COURSE DESCRIPTION

Course Title: Gas Engines I

Course Number: CAT 500
Course Length: 36 Hours
Course Format: 70% ILT, 30% Lab, 0% Web
Instructor(s): Geoff Bogner, Brandon Millikan
Class Max: 8
Class Minimum: 4
Course Cost(s): Internal none, Customers - $2150
Prerequisite(s): None

Course Description:
Gas Engines I students study the basic operating principles of gaseous-fueled engines. Emphasis is
on the composition of gaseous fuels, horsepower calculations, maintenance, fuel system, intake and
exhaust system, and the ignition system. In addition, the students learn about the media resources
available through SIS (Service Information System) and GERP (Gas Engine Rating Pro). The Lab
engine is a G3406, although the content covers the G300, G3300, G3400, and G3500 series of
Caterpillar engines.
Course Objectives:
Upon completion of this course, the participant will be able to:
Explain the operating principles of basic gaseous fueled engines
Understand the air fuel ratio differences between a standard, rich, and lean burn gas engine
Evaluate pre-ignition, detonation, and misfire
Calculate the effect of temperature, altitude, and fuel heat value on developed horsepower
Identify the proper media and procedures for preventive maintenance practices and schedules
Perform cooling system, lubrication system, and fuel system maintenance
Determine the effects of separate circuit after coolers on engine performance
Understand operation, define correct settings, and adjust a gas pressure regulator
Measure and calculate the pressure relationships in a gas engine
Understand operation and adjustments of a carburetor
Determine the effects of turbochargers and wastegates on engine performance
Correctly set up and tune a gas engine using an exhaust gas analyzer
Understand the Altronic magneto ignition system, and correctly set ignition timing
Perform diagnostic troubleshooting of a gas engine based on the learned class principles

Registration Information:
Wagner Training Institute 800.515.8692 (toll-free) 303.739.3198 (fax) www.wagnertraining.com
 COURSE DESCRIPTION

Course Title: Gas Engines II

Course Number: CAT 501
Course Length: 36 Hours
Course Format: 80% ILT, 20% Lab, 0% Web
Instructor(s): Geoff Bogner, Brandon Millikan
Class Max: 8
Class Minimum: 4
Course Cost(s): Internal none, Customers - $2150
Prerequisite(s): CAT 500 Gas Engines I

Course Description:
Gas Engines II (G3300, G3400, and G3500 Stoichiometric & Lean Burn Gas Engine Principles)
covers electrical systems and special considerations necessitated by lean burn low emissions gas
engines, specifically the G3500 Engine family. One day is spent in review of stoichiometric principles.
The remainder of the class is spent discussing principles of lean burn engines, the advanced wiring
associated with the accompanying control systems, and doing tests and adjustments on running
G3406 and G3516B engines. The effective use of Caterpillar service literature will be practiced.

Note: Students are asked to bring a calculator and safety glasses to class. Students should wear
work clothes for the lab and are required to wear work shoes (leather soles) in the building and lab
area.
Course Objectives:
Upon completion of this course, the participant will be able to:
Calculate the effects of turbochargers, aftercoolers, and wastegates on engine performance
Calculate the effects that altitude and temperature changes have on engine performance
Calculate the minimum gas supply pressure requirement for a gas engine
Calculate the full load gas flow based on Brake Specific Fuel Consumption (BSFC)
Connect and properly use Cat ET for setup and diagnostic of the ADEM 3 engine
Study the operation and set up of the engine Status Control Module (SCM)
Understand the progression of technology in engine and emission system controls
Understand the operation of the electronic air fuel ratio controls
Troubleshoot and repair an ADEM 3 air/fuel ratio controlled engine using wiring schematics,
service information and Cat ET

Registration Information:
Wagner Training Institute 800.515.8692 (toll-free) 303.739.3198 (fax) www.wagnertraining.com
 COURSE DESCRIPTION

Course Title: ADEM III

Course Number: CAT 520
Course Length: 36 Hours
Course Format: 65% ILT, 35% Lab, 0% Web
Instructor(s): Richard Blakney, Geoff Bogner, Brandon Millikan
Student Maximum: 8
Student Minimum: 4
Course Cost(s): Internal none, Customers - $2150
Prerequisite(s): CAT 500 Gas Engines I

Course Description:
The ADEM III course provides learners with an understanding of ADEM III control systems with an
emphasis on understanding wiring schematics, relevant service literature, and their effective use in
the troubleshooting process. Students also develop the skills required to properly setup and tune
G3500 A and B lean burn and ultra lean burn engines to the desired emission specifications.
Students use the emission analyzer as a tool during lab activities to understand the effects of
cylinder temperatures, as they relate to required emission levels and the adverse effects they can
have on the life of the engine.
Course Objectives:
Upon completion of this course, participants will be able to:
Understand the operating principles of Caterpillar ADEM III gas engine controls
Understand the electrical principles of the ADEM III control system
Understand wiring diagrams and symbols
Locate relevant service literature needed for the repair process
Develop troubleshooting skills to diagnose and effectively repair ADEM III control systems
Understand the operations of the air/fuel ratio of the engine control system
Understand the effective use of the emission analyzer to aid in troubleshooting and achieving
desired emission levels
Understand the initial installation and startup process

Registration Information:
Wagner Training Institute 800.515.8692 (toll-free) 303.739.3198 (fax) www.wagnertraining.com
 COURSE DESCRIPTION

Course Title: Applied Failure Analysis for Natural Gas Engines

Course Number: CAT 525
Course Length: 40 Hours
Course Format: 50% ILT, 50% Lab, 0% Web
Instructor(s): Dan Price
Student Maximum: 8
Student Minimum: 4
Course Cost(s): Internal none, Customers - $2150
Prerequisite(s): None

Course Description:
Applied Failure Analysis of Natural Gas Engines will focus on the basic principles of wear, fractures,
and managing the failure analysis process itself. Students learn to follow the failure analysis process
to arrive at the most probable root cause of failure. After instruction in these basics, students then
learn to apply the fundamentals to major components of natural gas engines. The course consists of
classroom instruction and laboratory exercises, and concludes with case studies of failures that have
occurred in the field.
Course Objectives:
Upon completion of this course, participants will be able to:
Understand the management of Applied Failure Analysis
Understand basic metallurgy, basic principles of fractures, and basic principles of wear
Understand failure analysis of engine bearings, crankshafts, engine valves, pistons, rings,
liners, and other natural gas engine components

Registration Information:
Wagner Training Institute 800.515.8692 (toll-free) 303.739.3198 (fax) www.wagnertraining.com