Copyright 1991, 2002 Caterpillar Inc. All Rights Reserved.

Page 1 of 3

3XF G3606 GAS ENGINE Engine News

Media Number SEBD9236-00 Publication Date 1996/06/12 Update Date 1996/10/11

Improvements To Check Valve Within Prechamber Group

Reduce Maintenance Schedule
1106

G3606 (3XF ), G3608 (4WF ), G3612 (1YG ), G3616 (4CG ) Engines

REFERENCE: Operation And Maintenance Manual (SEBU6278, SEBU6496), Systems Operation

Testing And Adjusting (SENR4258, SENR5528), Engine News, November 1995, "New Check
Valve Used In Prechamber Groups".

Recent improvements to the check valves within the prechamber group of the above G3600 Engines
have reduced the required maintenance performed on the check valves. As the result, the following
maintenance schedule should be used for the check valves.

Check Valve Maintenance Schedule At The 10,000 Hour

Interval

file://C:\sis\tmp\sis10A1prt.html 8/6/2002
Copyright 1991, 2002 Caterpillar Inc. All Rights Reserved. Page 2 of 3

Illustration 1: Location of a check valve within a typical prechamber group.

1. Remove the check valve from the cylinder head.

2. Visually inspect the check valve for combustion deposits on the barrel located directly below the
threads. If combustion deposits are evident, replace the valve.

3. Perform the followingLeak-Down Check on valves which do not show evidence of combustion
deposits on the barrels.

Leak-Down Check:

· Attach the Leak-Down Check tooling to a check valve. Refer toLeak-Down Check Tooling.
· Attach a regulated air supply to the leak-down test tooling.
· Pressurize the check valve to 827 kpa (120 psi) and close the isolation valve.
· For a check valve to pass the Leak-Down Check, the pressure must NOT drop below 689 kpa (100
psi) within a 10 second period.

· Repeat the Leak-Down Check for each check valve.

· The valves that do NOT pass the Leak-Down Check should be replaced with new check valves.
4. Place new O-rings and gaskets on the check valves that pass the Leak-Down Check.

5. Replace the new and refurbished check valves.

Leak-Down Check Tooling

The leak-down check tooling, as shown in Illustration 2, is used to supply regulated air to the check
valves. The tooling must include a pressure valve with a maximum reading of 1378 kpa (200 psi) and
a ball valve (or other quick action valve).

file://C:\sis\tmp\sis10A1prt.html 8/6/2002
Copyright 1991, 2002 Caterpillar Inc. All Rights Reserved. Page 3 of 3

The overall length between the check valve and the isolation valve must not be more than 305 mm
(12.0 in).

NOTE: The pressure gauge must be coupled as close as possible to the air line.

Illustration 2: Leak-Down Check Tooling (This is a reference drawing in order to construct this
tooling for the purpose of performing the Leak-Down Check.): (A) 11.2 mm (0.44 in) internal thread,
20 mm (0.8 in) depth, thread diameter is 1/4of an inch, 18 threads per inch. (B) 1.5 ± 0.5 mm (0.060
± 0.020 in) at 45 degrees. (C) Radius 0.4 ± 0.1 mm (0.016 ± 0.004 in). (D) 5.5 mm (0.2 in) internal
thread with 20 mm (0.8 in) depth. (E) 30.0 degrees. (F) Slot 11.11 mm (0.437 in) x 20.64 mm (0.813
in). (G) 61.7 mm (2.43 in). (H) Deburr. (I) Radius 3.50 mm (0.138 in). (J) 35.00 mm (1.378 in). (K)
Diameter 19.75 mm (0.778 in), to depth shown, 7/8of an inch, 9 internal threads per inch. (L) 16.50
mm (0.650 in). (M) 22.00 mm (0.866 in). (N) 19.00 mm (0.748 in). (O) Diameter 18.36 mm (0.723
in), to depth shown .
Copyright 1991, 2002 Caterpillar Inc.
All Rights Reserved.

file://C:\sis\tmp\sis10A1prt.html 8/6/2002