 kPa (99 kPa dry barometric pressure)and 25° C air. The fuel consumption is based on 35 API, 16° C fuel having an LHV of 42 780 kJ/kg used at 29° C with a density of 838.9 g/L. Tolerancesare -0/+5% on specific fuel consumption. Specific fuel consumption isbased on gross engine power and does not include the power deductionsfor cooling water pumps, lube oil pump, and fuel pump (i.e. FuelConsumption without pumps).See page 40 for fuel consumption comparison example.

FAST VESSEL RATINGSMARINE DIESEL OIL

COMMERCIALMax. Air Temp. to

Engine rpm bkW bhp PS Turbocharger/Sea Water Temp.

3612 800 3400 4560 4625 45/32° C1000 4250 5700 5780 45/32° C

3616 800 4500 6035 6120 45/32° C1000 5650 7575 7685 45/32° C

The above ratings are based on the following approximate load profile:• 85% of the engine operating hours at 100% of rated power• 15% of the engine operating hours at less than 50% of rated power

These ratings correspond to the ISO 3046 Fuel Stop Power definitions.

MILITARYMax. Air Temp. to

Engine rpm bkW† bhp PS Turbocharger/Sea Water Temp.

3612 1000 4500 6035 6120 45/32° C1000 4625 6200 6290 25/25° C

3616 1000 6000 8045 8160 45/32° C1000 6150 8245 8360 25/25° C

† Factory demonstration of overload is available.The above military ratings are based on the following approximate loadprofile:

• 3% of the engine operating hours at 100% of rated power• 82% of the engine operating hours at 85% of rated power• 15% of the engine operating hours at less than 50% of rated power

These ratings correspond to the ISO 3046 Fuel Stop Power definitions.

1514

3600 Engine FeaturesThe 3600 Engine Family is a modern, highly efficient engineseries consisting of in-line six and eight cylinder engines andvee engines of 12 and 16 cylinders. These are four stroke,non-reversible engines rated at speeds from 720 to 1000 rpm.They are turbocharged and aftercooled with a direct injectionfuel system that uses unit fuel injectors.

Engine Model3606. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In-line 6 cylinder3608. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In-line 8 cylinder3612. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vee 12 cylinder3616. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vee 16 cylinder

SpecificationsBore — mm (in). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280 (11)Stroke — mm (in). . . . . . . . . . . . . . . . . . . . . . . . . . . . .300 (11.8)Displacement per cyl. — L(in3) . . . . . . . . . . . . . . .18.5 (1127)Rotation (from flywheel end). . . . . . . . . . . . . . . . . . . .cw or ccwCompression Ratio (Distillate/HFO). . . . . . . . . . 13.0:1/12.4:1Aspiration. . . . . . . . . . . . . . . . . . . . . .Turbocharged-AftercooledRated Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .720–1000 rpmPiston Speed m/s (ft/s). . . . . . . . . . . . .7.2 (23.6) – 10.0 (32.8)

Engine blocksare made from a heavily ribbed, one piecegray iron alloy casting. Integral air intake plenums run the fulllength of the block, providing an even air distribution to thecylinders. The engine block is designed for four or six pointmounting.

Crankshafts are forged with a continuous grain flow,induction hardened, and regrindable. Counterweights at eachcylinder are welded to the crankshaft and ultrasonicallyinspected to assure weld integrity. The crankshaft end flangesare identical, allowing full power to be taken from either end.

Caterpillar Generator Set Dimensions

3606 3608 3612 3616L 7950 (313) 9240 (364) 8970 (353) 10 260 (404)mm (in)W 2425 (96) 2425 (96) 2515 (99) 2515 (99)mm (in)H 3480 (137) 3480 (137) 4110 (162) 4110 (162)mm (in)

Weight (dry) 34 100 41 400 51 200 64 500kg (lb) (75 000) (91 000) (112 700) (141 800)

Caterpillar Propulsion Engine Dimensions

3606 3608 3612 3616L 3988 (157) 4808 (189) 4562 (180) 5482 (216)mm (in)W 1748 (69) 1748 (69) 1714 (67) 1714 (67)mm (in)H1 2035 (80) 2035 (80) 2574 (101) 2574 (101)mm (in)H2 841 (33) 841 (33) 976 (38) 976 (38)mm (in)

Weight (dry) 15 700 19 000 25 100 30 000 kg (lb) (34 500) (41 800) (55 300) (65 900)

1716

Pistonsare two-piece with a forged steel crown and forgedaluminum skirt. This piston construction ensures excellentstrength and durability, and minimal weight. Pistons have fourrings — two in hardened grooves inthe piston crown, and two in the skirt.The top ring is plasma coated; thisprovides extra wear resistance andlowers lube oil resistance andconsumption. The two middle ringsare taper faced and chrome plated.The lower oil control ring is doublerail and chrome faced with a springexpander.

Main bearings are made of steel backed aluminum with anickel bonded lead/tin/copper overlay. Rillenlager technology,which alternates stripes of aluminum and overlay on thesurface, is used. This provides higher load carrying capabilityand reduces wear rates when compared to trimetal aluminumbearings. The bearings have no grooves in the lower bearingshell. This greatly reduces unit pressure loading whencompared to grooved bearings.

Rod and camshaft bearingsare made of steel backedaluminum with a copper bonded lead/tin overlay. Aluminumbearing material provides better characteristics in the areas ofheat conduction, resistance against corrosion, and ability toembed small particles that may otherwise damage journalsurfaces. Bearings have nogrooves, greatly reducing unitpressure load on the bearings.

Cylinder liners are induction hardened. The combination of induction hardened liners, one chrome/plasma-coated piston top ring, and three chrome-coated piston rings provides the lowest wear on running surfaces. The 3600 liners are plateau honed for better oil control.

Located at the top of the liner is a sleeve or “cuff” thatremoves carbon deposits from the top land of the piston. Thissleeve prevents the loss of oil control and reduced cylinderliner life by preventing carbon deposits from accumulatingand polishing the cylinder liner.

Connecting rods are forged, heat treated, and shot peenedbefore machining. The specialfour-bolt design and theelimination of bearing groovesallows for an extra large bearingwhich reduces bearing load andextends bearing life.

Valvesseat on replaceable induction-hardened inserts.Rotators on all valves maintain uniform temperature and wear pattern across the valve face and seat.

The exhaust valves used in heavy fuel engines are givenspecial attention to extend their life. The exhaust valvetemperature is reduced to approximately 410° C to minimizethe possibility of vanadium induced corrosion. A mnemonic80A material is used in the exhaust valve. The valve head iscoated with ceramics and water-cooled valve seats are used to maintain the low valve temperatures.

Piston Rings

Cuff

Cyl

ind

er L

iner

1918

Estimated Overhaul Intervals

Distillate Fuel Heavy Fuel(hrs) (hrs)

Periodic Component Service 8000-12 000 4000-6000

Top End Overhaul 16 000-24 000 8000-12 000

Major Overhaul 36 000-44 000 16 000-24 000

Overhaul intervals are based on: normal wear, proper preventivemaintenance, good quality lube oil, regular lube oil analysis, andload factor within defined parameters.NOTE: The above distillate intervals typically do not apply to fastvessel applications.

Periodic Component ServiceHeavy Fuel (4000-6000 hrs):CLEAN AND INSPECT—Fuel injectors, turbochargers, aftercooler core

Distillate and Heavy Fuel (8000-12 000 hrs):INSPECT/REPLACE —Temperature regulators (oil and water), water pump seals,exhaust shields

CLEAN AND INSPECT—Cooling system

INSPECT/CHECK —Engine protection devices, turbocharger, driven equipmentalignment, torsional coupling, governor/actuator, damper andcrankshaft seals, camshaft roller followers

Cooling System.There are two basic cooling systemconfigurations: single circuit and separate circuit. Bothconfigurations include an engine mounted plate-fin aftercoolerdesigned for high heat transfer. Both configurations includetwo water pumps that are engine driven from the front geartrain. The right-hand pump (as viewed from the flywheel end)supplies coolant to the cylinder block, heads, andturbochargers. The left-hand pump supplies coolant to theaftercooler and oil cooler.

Unit injectors eliminate the need for high pressure fuel lines.Maximum injection pressure is1400 bar on MDO engines and1520 bar on HFO engines.These pressures provide goodfuel atomization which isrequired for low fuelconsumption and heavy fueloperation. The 3600 unitinjectors have tip cooling forheavy fuel operation.

2120

Major OverhaulRemanufacture or rebuildCentrifugal filter bearings, starting motors, cylinder heads andair shutoff valve (HFO)

ReplaceFuel injectors, accessory group bearings, front gear trainbearings, cylinder head valves and valve guides, grind and lapvalves and seats (for full face contact), exhaust manifold sealsand bellows, exhaust shields, intake air lines seals, watertemperature regulators and seals, oil temperature regulators andseals, and cylinder head valve spring guides

Inspect/ReplaceAftercooler core, pistons, piston rings, cylinder liners, cylindersleeves (cuff), main bearings, connecting rod bearings, thrustbearings (except crankshaft), crankshaft, camshafts, camshaftbearings, rocker arm bearings, front gear group, rear gear group,rear gear train bearings, seals, o-ring seals and plugs, valvemechanism group, exhaust manifolds, shutoff controls andalarms, priority valve, turbocharger bearings, bushings and seals,oil pump bushings and seals, fuel transfer pump seals, oil coolerseals, thermocouples (if equipped), water pump bearing andseals, intake air liner seals and valve lubricator pump, gasketsand seals, connecting rod bearings

Clean and inspectOil cooler core, lube oil suction screen, crankcase side covers,central structure covers, camshaft front covers, camshaft drivegear covers, front housing group, gear inspection group, rearhousing group, rear structure covers, power take-off covers,priority valve group, crankshaft, valve mechanism covers, oillines, all water lines, oil cooler, vibration damper, and fuel lines

Top End OverhaulRemanufacture or rebuildUnit injectors, cylinder heads, intake and exhaust inserts, valvesprings, valve spring guides, valve locks, valve rotocoils, intakeand exhaust valves, dowels, grind and lap valves and seats (ifnot replaced), lap valves for full face contact, and air shutoffvalve (distillate)

ReplaceCylinder head gaskets, seals, o-ring seals and plugs,turbocharger bearings, bushings and seals, oil pump bearingsand seals, fuel transfer pump seals, oil cooler seals, watertemperature regulators and seals, oil temperature regulators andseals, exhaust manifold gaskets, thermocouples (if equipped),water pump bearings and seals, intake air seals, and valvelubricator pump (if equipped)

Inspect/ReplaceExhaust shields, cylinder sleeves (cuff), connecting rod bearings

Clean and inspectOil cooler core, oil suction screen, piston under crown

2322

Caterpillar cannot control base stock variations and lube oiladditive packages at locations around the world and thereforetakes no responsibility. Differences in load cycle, fuel quality,maintenance practices, and ambient conditions further prohibit aguarantee of lube oil performance at any installation. Pastperformance of a particular brand does not guarantee futureresults due to changes in formulation and regional differences. Itis the responsibility of the oil producer to verify the consistencyand quality level of the product.

LUBE OIL EXPERIENCE LIST FOR 3600Lube Oil Experience List for 3600Successful lube oil experiences in 3600 Series Engines aresummarized in the table on page 23. Inclusion in this listindicates that the particular lube oil has been successful onlyin a particular application and site. This list is not anendorsement nor recommendation for any particular lube oil.Caterpillar does not recommend any lube oil for 3600Engines other than our own branded Caterpillar DEO indistillate fuel burning applications.

When consumables such as oil, filters, additives, and similaritems made by other manufacturers are used on or inCaterpillar equipment, the Caterpillar warranty is not affectedsimply because of such use. The Caterpillar warrantycontinues to cover defects caused by Caterpillar material andworkmanship. Failures resulting from usage of othermanufacturers’consumables are not Caterpillar factorydefects and therefore are NOTcovered by the Caterpillarwarranty. Use of other manufacturers’consumables is at thediscretion of the customer, who assumes ALL risks for theeffects resulting from usage.

DISTILLATE FUELSAE HIGH LOADSUPPLIER NAME VISCOSITY TBN > 85%GRADE

Caterpillar DEO (CF) 40 13.5 YESDEO (CG-4) 15w-40 10.5 UNKNOWN

British Petroleum Vanellus C3 (CG-4) 15w-40 11 UNKNOWN

Chevron Delo 6170 40 17 UNKNOWNDelo 477 40 17 UNKNOWN

Exxon DeMar Xt 40 13 YESCM477 40 14 YESIOLUBE MDY 40 40 13 –

Mobil Mobilgard ADL 40 15 UNKNOWNDelvac MX (CG-4) 15w-40 10.1 UNKNOWNMobilgard HSD (CG-4) 15w-40 10.1 UNKNOWN

Shell Rimula (North America) 40 12 YES

Valvoline DDS 9207 40 13 UNKNOWN

HEAVY FUELCaltex/Chevron Delo 3400 Marine 40 40 UNKNOWN

Mobil Mobilgard 440 40 40 EXPECTED

Shell Argina-T 40 30 YESArgina-X 40 40 YES

Texaco Taro 40XL40 40 40 YESTaro 30DP40 40 30 YES

YES: Lube oil has had successful experience in engines operating above 85% load factorUNKNOWN: All documented experiences with the lube oil have been below 85% load factorEXPECTED: A field trial is in progress and the initial results are positive

2524

S•O•SSM Oil AnalysisThe S•O•S oil analysis tests have been developed byCaterpillar engineers and chemists to evaluate the conditionof your engines rather than just the condition of the oil.Additional tests may be performed if needed. Following is abrief description of the standard oil analysis tests offered inthe S•O•S program.

Wear Rate Analysis monitors wear by detecting, identifying,and assessing the amount and type of metal wear elements inthe oil. The rate at which wear metal particles increase fromsample to sample is as important as the quantity of particlesin the oil. For this reason, regular sampling at specifiedintervals is necessary to establish wear rate trends for eachoil-lubricated compartment.

Oil Contamination AnalysisSilicon, which indicates dirt entry, is quantified withspectrometric analysis on the oil sample. Additional tests areconducted for contamination of the oil by fuel, water, andglycol (coolant/antifreeze).

Oil Condition Analysis determines loss of the oil’slubricating properties. An infrared analysis instrument is usedto compare the properties of new oil to the properties of yourused oil sample. This test allows technicians to determine theextent to which the oil has deteriorated during use and toverify that the oil is performing up to specification during theentire oil change period.

Oil samples for these tests are generally taken by the customer.However, your Cat dealer can do it for you as part of acustomer support agreement designed to meet your needs.

S•O•SSM Coolant AnalysisCoolant or cooling system problems contribute to more than50 percent of all engine failures. These failures can be due toinadequate cooling system maintenance, incorrectconcentration, poor operational procedures such as extensivelugging or inadequate cooldown procedures, or systemproblems such as stray electrical current or block heaterfailure. These problems will eventually affect the oilcondition, and may cause oil oxidation or antiwear additivedropout. S•O•S coolant analysis is a two-level program thatdoes more than just check the condition of your coolant. Itdetermines the overall condition of the cooling system andcan identify problems with maintenance procedures andoperational practices.

Level 1: Basic Coolant Maintenance Checkconsists of fouranalytical tests and four observational parameters that notonly show major problems with the coolant, but can alsopredict some major cooling systems problems. Level 1 resultscan also determine when Level 2 analysis is needed.

Level 2: Comprehensive Cooling System Analysis involvesan extensive chemical evaluation of the coolant and its overalleffects on the inside of your cooling system. This series ofcomprehensive tests can identify subtle cooling systemproblems, determine probable causes, and help prioritize theurgency of needed corrections.

3600 Range of Available Ratings (bkW)

1000

3606

3608

3612

3616

2000 3000 4000 5000 6000

Distillate

Heavy Fuel

Heavy Fuel

Distillate

Heavy Fuel

Heavy Fuel

Distillate

Distillate

En

gin

e

2928

CATERPILLAR HEAVY FUEL OIL SPECIFICATIONS

Specifications Bunkered As Delivered(ASTM Test) CIMAC K 55 to Injectors

Viscosity (D 445) 55 cSt @ 100° C 10-171

maximum maximum

Density (D287) 10102 kg/m3

maximum –

Flash Point (D93) 60° C minimum –

Pour Point 30° C maximum –

Carbon Residue 22% (m/m) max.(ISO 10370) –

Ash (D482) 0.15% (m/m) max. –

Total Sediment 0.1% (m/m) max.after aging –

Water (D1744) 1% (v/v) maximum –

Sulfur (D3605) 5% (m/m) max –

Vanadium (D3605) 6003 ppm max. –

Aluminum & Silicon 802 mg/kg (ppm) 6 mg/kg (ppm)(D3605) maximum

Caterpillar Guidelines, in addition to CIMAC K55Sodium (D3605) – 503 ppm max.

Vanadium/Sodium – 53 minimum

Calcium (D3605) – 40 mg/kg (ppm) maximum

Zinc (D3605) – 10 mg/kg (ppm) maximum

Asphaltnes (D1319) – 15% (m/m) max

CCAI – 8604 max

Water & Sediment – 0.2% (m/m) max

1 Fuel temperature at engine inlet may not exceed 135° C2 Admissible with suitable treatment system only3 Vanadium and sodium compounds become corrosive at high exhaust

temperatures, especially so when sodium concentration becomes more than 20% of the vanadium concentration. Consult factory for fuel with vanadium >300 ppm or sodium >30 ppm.

4 Calculated Carbon Aromaticity Index limit is 850 for loads below 50% of rated kW output or for load cycling applications.

CATERPILLAR DISTILLATE DIESEL FUEL SPECIFICATIONSSpecifications (ASTM Test) Requirements

Aromatics (D 1319) 35% maximum

Ash (D 482) 0.02% weight maximum

Carbon Residue on 1.05% weight maximum

10% bottoms (D524)

Cetane Number (D613) 40 minimum

Cloud Point (D97) maximum not above lowest

expected ambient temperature

Copper Strip Corrosion (D130) No. 3 maximum

Distillation (D86) 10% @ 282° C (540° F) maximum

90% @ 360° C (680° F) maximum

Flash Point (D93) legal minimum

API Gravity (D287) 30 minimum/45 maximum

Pour Point (D97) 6° C (10° F) minimum below

ambient temperature

Sulfur (D3605 or D1552) 3% maximum

Viscosity (D445) 1.4 cSt minimum

Kinematic @ 40° C (104° F) 20.0 cSt maximum

Water & Sediment (D1796) 0.1% maximum

Water (D1744) 0.1% maximum

Sediment (D473) 0.05% weight maximum

Gums & Resins (D381) 10 mg/100 ml maximum

Lubricity by Scuffing 3100 g minimum

Load Wear Test or 0.45 mm maximum at 60° C (140° F) or

High Frequency Reciprocating Rig 0.38 maximum at 25° C (77° F)

3600 HFO ENGINE DESIGN FEATURES1. Mnemonic exhaust valves

2. Exhaust valve seat with direct water cooling

3. Unit type fuel injection w/ separate tip coolant passage

4. Oversized turbocharger for high air flow and cooling

5. Turbocharger water wash

3130

CA

LCU

LAT

ION

S —

EN

GLI

SH

1.Fu

el R

ate

(gal

lon

/min

)A

ssum

e 35

API

dis

tilla

te f

uel,

fuel

den

sity

= 7

.001

lb/g

al

RED

UC

ED E

QU

ATI

ON

EXA

MPL

E

1.1

RED

UC

ED E

QU

ATI

ON

EXA

MPL

E

160

min

1000

g7.

001

lbm

inut

ebk

W•h

rx

xx

x=

gram

sbk

W1

hr2.

205

lb1

U.S

. gal

U.S

. gal

lon

min

ute

=(g

/bkW

•hr)

(bkW

)(0.

0000

0529

3)U

.S. g

allo

n

min

ute

(200

g/b

kW)(

1850

bkW

)(0.

0000

0529

3) =

1.9

U.S

. gal

lon

7.00

1 lb

min

ute

=1

60 m

inhp

•hr

xx

xlb

hphr

1 ga

lU

.S. g

allo

n

min

ute

=(lb

/hp•

hr)(

hp)(

0.00

2381

)U

.S. g

allo

n min

ute

(0.3

29 lb

/hp•

hr)(

2480

hp)

(0.0

0238

1) =

1.9

U.S

. gal

lon

ENGINE BORE STROKE NUMBEROF

INCH MM INCH MM CYLINDERS

3606 11.02 280 11.81 300 L6

3608 11.02 280 11.81 300 L8

3612 11.02 280 11.81 300 V12

3616 11.02 280 11.81 300 V16

CONSTANTS FOR POWERENGINE DISPLACEMENT CALCULATIONS

K CIN3 L ENGLISH SI ENGLISH SI

3606 6763.8 110.84 117.1 1.08 44.85 8.82

3608 9018.4 147.78 87.8 8.12 59.81 11.76

3612 13527.6 221.67 58.6 5.41 89.71 17.64

3616 18036.8 295.56 43.9 4.06 119.61 23.52

PERFORMANCE CALCULATIONS

3332

CALCULATIONS — ENGLISH

3. Power (hp)

EXAMPLE

3.1 Power (hp)

POWER (hp) =

K =

BMEP (psi) x SPEED (rpm) x DISP (in )3

3

792 000

BMEP (psi) x SPEED (rpm)

K

792 000

DISPLACEMENT (in )

=

= 2485 hp291 (psi) x 1000 (rpm) x 6763.8 (in )3

792 000

POWER (hp) =TORQUE (lb•ft) x SPEED (rpm)

5252


2. Heat Rate (BTU/ekW•hr)Assume fuel with a LHV of 42 780 kJ/kg, 96.5% efficient generator

REDUCED EQUATION

EXAMPLE

kg ekW•hr=

1000 gbkW•hrx x x

g 1 bkW 1 kg 42 780 kJ

1.055 kJx

BTU BTU

0.965 ekW

ekW•hr=(g/bkW•hr)(42.02)

BTU

ekW•hr(200 g/bkW•hr)(42.02) = 8404

BTU

3534

CALCULATIONS — SI

5. Fuel Rate (liters/min)Assume 35 API distillate fuel, fuel density 838.9 g/L

REDUCED EQUATION

EXAMPLE

1 60 min 838.9 g minutebkW•hrx x x =

grams bkW 1 hr 1 liter liters

minute=(g/bkW•hr)(bkW)(0.00001987)

liters

minute(200 g/bkW)(1850 bkW)(0.00001987) = 7.35

liters


4. Torque (lb•ft)

4.1 Torque (lb•ft)

EXAMPLE

TORQUE (lb•ft) =

C =

BMEP (psi) x DISPLACEMENT (in )

= BMEP x C

150.797

DISPLACEMENT

150.797

3

TORQUE (lb•ft) =POWER (hp) x 5252

SPEED (rpm)

13 051 (lb•ft) =2480 (hp) x 5252

1000 (rpm)

3736

CALCULATIONS — SI

7. Power (kW)

EXAMPLE

POWER (kW) =

K =

BMEP (kPa) x SPEED (rpm) x DISP (L)

120 030

BMEP (kPa) x SPEED (rpm)

K

120 030

DISPLACEMENT (L)

=

= 5959 kW2420 (kPa) x 1000 (rpm) x 295.56 (L)

120 030

CALCULATIONS — SI

6. Heat Rate (kJ/ekW•hr)Assume fuel with a LHV of 42780 kJ/kg, 96.5% efficient generator

REDUCED EQUATION

EXAMPLE

kg ekW•hr=

1000 gbkW•hrx x x

g 1 bkW 1 kg 42 780 kJ kJ

0.965 ekW

ekW•hr=(g/bkW•hr)(44.33)

kJ

ekW•hr(200 g/bkW•hr)(44.33) = 8866

kJ

39

CALCULATIONS — MISCELLANEOUS9. BMEP (kPa)

10. PISTON SPEED (m/s)

11. OUTPUT FACTOR

12. PROPELLER DEMAND CURVE(i.e. cubic curve, prop curve)

EXAMPLE

NOTE: bhp can replace bkW directly

BMEP (kPa) =POWER (kW) x 120 030

SPEED (rpm) x DISPLACEMENT (L)

PISTON SPEED (m/s) =2 x STROKE (mm) x SPEED (rpm)

1000 x 60

OUTPUT FACTOR = BMEP (kPa) x PISTON SPEED (m/s)

POWERSpeed xx PowerMatch

Speed x

Speed Match= ( )

3

1458 bkW@ 700 rpmx 4250 bkWMatch

700 rpm

1000 rpm= ( )

3

CALCULATIONS — SI

8. Torque (N•m)

8.1 Torque (N•m)

EXAMPLE

TORQUE (N•m) =

C =

BMEP (kPa) x DISPLACEMENT (L)

= BMEP x C

12.566

DISPLACEMENT (L)

12.566

TORQUE (N•m) =POWER (kW) x 9552

SPEED (rpm)

17 671 (N•m) =1850 (kW) x 9552

1000 (rpm)

38

4140

CALCULATIONS — MISCELLANEOUS14. Fuel Consumption Example

Generator set package is producing 17.5 bkW•hr/U.S. gallon

What is the engine’s brake specific fuel consumption (BSFC) in g/bKW•hr?

The fuel type is IF380 HFO with a Lower Heating Value (LHV) of 39 900 and a density of 8.3 lb/gal. Assume the generator to be 96.5% efficient.

To convert the IF380 fuel which has a heating value of 39 900 to a standard reference (i.e. distillate) LHV of 42 780 kJ/kg follow the procedure below:

LHV = 39 900original

BSFC = 193.6new

LHV = 42 780new

gbkW•hr

BSFC = 207.6 X ( )new

gbkW•hr LHV

LHV original

new

CALCULATIONS — MISCELLANEOUS13. Load Factor (LF)

Assume fuel density = 838.9 g/L

EXAMPLE

NOTE: Total number of hours in the numerator must equal the total number of hours in the denominator.

PL = Part Load Factor (bkW or ekW)PL BSFC = Part Load Fuel Consumption (g/bkW•hr)FD = Fuel Density (g/liter)Time (hrs)

LF (%) = x 100Consumed fuel per year (liters or gallons)

Rated power fuel consumption per year (liters or gallons)( )LF (%) = x 100[(PL x PL BSFC x Time) + (PL x PL BSFC x Time) + . . . ] x FD

Rated Power x Rated Power BSFC x FD x 8000 hrs

LF (%) = x 100 = 67.78%[(1000 x 260 x 2000) + (2000 x 220 x 2000) + (4920 x 200 x 4000) ] x

4920 x 200 x x 8000

1838.9

1838.9

4342

CALCULATIONS — MISCELLANEOUS15. Fuel Consumption Comparison, cont.

The Caterpillar brake specific fuel consumption (BSFC) is based on an LHV of 42,780kJ/kg. Referring to example 13 on the previous page, we can convert the heating valueto 42,000 kJ/kg by:

The competitor’s fuel consumption is calculated with pumps. To calculate the fuelconsumption without pumps, use the following:

The Caterpillar BSFC is lower than the competitor’s.

BSFC = 190 X ( )gbkW•hr

BSFC = 190 X ( )gbkW•hr

gbkW•hr

42 780 kJ/kg42 000 kJ/kg

LHVLHV original

new

= 193.5

BSFC without pumps = BSFC with pumps - [(BSFC with pumps)*(% pump power losses)]

BSFC without pumps = 200 g/bkW•hr - (200 g/bkW•hr)*(0.03) = 194 g/bkW•hr

CALCULATIONS — MISCELLANEOUS15. Fuel Consumption ComparisonASSUMPTIONSAssume the Caterpillar fuel consumption is 190 g/bkW•hr without pumps, for a distillate3616 engine at 1000 rpm CSR rating. This is based on ISO 3046 standard conditions of100 kPa and 25° C and a fuel having a Lower Heating Value (LHV) of 42,780 kJ/kg.

Assume that the competitor’s fuel consumption is 200 g/bkW•hr with pumps, for acomparable engine rating, based on ISO 3046 standard conditions of 100 kPa and 25° Cand a fuel having an LHV of 42,000 kJ/kg. Contact the manufacturer for the exact pumppower consumption. We will assume the fuel consumption will decrease by 3% due topump power losses.

COMPARISONTo make a comparison between the two fuel consumption values equal, it is necessaryto base it on the same assumptions. We need to make the lower heating values thesame and make both fuel consumptions based on having no pumps.

4544

CONVERSIONSEnglish > SI

Millimeter (mm) = inch x 25.4Liter (L) = inch3 x 0.016Liter (L) = gallon x 3.79Gram (g) = ounce x 28.3

Kilogram (kg) = pound x 0.454Kilonewton (kN) = pound x 0.00445Newton meter (N•m) = lb•ft X 1.36

Kilopascal (kPa) = psi x 6.89Kilowatt (kW) = hp x 0.746

Kilowatt (kW) = Btu/min x 0.01758Kilojoule (kJ) = Btu x 1.055°Celsius (°C) = (°F -32) /1.8

SI > EnglishInch = 0.03937 x mm

Inch3 = liter x 61Gallon = liter x 0.26

Ounce = gram x 0.035Pound = kg x 2.2Pound = kN x 225Lb-ft = N•m x 0.74psi = kPa x 0.145hp = kW x 1.34Btu = kJ x 0.948

Btu/min = kW x 56.869°Fahrenheit = (°C x 1.8) + 32

SI Prefixes1 000 000 000 G giga

1 000 000 M mega1 000 k kilo

100 h hecto10 da deca0.1 d deci

0.01 c centi0.001 m milli

0.000 001 µ micro0.000 000 001 n nano

130

120

110

100

90

80

70

60

50

40

30

20

10

0

-10

-20

-30

2602502402302202122001901801701601501401301201101009080706050403220100

-10-20

°F °C ¡F ¡C550

540

530

520

510

500

490

480

470

460

450

440

430

420

410

400

390

380

370

360

350

102010101000990980970960950940930920910900890880870860850840830820810800790780770760750740730720710700690680670660

¡F ¡C750

740

730

720

710

700

690

680

670

660

650

640

630

620

610

600

590

580

570

560

550

1380137013601350134013301320131013001290128012701260125012401230122012101200119011801170116011501140113011201110110010901080107010601050104010301020

CONVERSIONSTEMPERATURE CONVERSION

4746

Caterpillar Offices

Caterpillar of AustraliaPRIVATE MAIL BAG 4

TULLAMARINEVICTORIA 3043, AUSTRALIA

Phone: ++61 03 9339-9333Fax: ++61 03 9338-9021

Caterpillar China LimitedLEVEL 8 ONE PACIFIC PLACE

88 QUEENSWAYG.P.O. BOX 3069

HONG KONGPhone: ++852 2848-0333Fax: ++852 2848-0440

Caterpillar North American Commercial Division(Mossville)

P.O. BOX 610MOSSVILLE, IL 61552

Phone: ++1-800-321-7332Fax: ++1-309-578-2559

(Lafayette)3701 S.R. 26 EAST

LAFAYETTE, IN 47905Phone: ++1-765-448-5000Fax: ++1-765-448-5586

Listing does not include all Caterpillar offices.

Caterpillar Offices

If you have any questions, please consult your localCaterpillar dealer. If you need assistance in finding adealer, consult one of our Caterpillar offices.

Caterpillar Americas Co.100 NE ADAMS ST.

PEORIA, ILUSA 61629-9340Phone: ++1-309-675-1762Fax: ++1-309-675-1764

Caterpillar Overseas S.A.76, ROUTE DE FRONTENEX

P.O. BOX 60001211 GENEVA 6SWITZERLAND

Phone: ++41 22 849 44 44Fax: ++41 22 849 49 84

Caterpillar Asia PTE. LTD.7 TRACTOR ROADSINGAPORE 627968

REPUBLIC OF SINGAPORE 9161Phone: ++65 662-8400Fax: ++65 662-8414

Caterpillar Power Systems Inc.SANNO GRAND BLDG., 8TH FLOOR

2-14-2 NAGATACHOCHIYODA-KU, TOKYO 100

JAPANPhone: (03) 3593-3231Fax: (03) 3593-3238

48

Notes:

49

Reference PublicationsTo receive one of the following brochures, please consult your local dealer.

Media # DescriptionLECQ4021 3600 Family of Heavy Fuel EnginesLECQ4022 3600 Family of EnginesLEDQ8363 3600 Diesel Lube Oil SelectionLEHX5458 3600 Family Generator Sets for Heavy Fuel (Spec. Sheet)LEHX5459 3600 Family Generator Sets (Spec. Sheet) Performance DataPEHP7076 Understanding the S•O•SSM Oil Analysis TestsRENR1357 Diesel Plant Operation HandbookRENR1358 3600 Diesel Service Handbook (3-Volume Set)SEBD0640 Oil and Your EngineSEBD0717 Diesel Fuels and Your EngineSEBD0970 Coolant and Your EngineSEBD9129 3600 Engine News Special EditionSEBU6965 3600 Diesel Operation and Maintenance Manual — DistillateSEBU6966 3600 Diesel Operation and Maintenance Manual — HFOSEBU7003 3600 Fluids Recommendations for Lube Oil, Fuel,

and CoolantsSELU6965 Maintenance Wall Chart — DistillateSELU6966 Maintenance Wall Chart — HFO

3618 PublicationLEHM6711 3618 Marine Propulsion Engine

51

Notes:

50

Notes:

LEXQ7766-02 Printed in U.S.A. © 1998 Caterpillar Inc.All rights reserved.

Materials and specifications are subject to change without notice.The International System of Units (SI) is used in this publication.

3612 Cutaway

Pocket Guide - 3600 (LEXQ7766)

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Transcript of Pocket Guide - 3600 (LEXQ7766)