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MAINTENANCE INTERVALS - Safety

1. Illustration 50 g01103365 1 Filter case 2 Nut 3 Loosen nut 2 Hold filter case 1 and remove nut 2 Prepare to catch the fuel that is inside of the filter case with a suitable container Remove the filter case from the mounting bolt 4 Remove the element and wash the element in clean nonflammable solvent Allow the element to dry Inspect the element Install a new element if the old element is damaged or deteriorated 5 Clean the inside of the filter case Allow the filter case to dry 6 Inspect the O ring seals Obtain new seal rings if the old seal rings are damaged or deteriorated Ensure that the sealing surfaces for the seals are clean Install the seals NOTICE Do not fill the fuel filters with fuel before installing the fuel filters The fuel will not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts 7 Place the element in the filter case Slide the filter case over the mounting bolt 8 Install the nut 9 Open the fuel supply valve SEBU8666 07 85 Maintenance Section Fuel System Primary Filter Water Separator Drain 10 Prime the fuel system See this Operation and Maintenance Manual Fuel System Prime topic 102310280 Fuel System Primary Filter Water Separator Drain SMCS Code 1260
2. 1 Fill the cooling system with Extended Life Coolant ELC After filling the cooling system do not install the radiator filler cap 2 Open the water inlet for the separate circuit aftercooler Start the engine Operate the engine in order to purge the air from the cavities of the engine block Allow the ELC to warm and allow the coolant level to stabilize Stop the engine 66 Maintenance Section Cooling System Coolant Extender ELC Add SEBU8666 07 3 Check the coolant level Maintain the coolant to the proper level on the sight gauge if equipped If a sight gauge is not equipped maintain the coolant within 13 mm 0 5 inch below the bottom of the filler pipe 4 Clean the radiator filler cap Inspect the gaskets of the radiator cap If the gaskets of the radiator filler cap are damaged discard the old radiator filler cap and install a new radiator filler cap If the gaskets of the radiator filler cap are not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the radiator filler cap The correct pressure is stamped on the face of the radiator filler cap If the radiator filler cap does not maintain the correct pressure install a new radiator filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 102076027 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Cat ELC Extended Life Coolant does not require the frequent Su
3. 2 Close the drain valve 101041029 Batteries Replace SMCS Code 1401 510 Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite This can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced 1 Turn the key start switch to the OFF position Remove the key and all electrical loads 2 Turn OFF the battery charger Disconnect the charger 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the ground plane Disconnect the cable from the NEGATIVE battery terminal 60 Maintenance Section Battery Electrolyte Level Check SEBU8666 07 4 The POSITIVE cable connects the POSITIVE battery terminal to the starting motor Disconnect the cable from the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Return used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before connecting the cables ensure that the key start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Connect the cable from the ground plane to the NEGATIVE battery terminal 102
4. Inspecting the alignment of the driven equipment Most owners will save money by overhauling the engine at the intervals that are recommended in this Operation and Maintenance Manual Consider the graph in Illustration 58 Illustration 58 g00745964 Y Cost X Time 1 Cost of maintenance and repair that is planned 2 Cost of maintenance and repair that is not planned In Illustration 58 line 1 represents the maintenance and repair costs for an owner that followed the recommendations for inspection maintenance and repair The peaks represent overhauls Line 2 represents the maintenance and repair costs for an owner that chose to operate beyond the recommended intervals The initial cost of the repair after failure philosophy is lower Also the first overhaul was delayed However the peaks are significantly higher than the peaks for the customer that used the repair before failure philosophy The higher peaks result from two key factors Delaying an overhaul until a breakdown increases the chance of a catastrophic failure This type of failure requires more parts labor and cleanup Excessive wear means that fewer components will be reusable More labor may be required for salvage or repair of the components When all of the costs are considered repair before failure is the least expensive alternative for most components and engines It is not practical to wait until the eng
5. The chemical limits were developed in order to maintain the expected aftertreatment devices life performance and service intervals Use of oils other than Cat DEO ULS or oils that do not meet the Cat ECF 3 specification and the API CJ 4 oil category and or ACEA E9 category for EU and Japan specific applications listed above in aftertreatment equipped engines can negatively affect performance of the aftertreatment devices can contribute to Diesel Particulate Filter DPF plugging and or can cause the need for more frequent DPF ash service intervals Refer to your aftertreatment device documentation if available for additional guidance Typical aftertreatment systems include the following e Diesel Particulate Filters DPF e Diesel Oxidation Catalysts DOC e Selective Catalytic Reduction SCR e Lean NOx Traps LNT Other systems may apply For pre Tier 4 engines that use ULSD and LSD fuels if the recommended Cat DEO ULS is not used commercial oils that meet Cat ECF 3 Cat ECF 2 or Cat ECF 1 a are acceptable SEBU8666 07 51 Maintenance Section Refill Capacities Commercial oils that meet Cat ECF 3 specifications may be used in these applications if an oil analysis program is followed The oil change interval is affected by the fuel sulfur level Note For on Highway engines fluids recommendations refer to the Operation and Maintenance Manual of your engine and also refer to the most current revision level of Spe
6. exhaust leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water Note Use care when you use steam cleaning Use care when you use high pressure water Direct spray to rotating electrics or electronic components can cause nonfixable damage NOTICE Water and or condensation can cause damage to electrical components Protect all electrical compo nents from exposure to water e Ensure that the coolant lines are properly clamped Ensure that the fittings are tight Check for leaks Check the condition of all pipes e Inspect the water pump for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive
7. 1 A more detailed coolant analysis is recommended periodically For example considerable deposits are found in the water jacket areas on the external cooling system but the concentrations of coolant additives were carefully maintained The coolant water probably contained minerals which were deposited on the engine over time A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system A full water analysis may be obtained from the following sources e Caterpillar dealer e Local water utility company e Agricultural agent e Independent laboratory Caterpillar recommends an S O S coolant analysis Level Il This is a comprehensive chemical evaluation of the coolant This analysis is also a check of the overall condition of the inside of the cooling system The following services are provided Full Level analysis Identification of the source of metal corrosion and of contaminants Identification of buildup of the impurities that cause corrosion Identification of buildup of the impurities that cause scaling Determination of possible electrolysis within the engines cooling system A report of the results of the analysis is provided Maintenance recommendations are based on the results For more information about S O S coolant analysis consult your Caterpillar dealer 104688249 Overhaul Top End SMCS Code 7595 020 TE Refer to this Operation
8. 22 F 30 C 86 F SAE 5W 40 30 C 22 F 50 C 122 F SAE 10W 30 18 C 0 F 40 C 104 F SAE 10W 40 18 C 0 F 50 C 122 F SAE 15W 40 9 5 C 15 F 50 C 122 F Oil Change Intervals Note Decrease the interval between oil changes by 20 percent and or increase the API service classification for severe service Operation at high load factors of 80 percent or more for extended periods of time is considered extreme service Refer to Caterpillar Publication PEDP7035 S O S Fluid Analysis Interpretation Guide in order to understand optimizing oil change intervals Refer to Operation and Maintenance Manual Engine Oil and Filter Change for more information about oil change intervals Lubricant Capacities The capacity of the engine lubrication system includes the capacity of the oil filters that are installed at the factory Auxiliary oil filter systems if equipped will require additional oil Refer to the specifications that are provided by the OEM of the auxiliary oil filter system 52 Maintenance Section Refill Capacities SEBU8666 07 3512C HD Engine Table 18 Approximate Refill Capacities for 3512C HD Engine Lubrication Systems Compartment or System Liters US Gallons Standard sump 308 81 Fuel Fuel Recommendations In North America diesel fuel that is identified as No 1 D or No 2 D in ASTM D975 generally mee
9. European ULSD 0 0010 percent 10ppm mg kg sulfur fuel is required by regulation for use in engines certified to European nonroad Stage IIIB and newer standards and are equipped with exhaust aftertreat ment systems Certain governments localities and or applications MAY require the use of ULSD fuel Consult federal state and local authorities for guidance on fuel re quirements for your area Typical aftertreatment systems include Diesel Partic ulate Filters DPF Diesel Oxidation Catalysts DOC Selective Catalytic Reduction SCR and or Lean NOx Traps LNT Other systems may apply Low sulfur diesel LSD fuel 0 05 percent 500 ppm mg kg sulfur is strongly recommended for use in en gines that are pre Tier 4 models while diesel fuel with gt 0 05 percent 500 ppm mg kg sulfur is acceptable for use in areas of the world where allowed by law Pre Tier 4 engines that are equipped with a Diesel Ox idation Catalyst DOC require the use of LSD fuel or ULSD fuel ULSD fuel or sulfur free diesel fuel are applicable for use in all engines regardless of the engine Tier or Stage Use appropriate lubricating oils that are compatible with the engine certification and aftertreatment system and with the fuel sulfur levels Refer to the Diesel Fuel Sulfur Impacts article of this Fuels Specifications section and to the Lubricants Specifications section of this Special Publication Cat DEO ULS oil is available
10. MPGM 102039603 Battery or Battery Cable Disconnect SMCS Code 1401 1402 029 The connection of battery cables to a battery and the disconnection of battery cables from a battery may cause an explosion which may result in injury or death The connection and the disconnection of other electrical equipment may also cause an explosion which may result in injury or death The procedures for the connection and the disconnec tion of battery cables and other electrical equip ment should only be performed in a nonexplosive atmosphere The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury _ Turn the start switch to the OFF position Turn the ignition switch if equipped to the OFF position and remove the key and all electrical loads N Disconnect the negative battery terminal at the battery that goes to the start switch Ensure that the cable cannot contact the terminal When four 12 volt batteries are involved the negative side of two batteries must be disconnected eo Tape the leads in order to help prevent accidental starting A Proceed with necessary system repairs Reverse the steps in order to reconnect all of the cables SEBU8666 07 61 Maintenance Se
11. and oil Note Refer to Inspecting the Air Cleaner Elements Inspecting the Air Cleaner Elements Illustration 39 g00281693 Inspect the clean dry air cleaner element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the air cleaner element Rotate the air cleaner element Inspect the air cleaner element for tears and or holes Inspect the air cleaner element for light that may show through the filter material If it is necessary in order to confirm the result compare the air cleaner element to a new air cleaner element that has the same part number Do not use an air cleaner element that has any tears and or holes in the filter material Do not use an air cleaner element with damaged pleats gaskets or seals Discard damaged air cleaner elements Storing Air Cleaner Elements If an air cleaner element that passes inspection will not be used the air cleaner element can be stored for future use Illustration 40 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the air cleaner elements in Volatile Corrosion Inhibited VCI paper 76 Maintenance Section Engine Air Precleaner Clean SEBU8666 07 Place the air cleaner element into a box for storage For identification mark the outside of the box and mark the air cleaner element Include the
12. by Caterpillar or the OEM of the installation Record the total cooling system capacity in the appropriate Table Engine with 2 Stage Aftercooler 3512C HD Engine Table 20 Approximate Refill Capacities for the 3512C HD Engine Cooling System with 2 Stage Aftercooler Compartment or System Liters US Gallons Jacket water system 160 L 41 6 US gal Separate circuit aftercooler 22 8L 6 US gal External system Total cooling system Refer to Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations for additional information that relates to engine oil Lubricating Grease NOTICE These recommendations are subject to change with out notice Contact your local Caterpillar dealer for the most up to date recommendations Before selecting a grease the performance requirements must be determined Consult the OEM of the equipment for the recommended grease Then consult with your Caterpillar dealer for a list of greases that have the performance specifications and the available sizes of the container Note Always choose a grease that meets the recommendations or a grease that exceeds the recommendations that are specified by the equipment manufacturer for the application Note Purge all of the old grease from the joint when the grease is changed from one type of grease to another type of grease Purge all of the old grease from the joint when a different su
13. cavities of the engine block Allow the coolant to warm and allow the coolant level to stabilize Stop the engine 3 Check the coolant level Maintain the coolant to the proper level on the sight gauge if equipped If a sight gauge is not equipped maintain the coolant within 13 mm 0 5 inch below the bottom of the filler pipe 4 Clean the radiator filler cap Inspect the gaskets of the radiator filler cap If the gaskets of the radiator filler cap are damaged discard the old radiator filler cap and install a new radiator filler cap If the gaskets of the radiator filler cap are not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the radiator filler cap The correct pressure is stamped on the face of the radiator filler cap If the radiator filler cap does not maintain the correct pressure install a new radiator filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 104041130 Cooling System Coolant ELC Change SMCS Code 1350 044 NL Use only clean water to flush the cooling system when Extended Life Coolant ELC is drained and replaced SEBU8666 07 65 Maintenance Section Cooling System Coolant ELC Change Drain the Cooling System 1 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler Ensure that the engine will not start when the cooling system is drained 2 Loosen the ra
14. change This record will help to provide the most accurate analysis 104047621 Engine Oil Sample Obtain SMCS Code 1348 554 SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean SEBU8666 07 79 Maintenance Section Engine Oil and Filter Change Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pr
15. coolant leakage may indicate the need to replace the water pump seal For the removal of water pump and the installation of water pump and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer Inspect the lubrication system for leaks at the following locations front crankshaft seal rear crankshaft seal oil pan oil filters valve cover turbocharger external oil lines and connections Inspect the fuel system for leaks Look for loose fuel line clamps or connections Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps or connections Ensure that the exhaust system is properly clamped Ensure that the connections are tight Check for leaks Check the condition of all connections and components of the exhaust system Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and f
16. damper e Cylinder head assembly e Cylinder liners e Engine mounts e Scavenge oil pump e Engine wiring harness e Exhaust manifold seals e Exhaust manifold bellows e Fuel pressure regulating valve e Fuel priming pump e Fuel transfer pump e Inlet manifold gaskets e Inlet manifold seals e Oil cooler core e Oil pump e Pistons e Piston pins e Prelube pump e Pushrods e Rocker arms e Spacer plate e Software update e Turbocharger Inspection of Components Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts Aftercooler core Camshaft Crankshaft Driven equipment alignment Engine cylinder block Engine control module Exhaust bellow shields Flywheel Front gear train gears Oil suction screen Rear gear train Inspect the camshaft for damage to the journals and the lobes Inspect the crankshaft for any of the following conditions e Deflection e Damage to the journals e Bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the following components e Rod bearing e Main bearings Note If the crankshaft or the camshaft are removed for any reason use the
17. determining the overhaul intervals include the following considerations e Performance of preventive maintenance e Use of recommended lubricants e Use of recommended coolants e Use of recommended fuels Proper installation Operating conditions e Operation within acceptable limits Engine load e Engine speed Generally engines that are operated at a reduced load and or speed achieve more service life before an overhaul However this service life is for engines that are properly operated and maintained Other factors must also be considered for determining a major overhaul e The total amount of fuel consumption e The service hours of the engine e An increase of oil consumption e An increase of crankcase blowby e The wear metal analysis of the lube oil e An increase in the levels of noise and vibration An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need serviced An increase in the levels of noise and vibration indicates that rotating parts require service Note Oil analysis may indicate a decrease of wear metals in the lube oil The cylinder liners may be worn so that polishing of the bore occurs Also the increased use of lube oil will dilute the wear metals Monitor the engine as the engine accumulates service hours Consult your Cat dealer about scheduling a major overhaul Note The driven equipment may also require service when the engine is overhaul
18. e The damper is dented cracked or leaking e The paint on the damper is discolored from heat e The engine has had a failure because of a broken crankshaft The crankshaft bearings are showing excessive wear e There is a large amount of gear train wear that is not caused by a lack of oil Removal and Installation Refer to the Disassembly and Assembly Manual Vibration Damper Remove and Install article or consult your Cat dealer for information about damper replacement 100449093 Driven Equipment Check SMCS Code 3279 535 To minimize bearing problems and vibration of the engine crankshaft and the driven equipment the alignment between the engine and driven equipment must be maintained properly Check the alignment according to the instructions that are provided by the following manufacturers e Caterpillar e OEM of the coupling e OEM of the driven equipment 100935098 Driven Equipment Inspect Replace Lubricate SMCS Code 3279 040 Observe the driven equipment during operation Look for the following items e Unusual noise and vibration e Loose connections e Damaged parts Perform any maintenance that is recommended by the OEM of the driven equipment Refer to the literature of the OEM of the driven equipment for the following service instructions e Inspection e Lubricating grease and lubricating oil requirements e Specifications for adjustment e Replacement of components e Require
19. end of the engine speed timing sensor Check for signs of wear and contaminants 2 Clean the metal shavings and other debris from the face of the magnet 3 Install the engine speed timing sensor according to the information in the Service Manual Specifications Starting Motor Inspect If equipped SMCS Code 1451 040 1453 040 Air Starting Motor If the starting motor fails the engine may not start in an emergency situation A scheduled inspection of the starting motor is recommended The starting motor pinion and the flywheel ring gear must be in good condition in order for the engine to start properly The engine will not start if the starting motor pinion does not engage the flywheel ring gear The teeth of the starting motor pinion and the flywheel ring gear can be damaged because of irregular engagement Inspect the starting motor for proper operation Listen for grinding when the engine is started Inspect the teeth of the starting motor pinion and the flywheel ring gear Look for patterns of wear on the teeth Look for teeth that are broken or chipped If damaged teeth are found the starting motor pinion and the flywheel ring gear must be replaced Personal injury or death can result from improp erly checking for a leak Always use a board or cardboard when checking for a leak Escaping air or fluid under pressure even a pin hole size leak can penetrate body tis sue causing serious injury and possib
20. every three cleanings of the primary air cleaner element When the engine is operating in environments that are dusty or dirty air cleaner elements may require more frequent replacement Illustration 33 g00736431 1 Cover 2 Primary air cleaner element 3 Secondary air cleaner element 4 Turbocharger air inlet 1 Remove the cover Remove the primary air cleaner element 2 The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element Note Refer to Cleaning the Primary Air Cleaner Elements 3 Cover the turbocharger air inlet with tape in order to keep out dirt 4 Clean the inside of the air cleaner cover and body with a clean dry cloth 5 Remove the tape for the turbocharger air inlet Install the secondary air cleaner element Install a primary air cleaner element that is new or cleaned 6 Install the air cleaner cover 7 Reset the air cleaner service indicator Cleaning the Primary Air Cleaner Elements The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected When the primary air cleaner element is cleaned check for rips or tears in the filter material The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean primary air cleaner elements while dirty elements a
21. for the correct air cleaner element e Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element e The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected e The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Illustration 37 g00735127 1 Cover 2 Air cleaner element 3 Turbocharger air inlet 1 Remove the air cleaner cover Remove the air cleaner element Note Refer to Cleaning the Air Cleaner Elements 2 Cover the air inlet with tape in order to keep dirt out 3 Clean the inside of the air cleaner cover and body with a clean dry cloth 4 Remove the tape for the air inlet Install an air cleaner element that is new or cleaned 5 Install the air cleaner cover 6 Reset the air cleaner service indicator Cleaning the Air Cleaner Elements N
22. of the equip ment or your Caterpillar dealer regarding welding on a Chassis frame or rail Proper welding procedures are necessary in order to avoid damage to the engine s ECM sensors and associated components When possible remove the component from the unit and then weld the component If removal of the component is not possible the following procedure must be followed when you weld on a unit that is equipped with a Caterpillar Electronic Engine The following procedure is considered to be the safest procedure to weld on a component This procedure should provide a minimum risk of damage to electronic components NOTICE Do not ground the welder to electrical components such as the ECM or sensors Improper grounding can cause damage to the drive train the bearings hy draulic components electrical components and other components Do not ground the welder across the centerline of the package Improper grounding could cause damage to the bearings the crankshaft the rotor shaft and other components Clamp the ground cable from the welder to the com ponent that will be welded Place the clamp as close as possible to the weld This will help reduce the pos sibility of damage Note Perform the welding in areas that are free from explosive hazards 1 Stop the engine Turn the switched power to the OFF position 2 Disconnect the negative battery cable from the battery If a battery disconnect switch is provide
23. personal injury Do not allow hot oil or hot components to contact the skin Note When possible perform the maintenance while the engine is off Illustration 55 g02260278 1 Release latches 6 that hold the canister to filter base assembly 5 Note Removing canister 7 may be difficult while the engine is operating The canister has negative air pressure while the engine is operating This negative air pressure creates a vacuum 2 Lower the canister in order to expose the element There may be oil in the bottom of the canister Avoid spilling the oil 3 Remove the filter element by pulling down Dispose of the used element properly 4 Remove the O ring assembly on the top end cap of the used element 5 Replace the O ring seal on the bottom of the filter base assembly 6 Install the new O ring on the top end cap of the element Install the element into the correct place 7 Replace the canister and align the canister with the boss on the filter base assembly 8 Clamp the latches in the closed position SEBU8666 07 89 Maintenance Section Fumes Disposal Filter Service Indicator Check 104434870 Fumes Disposal Filter Service Indicator Check SMCS Code 1074 535 IND 1317 535 IND OJO O g01768374 Illustration 56 Typica
24. protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air cleaner elements in Volatile Corrosion Inhibited VCI paper Place the primary air cleaner element into a box for storage For identification mark the outside of the box and mark the primary air cleaner element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location Engine Air Cleaner Element Single Element Clean Replace SMCS Code 1051 1054 037 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine 74 Maintenance Section SEBU8666 07 Engine Air Cleaner Element Single Element Clean Replace Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer
25. water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank during the following conditions e Weekly e Oil change e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank A four micron c absolute filter for the breather vent on the fuel tank is also recommended If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used Fumes Disp
26. 00 Service Hours or Every 184 Day FRA Inspection Crankshaft Vibration Damper Inspect 69 Driven Equipment Check ccceeeeteeeeeenes 70 Engine Clean ea oa EA E 70 Engine Mounts Check sssseisseeeireseerrresrrerss 77 Every 3000 Service Hours Catalyst Module Inspect n 61 Cooling System Coolant DEAC Change 62 Cooling System Coolant Extender ELC Add 66 SEBU8666 07 57 Maintenance Section Maintenance Interval Schedule Every 4000 Service Hours or Every Yearly FRA Inspection Air Compressor Inspect cccceeeeeeeeeteeeeees 58 Engine Valve Lash Inspect Adjust 0 0 0 0 82 Fuel Injector Inspect Adjust eeeeeeeeeeees 83 Prelube Pump Inspect e ceeeeeteeteeeees 106 Starting Motor Inspect eeeeeeeeeteeeeeenees 107 Every 6000 Service Hours Cooling System Coolant ELC Change 64 Cooling System Water Temperature Regulator Replaces ce cehnee nett ae tennant 69 Speed Sensor Clean Inspect 0 0eee 107 Every 8000 Service Hours or Every 2 Year FRA Inspection Turbocharger Inspect n se 108 Water Pump Inspect cccccceeeeeeeeeeeeeteteees 110 Overhaul Aftercooler Core Inspect Clean 00008 58 Overhaul IN Frame ceeeecseeeeeeeeeeeeentteeeeeeeaes 96 Overhaul Major siiret eE 98 Overhaul Top End eeeeeeeeeeeeeeeeeeeeeteeee
27. 1 535 Check the catalyst module inlet and outlet fittings and connections for external exhaust leaks No leaks are acceptable 104801352 Catalyst Module Inspect SMCS Code 1091 040 In order to inspect the catalyst module perform the following steps 1 Inspect the catalyst module fittings and connections for external leaks No leaks are acceptable 2 Inspect the catalyst module and condensation drain lines for proper water drain capabilities 3 Inspect the mounting of the catalyst module 4 Inspect the catalyst module outlet and remove any debris 104687907 Catalyst Module Replace SMCS Code 1091 510 NOTICE Ensure that all components are free of contaminants before installing Contaminants may cause premature wear and reduced component service life NOTICE Ensure that all components have cooled before per forming maintenance on the components Use a hoist to remove heavy components All supporting members chains and cables should be parallel to each other The chains and cables should be perpendicular to the top of the object that is being lifted Some removals require lifting fixtures in order to obtain proper balance and safety Use the lifting eyes that are on the catalyst module 62 Maintenance Section Cooling System Coolant DEAC Change SEBU8666 07 Lifting eyes are designed and installed for the specific component Alterations to the lifting eyes make the lifti
28. 543 1263 543 Illustration 51 g01157156 1 Bowl 2 Drain Bowl 1 should be monitored daily for signs of water If water is present drain the water from the bowl 1 Open drain 2 The drain is a self ventilated drain Catch the draining water in a suitable container Dispose of the water properly 2 Close the drain NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system 103826612 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately Replace the secondary fuel filter element whenever the following conditions occur e The pressure gauge for the fuel filter registers 103 kPa 15 psi e The fuel filters have been used for 1000 service hours 1 Stop the engine Ensure that the engine will not start during this procedure 2 Shut off the fuel supply valve to the engine NOTICE Do not allo
29. 601752 Battery Electrolyte Level Check SMCS Code 1401 535 FLV When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water e A mixture of 0 1 L 0 11 qt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or
30. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel SEBU8666 07 87 Maintenance Section Fumes Disposal Filter Element Replace Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Note Failure to properly close the drain can allow air into the system which could have detrimental results to performance Check the fuel daily Drain the
31. CS Code 1803 040 An engine can be damaged by an air compressor that fails The engine oil lubricates the engine and the air compressor Failure of the air compressor could cause particles from the air compressor to contaminate the engine oil The circulation of these contaminants through the engine s lubrication system could damage the main bearings and the connecting rod bearings For information on inspection of the air compressor see the Service manual or see the literature that is provided by the OEM of the air compressor Consult your Caterpillar dealer for assistance SEBU8666 07 59 Maintenance Section Air Tank Moisture and Sediment Drain Personal injury or death can result from improp erly checking for a leak Always use a board or cardboard when checking for a leak Escaping air or fluid under pressure even a pin hole size leak can penetrate body tis sue causing 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 1 Inspect the air compressor and the components that are related to the air compressor for leaks Listen for air leaks Before you disconnect any line from the air com pressor purge the system of pressurized air Failure to purge the pressurized air before you ser vice the air compressor can result in personal in jury 2 Release all of the air pressure from the system 3 Remove th
32. Cat multigrade oil provides superior performance in Cat diesel engines Cat multigrade oils exceed many of the performance requirements of other manufacturers of diesel engines Therefore these oils are excellent choices for many mixed fleets True high performance oil is produced by using a combination of the following factors industry standard tests proprietary tests field tests and often prior experience with similar formulations The design and the development of Caterpillar lubricants that are both high performance and high quality are based on these factors Note Cat DEO ULS is excellent choices for many mixed fleets Refer to your engine manufacturer literature and requirements Note API CG 4 oil category is obsolete The API American Petroleum Institute does not license this category effective August 2009 Oils that claim API CG 4 are not recommended for Caterpillar engines Commercial Oils Commercial Crankcase Fluid Recommendations for all Current and Noncurrent Caterpillar Diesel Engines that are Covered by this Special Publication Note Non Caterpillar commercial oils are as a group second choice oils Within this grouping of second choice oils there are tiered levels of performance 50 Maintenance Section Refill Capacities SEBU8666 07 NOTICE Cat does not warrant the quality or performance of non Cat fluids Caterpillar developed the Engine Crankcase Fluid ECF specifications to ensure t
33. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR aon 2012 Operation and Maintenance Manual 3512C HD Locomotive Engine NJT1 Up 3512C HD Engine 48 Maintenance Section Refill Capacities SEBU8666 07 Maintenance Section Refill Capacities 104137447 Refill Capacities and Recommendations SMCS Code 1348 1395 7560 Lubrication System Lubricant Recommendations Cat DEO ULS Diesel Engine Oil Ultra Low Sulfur Cat oils have been developed and tested in order to provide the full performance and service life that has been designed and built into Cat engines Cat oils are currently used to fill diesel engines at the factory These oils are offered by Cat dealers for continued use when the engine oil is changed Consult your Cat dealer for more information on these oils Due to the additional full scale proprietary engine testing required of Cat DEO ULS and due to significant variations in the quality and in the performance of commercially available oils Caterpillar makes the following recommendation for e Cat DEO ULS Diesel Engine Oil Ultra Low Sulfur 15W 40 and 10W 30 Cat DEO ULS multigrade oils are formulated with the correct amounts of detergents dispersants and alkalinity in order to provide superior performance in Cat diesel engines where recommended for use Note Cat DEO ULS oil is the preferred oil f
34. OTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The air cleaner element can be used up to six times if the element is properly cleaned and inspected When the air cleaner element is cleaned check for rips or tears in the filter material The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage co
35. The engine oil level should be between ADD mark 5 and FULL mark 6 NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can cause the crankshaft to dip into the oil This will reduce the power that is devel oped and also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling oil blowing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber De posits in the combustion chamber lead to the following problems guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately 3 If necessary add engine oil For the correct engine oil to use refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section Do not fill the crankcase above the FULL mark on the engine oil level gauge Clean the filler cap 1 Install the filler cap 4 Record the amount of engine oil that is added For the next engine oil sample and analysis include the total amount of engine oil that has been added since the previous oil
36. al is damaged or deteriorated 7 Install retainer 8 spring 7 and cover 2 Ensure that the retainer and the spring are properly seated between the oil filter elements and the cover Inspect the Used Oil Filter Elements Cut the used oil filter element open with a utility knife Remove the metal wrap Cut the filter element free from the end caps Spread apart the pleats and inspect the element for metal debris An excessive amount of debris in the element may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the element Ferrous metals may indicate wear on the steel and the cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts the brass parts or the bronze parts of the engine Parts that may be affected include the following components main bearings rod bearings turbocharger bearings and cylinder heads Aluminum debris may indicate problems with the bearings of the front gears If aluminum debris is found inspect the crankshaft vibration damper and the bearings of the front idler gear Due to normal wear and friction small amounts of debris may be found in the oil filter element If an excessive amount of debris is found in the oil filter element consult your Caterpillar dealer in order to arrange for further oil analysis Fill the Crankcase NOTICE If the engine is equipped with an auxil
37. and Maintenance Manual Maintenance Recommendations in order to determine the maintenance interval for a top end overhaul A top end overhaul involves the removal the inspection and the rework of the cylinder head components Some additional components are replaced and serviced Your Cat dealer can provide these services and components Your Cat dealer can ensure that the components are operating within the appropriate specifications Note The driven equipment may also require service when the engine is overhauled Refer to the literature that is provided by the OEM of the driven equipment SEBU8666 07 101 Maintenance Section Overhaul Top End Top End Overhaul If you elect to perform an overhaul without the services of a Caterpillar dealer be aware of the following recommendations Cylinder Head Assembly Inspect the cylinder head assembly according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts Your Cat dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications The use of out of spec parts will cause unscheduled downtime and or costly repairs Unit Injectors Replace the unit injectors Consult your Cat dealer about exchanging the unit injec
38. and Recommendations or consult your Caterpillar dealer 104051750 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJO003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6251 Cater
39. bearings Note If the crankshaft or the camshaft are removed for any reason use the magnetic particle inspection process to check for cracks Replace the crankshaft vibration damper if any of the following conditions occur e Engine failure due to a broken crankshaft e Excessive wear of the front bearing for the crankshaft e Excessive wear of the gear train that is not caused by a lack of lubrication Inspect the gears of the gear train and inspect the gear train bushings for the following conditions e Worn gear teeth e Unusual fit e Unusual wear In addition to the inspection of components inspect the alignment of the driven equipment See the Application and Installation Guide for the engine or see the literature that is provided by the OEM of the driven equipment Cleaning of Components Clean the oil cooler core and the aftercooler core Then pressure test both of these cores For instructions on cleaning the cores see this Operation and Maintenance Manual Aftercooler Core Inspect Clean topic Clean the oil suction screen Also remove side covers in order to clean the oil sump For instructions on removal and installation of components see the Service Manual Disassembly and Assembly module Obtain a Coolant Analysis For a conventional heavy duty antifreeze coolant solution check the concentration of supplemental coolant additive SCA regularly The concentration of SCA can be checked wit
40. cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require clearances that are precise The turbocharger cartridge must be balanced due to high rpm Severe service applications can accelerate the wear of the components Severe service applications may require more frequent inspections of the turbocharger Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine or consult your Caterpillar dealer for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wh
41. cial Publication SEBU6385 Caterpillar On Highway Diesel Engine Fluids Recommendations or consult your Caterpillar dealer NOTICE In selecting oil for any engine application both the oil viscosity and oil performance category specifica tion as specified by the engine manufacturer must be defined and satisfied Using only one of these param eters will not sufficiently define oil for an engine appli cation In order to make the proper diesel engine oil viscosity grade choice refer to the Lubricant Viscosities for Ambient Temperatures table in this Special Publication NOTICE Failure to follow these oil recommendations can cause shortened engine service life due to deposits and or excessive wear NOTICE Do not use single grade API CF oils or multigrade API CF oils in Caterpillar Series 3500 Series C175 and smaller Direct Injection DI diesel engines API CF oils may only be used in Caterpillar Series 3600 and Series C280 diesel engines and older Caterpillar engines that have precombustion chamber PC fuel systems Oils that are used in Caterpillar Series 3600 and Series C280 diesel engines must also pass a 7000 field performance evaluation Consult your Caterpillar dealer for details NOTICE Do not add new engine oil waste engine oil or any oil product to the fuel unless the engine is designed and certified to burn diesel engine oil for exam ple Caterpillar ORS designed for large engines Ca
42. cooler core Remove any other trapped debris from the inside and from the outside of the core Note Do not use high pressure when the fins are cleaned High pressure can damage the fins 6 Wash the core with hot soapy water 7 Flush the core thoroughly in order to remove residue and remaining debris Flush the core with clean fresh water until the water that is exiting the core is clear and free of debris Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 8 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 9 Prior to installation inspect any O rings or seals for damage If necessary replace the O rings or seals 10 Inspect the core for trapped debris and cleanliness If it is necessary remove the debris and repeat the cleaning procedure 11 Inspect the core for damage and perform a pressure test in order to detect leaks Many shops that service radiators are equipped to perform pressure tests 12 Install the core Refer to Disassembly and Assembly Manual Aftercooler Remove and Install for the procedure For more information on cleaning the core consult your Caterpillar dealer i01076631 Air Compressor Inspect SM
43. ction Belts Inspect Adjust Replace 104035000 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspection Inspect the alternator belt and the fan drive belts for wear and for cracking Replace the belts if the belts are not in good condition Check the belt tension according to the information in the Service Manual Specifications Slippage of loose belts can reduce the efficiency of the driven components Vibration of loose belts can cause unnecessary wear on the following components e Belts e Pulleys e Bearings If the belts are too tight unnecessary stress is placed on the components This stress reduces the service life of the components Adjusting the Fan Drive Belt 1 Loosen the mounting bolt for the pulley 2 Loosen the adjusting nut for the pulley 3 Move the pulley in order to adjust the belt tension 4 Tighten the adjusting nut to the proper torque 5 Tighten the mounting bolt to the proper torque For the proper torque specifications refer to the Service Manual Specifications module Replacement For applications that require multiple drive belts replace the drive belts in matched sets Replacing one drive belt of a matched set will cause the new drive belt to carry more load because the older drive belts are stretched The additional load on the new drive belt could cause the new drive belt to fail 104801348 Catalyst Module Check SMCS Code 109
44. ctrical electronic components are used as a ground for the welder or electrical electronic components are located between the welder ground and the weld current flow from the welder could severely damage the component 5 Protect the wiring harness from welding debris and spatter 6 Use standard welding practices to weld the materials 56 Maintenance Section Maintenance Interval Schedule SEBU8666 07 104822398 Maintenance Interval Schedule SMCS Code 1000 4450 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of all maintenance which includes the following items performing all adjustments using proper lubricants fluids and filters and replacing old components with new components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Before each consecutive interval is performed all maintenance from the previous intervals must be performed Choose the interval that occurs first in order to determine the correct maintenance interval fuel consumption service hours and calendar time Products that operate in severe operating conditions may require more frequent maintenance All of the following will affect the oil change inte
45. d open the switch 3 Disconnect the J1 P1 and J2 P2 connectors from the ECM Move the harness to a position that will not allow the harness to accidentally move back and make contact with any of the ECM pins SEBU8666 07 55 Maintenance Section Maintenance Recommendations Illustration 29 g01075639 Use the example above The current flow from the welder to the ground clamp of the welder will not cause damage to any associated components 1 Engine 2 Welding electrode 3 Keyswitch in the OFF position 4 Battery disconnect switch in the open position 5 Disconnected battery cables 6 Battery 7 Electrical Electronic component 8 Minimum distance between the component that is being welded and any electrical electronic component 9 The component that is being welded 10 Current path of the welder 11 Ground clamp for the welder 4 Connect the welding ground cable directly to the part that will be welded Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings hydraulic components electrical components and ground straps Note If ele
46. d Maintenance Manual Fuel System Prime for information about priming the engine with fuel 8 Start the engine Inspect the fuel system for leaks Lubrication System Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin 1 Drain the oil from the lubrication system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose with a new hose 5 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 6 Refill the lubrication system Refer to this Operation and Maintenance Manual Engine Oil Level Check in order to ensure that the lubrication system is filled with the proper amount of engine oil 7 Start the engine Inspect the lubrication system for leaks Air System 1 Remove the hose clamps 2 Disconnect the old hose 3 Replace the old hose with a new hose 4 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps Note The bellows and the V clamps that are used on the bellows should never be reused 5 Start the e
47. d Top End Overhaul 54000 Service Hours 4500000 L 1188900 US gal 72000 Service Hours 6000000 L 1585200 US gal Major Overhaul 1 Fuel consumption is based on a load factor of approximately 25 percent Use the actual records of fuel consumption when Table 28 possible If the actual records are not available use Equation For Calculating Overhaul Intervals the following procedure in order to estimate the fuel consumption FIR H F is the estimated total amount of fuel consumption of 1 Estimate the average percent of the load for the the engine operation of the engine R is the rate of fuel consumption in liters per hour or 2 Refer to the fuel consumption data in the Technical gallons per hour Marketing Information TMI for your engine H is the number of estimated hours until the overhaul This data will determine the fuel consumption interval for the percent of the load that was estimated in Step 1 Use this figure as variable F for the equation in Table 28 For more information about Oil Consumption as an Overhaul the Technical Marketing Information TMI for your Indicator engine consult your Cat dealer Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Cat engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance inter
48. d and malfunction of the electric starting system 108 Maintenance Section Turbocharger Inspect SEBU8666 07 Inspect the electrical system for the following conditions e Loose connections e Corrosion e Wires that are worn or frayed e Cleanliness Removal and Installation of the Starting Motor Refer to the Service Manual Disassembly and Assembly module for information on removing the starting motor and installing the starting motor Consult your Caterpillar dealer for assistance and or for options on replacement of the starting motor 101261768 Turbocharger Inspect SMCS Code 1052 040 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Fouling of the compressor can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel could allow parts from the compressor wheel to enter an engine cylinder This can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not
49. d result in excessive fuel usage and or shortened engine component life The valve bridge adjustment must be performed before making a valve lash adjustment If the valve lash is within the tolerance an adjustment of the valve lash is NOT necessary Perform the valve lash setting when the engine is cold After the engine has been shut down and the valve covers are removed the engine is considered cold Before performing maintenance prevent the entry of foreign matter into the top of the cylinder head and the valve mechanism Thoroughly clean the area around the valve mechanism covers For the valve lash setting see Systems Operation Testing and Adjusting Valve Lash and Valve Bridge Adjustment 104801354 Fuel Injector Inspect Adjust SMCS Code 1290 025 Note Perform this procedure when the engine valve lash is inspected The Electronic Control Module produces high voltage To prevent personal injury make sure the Electronic Control Module is not powered and the unit injector solenoids are disconnected NOTICE The camshafts must be correctly timed with the crank shaft before an adjustment of the lash for the fuel in jector is made The timing pins must be removed from the camshafts before the crankshaft is turned or dam age to the cylinder block will be the result Inspect the adjustment of the lash for the fuel injector according to the Systems Operation Testing And Adjusting UENR0519 Fuel Injecto
50. dations Cleanliness Unless the equipment is cleaned regularly extended operation in a dirty environment and in a dusty environment can damage components Built up mud dirt and dust can encase components This can make maintenance difficult The buildup can contain corrosive chemicals Corrosive chemicals and salt can damage some components Improper Operating Procedures e Extended operation at low idle e Minimum cool down periods after high load factor operation Operating the engine beyond the guidelines for the engine rating Operating the engine at loads that are greater than the rated load SEBU8666 07 105 Maintenance Section Overhaul Considerations e Operating the engine at speeds that are greater than the rated speed e Use of the engine for an application that is not approved Improper Maintenance Practices e Extension of maintenance intervals e Not using recommended fuel lubricants and coolant antifreeze Overhaul Information An overhaul is replacing the major worn components of the engine An overhaul interval is a maintenance interval that is planned The engine is rebuilt with certain rebuilt parts or new parts that replace the worn parts An overhaul also includes the following maintenance e Inspection of all the parts that are visible during the disassembly e Replacement of the seals and gaskets that are removed Cleaning of the internal passages of the engine and the engine block
51. diator filler cap slowly in order to relieve any pressure Remove the radiator filler cap Note For the location of the coolant drain see the service literature that is provided by the OEM of the locomotive oO ed yy S ONG gt O 3 B Illustration 32 g00831734 Location of the cooling system drain plugs 1 Oil cooler 2 Jacket water pump 3 Cylinder block Note If the engine has a jacket water heater drain the coolant from the heater 3 Open the coolant drain Remove cooling system drain plug 1 Remove cooling system drain plug 2 Remove cooling system drain plug 3 Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools Outside U S A 309 675 6277 Inside U S A 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL CSTG COSA Geneva Switzerland 41 22 849 40 56 Clean the Cooli
52. e and the outlet side of the fuel filter As the fuel filter element becomes plugged the difference in pressure between the two sides of the fuel filter increases The nominal fuel filter differential pressure during normal engine operation is approximately 60 kPa 9 psi Replace the secondary fuel filter elements when the fuel filter differential pressure reaches 103 kPa 15 psi For instructions on replacement of the secondary fuel filter elements see this Operation and Maintenance Manual Fuel System Secondary Filter Replace topic Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately 1 Stop the engine Ensure that the engine will not start during this procedure 2 Shut off the fuel supply valve to the engine NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately
53. e discharge fittings Inspect the discharge port and the discharge line for excessive carbon deposits If excessive carbon is built up in the discharge port and or the discharge line clean the components or replace the components Inspect the air compressor more thoroughly 104534752 Air Tank Moisture and Sediment Drain SMCS Code 1466 543 M amp S Moisture and sediment in the air starting system can cause the following conditions e Freezing e Corrosion of internal parts e Malfunction of the air starting system When opening the drain valve wear protective gloves a protective face shield protective cloth ing and protective shoes Pressurized air could cause debris to be blown and result in personal injury NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Open the drain valve that is on the bottom of the air tank Allow the moisture and sediment to drain
54. e hose that is being replaced Drain the coolant into a suitable clean container The coolant can be reused o Remove the hose clamps N Disconnect the old hose Replace the old hose with a new hose Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 10 Refill the cooling system 11 Clean the filler cap for the cooling system Inspect the gaskets on the filler cap Replace the filler cap if the gaskets are damaged Install the filler cap 12 Start the engine Inspect the cooling system for leaks Fuel System Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses ca
55. e these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications The use of out of spec parts will cause unscheduled downtime and or costly repairs Unit Injectors Replace the unit injectors Consult your Cat dealer about exchanging the unit injectors Your Caterpillar dealer can provide these services and components The wear of unit injectors is affected by the following considerations e Quality of the fuel e Quality of the filtration of the fuel SEBU8666 07 103 Maintenance Section Overhaul Top End The wear of the unit injectors can result in elevated levels of exhaust emissions and or poor engine performance The misfire of a single cylinder is not typically attributed to normal wear This condition can be repaired by replacing the faulty unit injector The following circumstances indicate that the unit injectors should be inspected more frequently e Use of fuels that are not recommended in this Operation and Maintenance Manual Refill Capacities and Recommendations e Extreme ambient temperatures that reduce the ability of the fuel to provide lubrication Frequent plugging of the fuel filters Insufficient maintenance of the fuel tank or the fuel storage tank that can allow excessive water sediment and other contaminants e Insufficient maintenance of the fuel filters Oil Suction Screen Clean the oil suction screen a
56. ed Refer to the literature that is provided by the OEM of the driven equipment Using Fuel Consumption For Calculating the Overhaul Intervals Experience has shown that maintenance intervals are most accurately based on fuel consumption Fuel consumption corresponds more accurately to the engine load Table 26 list average ranges of fuel consumption and service hours for a load factor of approximately 40 percent Table 27 list average ranges of fuel consumption and service hours for a load factor of approximately 25 percent 95 Maintenance Section Maintenance Recommendations SEBU8666 07 Table 26 Maintenance Interval Schedule Service Hours and Fuel Consumption for 3512C Locomotive Engines Interval Rated 1601 To 1800 RPM Top End Overhaul 10000 Service Hours 1500000 L 396300 US gal In Frame Inspection Overhaul 20000 Service Hours 3000000 L 792600 US gal Second Top End Overhaul 30000 Service Hours 4500000 L 1188900 US gal Major Overhaul 40000 Service Hours 6000000 L 1585200 US gal 1 Fuel consumption is based on a load factor of approximately 40 percent Table 27 Maintenance Interval Schedule Service Hours and Fuel Consumption for 3512C Locomotive Engines Interval Rated 1601 To 1800 RPM Top End Overhaul 18000 Service Hours 1500000 L 396300 US gal In Frame Inspection Overhaul 36000 Service Hours 3000000 L 792600 US gal Secon
57. eeennaes 100 Overhaul Considerations 2 eceeeeeeeees 104 Every 4 500 000 L 1 189 000 US gal of Fuel or 30 000 Service Hours Catalyst Module Replace n 61 58 Maintenance Section Aftercooler Core Inspect Clean SEBU8666 07 102828620 Aftercooler Core Inspect Clean SMCS Code 1063 040 1064 571 1 Remove the core Refer to the Disassembly and Assembly Manual Aftercooler Remove and Install for the procedure 2 Turn the aftercooler core on one side in order to remove debris Remove the debris that is accessible NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 3 Back flush the core with cleaner Caterpillar recommends the use of Hydrosolv liquid cleaner Table 21 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 21 Hydrosolv Liquid Cleaners Part ee Number Description Size 1U 5490 Hydrosolv 4165 19 L 5 US gallon 174 6854 Hydrosolv 100 19 L 5 US gallon 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Consult your Caterpillar dealer for more information 4 Remove the drain plug 5 Steam clean the core in order to remove any residue Flush the fins of the after
58. eel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the turbocharger wheel and the turbocharger housing the turbocharger should be reconditioned or replaced 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber 4 Inspect the bore of the turbine housing for corrosion 5 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 6 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing SEBU8666 07 109 Maintenance Section Walk Around Inspection 102155206 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks coolant leaks
59. engine parameters e Horsepower e Range of rpm e Fuel consumption Fuel quality e Altitude e Maintenance intervals Selection of oil Selection of coolant e Environmental qualities Installation Refer to the standards for your engine or consult your Caterpillar dealer in order to determine if your engine is operating within the defined parameters Severe operation can accelerate component wear Engines that are operating under severe conditions may need more frequent maintenance intervals for the following reasons e Maximum reliability e Retention of full service life Because of individual applications it is not possible to identify all of the factors which can contribute to severe operation Consult your Caterpillar dealer about the maintenance that is needed for your specific engine The following factors can contribute to severe operation environment improper operating procedures and improper maintenance practices Environmental Factors Extreme Ambient Temperatures Extended operation in environments that are extremely cold or hot can damage components Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures Extremely hot inlet air reduces the performance capabilities of the engine Note See this Operation and Maintenance Manual Cold Weather Operation topic Operation Section or see Supplement SEBU5898 Cold Weather Recommen
60. epare to catch the oil in a suitable container Clean up any spilled oil with absorbent towels or pillows DO NOT use absorbent particles to clean up the oil Personal injury can result from parts and or cov ers under spring pressure Spring force will be released when covers are re moved Be prepared to hold spring loaded covers as the bolts are loosened 3 Be alert to the spring force Gradually loosen but do not remove bolts 1 Before removing bolts 1 pry cover 2 loose or tap the cover with a rubber mallet in order to relieve any spring pressure g00799721 Illustration 48 Section view of the engine oil filter 2 Cover 6 O ring seal Spring 8 Retainer 9 Oil filter element 4 Remove cover 2 and spring 7 Remove O ring seal 6 retainer 8 and oil filter elements 9 NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 5 Ensure that the new oil filter elements are in good condition Install the new oil filter elements 6 Inspect the O ring seal Ensure that the surfaces for the O ring seal are clean Install a new O ring seal if the old O ring se
61. er has the proper air cleaner elements for your application Consult your Cat dealer for the correct air cleaner element Operating conditions dust dirt and debris may require more frequent service of the air cleaner element The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation check the air cleaner elements thoroughly for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings 72 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace SEBU8666 07 The secondary air cleaner element is not serviceable or washable The secondary air cleaner element should be removed and discarded for
62. essure to be obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The fluid sampling bottle includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Illustration 46 g02261113 Engine oil sampling port If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEgj0047 How To Take A Good S 0 S Oil Sample Consult your Cat dealer for complete information and assistance in establishing an S O S program for your engine 104049689 Engine Oil and Filter Change SMCS Code 1318 510 The oil change interval will be affected by the following items e Air fuel ratio e Ambient air conditions e Engine application e Fuel type e Oil type e Size of the oil sump Note For engines that operate at high load factors
63. following information e Date of cleaning e Number of cleanings Store the box in a dry location 100853903 Engine Air Precleaner Clean SMCS Code 1055 070 The precleaner removes dust and debris from the inlet air prior to the engine air cleaner This helps to reduce the inlet air restriction This also increases the service life of the air cleaner elements Clean the precleaner on a daily basis When the engine is operated in dusty environments more frequent cleaning is required For instructions on cleaning the precleaner see the service literature that is provided by the OEM of the locomotive 101225429 Engine Crankcase Breather Clean SMCS Code 1317 070 If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage Illustration 41 g00597463 1 Loosen clamp 1 Slide the clamp down on tube 2 2 Loosen clamps 3 Remove both breathers as a unit Illustration 42 g00597465 3 Remove O ring seals 4 from the valve covers Inspect the O ring seals for good condition Obtain new O ring seals if necessary ee Illustration 43 g00597466 4 Remove two clamps 6 Remove both breathers 5 from hose tee 7 Inspect the hose tee for cracks If the tee is cracked disca
64. fter the oil has been drained Note Approximately 1 L 1 qt of oil will remain in the housing after the sump has been drained This oil will pour out of the housing when cover 1 is removed Prepare to catch the oil in a pan Clean up any spilled oil with absorbent towels or pillows DO NOT use absorbent particles to clean up the oil 1 Remove the screen assembly according to the instructions in the Service Manual Disassembly and Assembly module Discard the used O ring seals 2 Wash the screen assembly in clean nonflammable solvent Allow the screen assembly to dry before installation 3 Remove side covers in order to gain access to the sump Clean the bottom of the sump with absorbent towels or pillows When the bottom of the sump is clean install the side covers 4 Inspect the screen assembly for good condition Obtain a new screen assembly if necessary Install the screen assembly Install new O ring seals Replacement of Components Replace the following components during the second top end overhaul e Electronic unit injectors e Catalyst Module Inspection Reconditioning or Exchanging of Components Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts Recondition the worn components or exchange t
65. h an S O S coolant analysis Level A more detailed coolant analysis is recommended periodically For example considerable deposits are found in the water jacket areas on the external cooling system but the concentrations of coolant additives were carefully maintained The water in the coolant probably contained minerals which were deposited on the engine over a period of time A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system A full water analysis may be obtained from the following sources 98 Maintenance Section Overhaul Major SEBU8666 07 e Caterpillar dealer e Local water utility company e Agricultural agent e Independent laboratory Caterpillar recommends an S O S coolant analysis Level Il This is a comprehensive chemical evaluation of the coolant This analysis is also a check of the overall condition of the inside of the cooling system The following services are provided e Full Level analysis Identification of the source of metal corrosion and of contaminants Identification of buildup of the impurities that cause corrosion Identification of buildup of the impurities that cause scaling Determination of possible electrolysis within the engines cooling system A report of the results of the analysis is provided Maintenance recommendations are based on the results For more information about S O S coolant analysis co
66. half of the service life of the ELC 4 An extender must be added at 3000 service hours or one half of the service life of the coolant 5 The concentration of Cat SCA in a cooling system that uses Cat SCA and water should be from 6 to 8 by volume 6 Refer to this Special Publication General Coolant Information under the section that discusses the requirements for water 7 Consult the supplier for the commercial SCA for instructions on usage Also refer to this Special Publication Water Supplemental Coolant Additive topic for additional information SEBU8666 07 53 Maintenance Section Refill Capacities Note These coolant change intervals are only achievable with annual S O S Services Level 2 coolant sampling and analysis Cat ELC can be recycled into conventional coolants Cat ELC Cat DEAC Cat Extender and Cat SCA are available in several differently sized containers Refer to Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations for additional information that relates to coolants Coolant Capacities To maintain the cooling system the total cooling system capacity must be determined The total cooling system capacity will vary between individual installations The total cooling system capacity can include the following components engine expansion tank heat exchanger radiator keel cooler and piping Refer to the specifications that are provided
67. hange topic 104034926 Engine Oil Level Check SMCS Code 1348 535 FLV The most accurate check of the engine oil level is obtained when the engine has been stopped for a minimum of 45 minutes TS Ta L ae Illustration 44 g01208341 1 Filler cap 2 Engine oil level gauge dipstick 1 Remove filler cap 1 in order to ensure that the crankcase pressure is equal to the atmospheric pressure 78 Maintenance Section Engine Oil Sample Obtain SEBU8666 07 Excess pressure or a slight vacuum will affect engine oil level that is measured 2 Ensure that engine oil level gauge 2 is seated ADD RS FULL SY ENGINE STOPPED WITH OIL COLD 4 J k o p 00 m 3g ENGINE AT LOW IDLE WITH WARN OIL Illustration 45 g00735162 3 ENGINE STOPPED WITH OIL COLD side 4 ENGINE AT LOW IDLE WITH WARM OIL side 5 ADD mark 6 FULL mark a If the engine is stopped remove the engine oil level gauge Observe the engine oil level on ENGINE STOPPED WITH OIL COLD side 3 b If the engine is operating reduce the engine speed to low idle Remove the engine oil level gauge and observe the engine oil level on ENGINE AT LOW IDLE WITH WARM OIL side 4
68. hat the engine will not start when the cooling system is drained Loosen the radiator filler cap slowly in order to relieve any pressure Remove the radiator filler cap Remove the cooling system drain plugs Open the coolant drain Allow the water to drain NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 6 Flush the cooling system with clean water until the water that drains is clean Close the coolant drain Clean the cooling system drain plugs and install the cooling system drain plugs Fill the Cooling System Note For information about the proper coolant to use see Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations For the capacity of the cooling system see this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with antifreeze coolant After filling the cooling system do not install the radiator filler cap 2 Open the water inlet for the separate circuit aftercooler Start the engine Operate the engine in order to purge the air from the
69. he components if necessary Your Caterpillar dealer can provide these services and components Camshaft followers Connecting rods Connecting rod bearings Cylinder head assembly Cylinder liners Scavenge oil pump Engine wiring harness Exhaust manifold seals Exhaust manifold bellows Fuel pressure regulating valve Fuel priming pump Fuel transfer pump Inlet manifold gaskets Inlet manifold seals Oil pump Pistons Piston pins Prelube pump Pushrods Rocker arms Spacer plate Software update Turbocharger 104 Maintenance Section Overhaul Considerations SEBU8666 07 Inspection of Components Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts e Aftercooler core e Camshaft Crankshaft Driven equipment alignment e Engine control module Exhaust bellow shields e Oil suction screen Note Inspect only two of the components from each cylinder bank Inspecting only two components will provide an adequate example of the condition of the other components 103101741 Overhaul Considerations SMCS Code 7595 043 Severe Operation Severe operation is the use of an engine that exceeds current published standards for that engine Caterpillar maintains standards for the following
70. he availability of high performance commercial diesel engine oils in order to provide satisfactory life and performance in Cat diesel engines where recommended for use There are three current Cat ECF specifications Cat ECF 1 a Cat ECF 2 and Cat ECF 3 Each higher Cat ECF specification provides increased performance over lower Cat ECF specifications For example Cat ECF 3 provides higher performance than Cat ECF 2 and Cat ECF 3 provides much higher performance than Cat ECF 1 a API category oils that have not met the requirements of at least one Cat ECF specification may cause reduced engine life Note The Cat ECF 3 specification was released in October 2006 Oils that meet the API CJ 4 oil category requirements are Cat ECF 3 specification compliant Note The Cat ECF 1 a and Cat ECF 2 specifications replaced the Cat ECF 1 specification as of 1 March 2007 Note Cat and DEO ULS is required to pass additional proprietary full scale diesel engine testing that is beyond the testing required by the various Cat ECF specifications and by the various API oil categories they also meet This additional proprietary testing helps ensure that Cat multigrade diesel engine oils when used as recommended provide superior performance in Cat diesel engines If Cat DEO ULS multigrade oil is not used as a second choice use only commercial oils that meet the recommendations and requirements stated below When the recommended Cat DEO ULS oil
71. iary oil filter system extra oil must be added when filling the crankcase If equipped with an auxiliary oil filter system that is not supplied by Caterpillar follow the recommendations of the OEM 82 Maintenance Section Engine Protective Devices Check SEBU8666 07 NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can cause the crankshaft to dip into the oil This will reduce the power that is devel oped and also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling oil blowing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber De posits in the combustion chamber lead to the following problems guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately 1 Remove the oil filler cap Fill the crankcase through the oil filler tube only For the amount of oil to use refer to this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section Clean the oil filler cap Install the oil filler cap NOTICE To
72. ications on Reusability or Salvage of Used Parts Recondition the worn components or exchange the components if necessary Your Caterpillar dealer can provide these services and components e Camshaft followers Cylinder head assembly e Scavenge oil pump e Engine wiring harness e Exhaust manifold seals e Exhaust manifold bellows e Fuel pressure regulating valve Fuel priming pump Fuel transfer pump Inlet manifold gaskets Inlet manifold seals e Oil pump e Prelube pump e Pushrods e Rocker arms Spacer plate Software update e Turbocharger Inspection of Components Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts e Aftercooler core e Camshaft e Driven equipment alignment e Engine control module e Exhaust bellow shields e Oil suction screen Top End Overhaul Second If you elect to perform an overhaul without the services of a Cat dealer be aware of the following recommendations Cylinder Head Assembly Inspect the cylinder head assembly according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts Your Cat dealer can provid
73. in a suitable container Clean up any spilled fuel with absorbent towels or pillows DO NOT use absorbent particles to clean up the fuel Personal injury can result from parts and or cov ers under spring pressure Spring force will be released when covers are re moved Be prepared to hold spring loaded covers as the bolts are loosened 5 Be alert to the spring force Gradually loosen but do not remove bolts 4 Before removing bolts 5 pry cover 4 loose in order to relieve any spring pressure Remove cover 4 Remove the O ring seal on the inside of the cover Remove the fuel filter elements 6 Clean cover 4 and clean the O ring seal Clean the inside of the fuel filter housing 7 Install new fuel filter elements 8 Inspect the O ring seal Ensure that the surfaces for the O ring seal are clean Install a new O ring seal if the old O ring seal is damaged or deteriorated 9 Install cover 4 Ensure that the springs are seated properly between the cover and the fuel filter elements 10 Open the fuel supply valve Reconnect the battery 11 Prime the fuel system Refer to this Operation and Maintenance Manual Fuel System Prime topic Maintenance Section 104363480 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product
74. in various viscosity grades that include SAE 10W 30 SAE 15W 40 SAE 5W 40 and SAE OW 40 Refer to the Caterpillar Lubricants Table in the Lubricant Information article for details Multigrade oils provide the correct viscosity for a broad range of operating temperatures Multigrade oils are effective in maintaining low oil consumption and low levels of piston deposits Cat DEO ULS oil can be used in other manufacturer diesel engines and in gasoline engines Refer to the engine manufacturer literature for the recommended categories specifications Compare the categories specifications to the specifications of Cat DEO ULS oil The current industry standards for Cat DEO ULS multigrade oil are listed on the product labels and on the datasheets for the product Consult your Caterpillar dealer for part numbers and for available sizes of containers Cat DEO ULS multigrade exceeds the requirements of the following Cat Engine Crankcase Fluid ECF specifications Cat ECF 1 a Cat ECF 2 and Cat ECF 3 Cat DEO ULS multigrade exceeds the performance requirements for the following API oil categories API CJ 4 API Cl 4 API Cl 4 PLUS API CH 4 and API CF Cat DEO ULS multigrade is compatible for use in aftertreatment device equipped engines Cat multigrade oils pass proprietary tests that include the following sticking of the piston rings piston deposits oil control tests wear tests and soot tests Proprietary tests help ensure that
75. ine exhibits symptoms of excessive wear or failure It is not less costly to wait A planned overhaul before failure may be the best value for the following reasons Costly unplanned downtime can be avoided Many original parts can be reused according to the guidelines for reusable parts The service life of the engine can be extended without the risk of a major catastrophe due to engine failure Achieve the best cost value relationship per hour of extended service life Overhaul Inspection Refer to the Service Manual for the disassembly and assembly procedures that are necessary in order to perform the required maintenance on the items that are listed Consult your Caterpillar dealer for assistance To determine the reusability publications that are needed to inspect the engine refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts 106 Maintenance Section Prelube Pump Inspect SEBU8666 07 The Guidelines For Reusable Parts and Salvage Operations is part of an established Caterpillar parts reusability program These guidelines were developed in order to assist Caterpillar dealers and customers reduce costs by avoiding unnecessary expenditures for new parts If the engine parts comply with the established inspection specifications the parts can be reused The use of out of spec parts could result in unscheduled downtime and or c
76. intenance Section Instrument Panel Inspect Table 25 Daily Engine Log Engine Serial Number Date Engine hours Authorization Engine rpm Percent load Ambient temperature Inlet manifold air temperature Inlet manifold air pressure Air restriction left Air restriction right Jacket water temperature SCAC water temperature Engine oil temperature Engine oil pressure Fuel pressure Fuel filter differential pressure Exhaust manifold temperature left Exhaust manifold temperature right Cylinder temperature 1 Cylinder temperature 2 Cylinder temperature 3 Cylinder temperature 4 Cylinder temperature 5 Cylinder temperature 7 Cylinder temperature 8 Cylinder temperature 9 Cylinder temperature 6 0 Cylinder temperature 1 Cylinder temperature 11 Cylinder temperature 12 Cylinder temperature 13 Cylinder temperature 14 Cylinder temperature 15 Cylinder temperature 16 Generator rear bearing temperature Generator stator temperature Generator voltage Generator amperage Comments 94 Maintenance Section Maintenance Recommendations SEBU8666 07 104526746 Maintenance Recommendations SMCS Code 1000 Overhaul Intervals Some factors that are important for
77. is not used commercial oils that meet the requirements of the Cat ECF 1 a Cat ECF 2 and or the Cat ECF 3 specification are acceptable but second choice for use in Cat diesel engines that are covered by this Special Publication Cat DEO ULS or oils that meet the Cat ECF 3 specification and the API CJ 4 oil category are required for use in nonroad Tier 4 United States Environmental Protection Agency U S EPA certified engines that are equipped with aftertreatment devices Cat DEO ULS or oils that meet the Cat ECF 3 specification and the API CJ 4 are required for use in the applications listed below If oils meeting the Cat ECF 3 specification and the API CJ 4 specifications are not available oils meeting ACAE E9 may be used ACAE E9 oils meet the chemical limits designed to maintain aftertreatment device life ACAE E9 oils are validated using some but not all ECF 3 and API CJ 4 standard engine performance tests Consult your oil supplier when considering use of an oil that is not Cat ECF 3 or API CJ 4 qualified e Nonroad EU Stage IIIB and IV type approved engines that are equipped with aftertreatment devices e Nonroad Japan Step 4 approved engines that are equipped with aftertreatment devices Cat DEO ULS and oils meeting the Cat ECF 3 specification and the API CJ 4 and ACEA E9 oil categories have the following chemical limits e 1 percent maximum sulfated ash e 0 12 percent maximum phosphorous e 0 4 percent maximum sulfur
78. isconnect the coupling Replace the Oil Filter Elements Replace the engine oil filters when any of the following conditions occur e Every oil change e The engine oil filter differential pressure reaches 103 kPa 15 psi e The oil filter elements have been used for 1000 service hours Note Do not attempt to clean the used oil filters Used oil filters will retain waste particles The used oil filters would not filter the oil properly Service tools are available to aid in the service of oil filters Consult your Caterpillar dealer for the part names and the part numbers Follow the instructions that are supplied with the service tools If the service tools are not used perform the following appropriate procedure er 1 Illustration 47 g01959342 1 Bolts 2 Cover 3 Plug 4 Drain valve 5 Drain Note Drain the oil into a suitable container Dispose of the oil according to local regulations 1 Connect a hose to drain 5 Place the other end of the hose into a suitable container in order to collect the oil 2 Open drain valve 4 Remove plug 3 Allow the oil to drain Clean the plug and install the plug Close the drain valve Remove the hose from the drain SEBU8666 07 81 Maintenance Section Engine Oil and Filter Change Note Some oil will remain in the housing after the oil has been drained This oil will pour out of the housing when cover 2 is removed Pr
79. ition can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface Refer to two articles in the Disassembly and Assembly Manual Water Temperature Regulators Remove and Water Temperature Regulators Install for the replacement procedure of the water temperature regulator or consult your Caterpillar dealer Note If only the water temperature regulators are replaced drain
80. ive concentra tion can form deposits on the higher temperature sur faces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temperature components Excessive supplemental coolant additive concentra tion could also result in blockage of the heat exchang er overheating and or accelerated wear of the water pump seal Do not exceed the recommended amount of supple mental coolant additive concentration 3 Add the proper amount of SCA The concentration of the SCA depends on the type of coolant that is used To determine the proper amount see this Operation and Maintenance Manual Refill Capacities and Recommendations topic 4 Clean the cooling system filler cap Install the cooling system filler cap 103645060 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime Refer to this Operation and Maintenance Manual Maintenance Interval Schedule for the proper maintenance interval A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails in the closed pos
81. l example 1 Plastic cover 2 Service indicator The fumes disposal filter is equipped with a service indicator If the fumes disposal filter becomes plugged increased restriction of the filter will cause the crankcase pressure to become positive When the pressure continues to rise the service indicator will show through the plastic cover The service indicator indicates the need for the fumes disposal filter to be changed Refer to the Operation and Maintenance Manual Fumes Disposal Filter Replace topic for more information Note Check the service indicator when the engine is running at low idle 104301694 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Hoses and clamps must be inspected periodically in order to ensure safe operation and continuous operation of the engine Take proper safety precautions before inspecting or replacing hoses and clamps Note Always use a board or cardboard when the engine components are checked for leaks Leaking fluid that is under pressure can cause serious injury or possible death Leaks that are the size of a pin hole are included Refer to Operation and Maintenance Manual General Hazard Information for more information Inspect the Hoses and the Clamps Inspect all hoses for leaks that are caused by the following conditions Replace any hose which exhibits any of the following conditions Failure to replace a hose which exhibits any of the follo
82. lant antifreeze that meets the ASTM D6210 specification WILL NOT require a treatment with an SCA at the initial fill Read the label or the instructions that are provided by the manufacturer of the commercial heavy duty coolant antifreeze Note These coolants WILL require a treatment with a supplemental coolant additive on a maintenance basis NOTICE All Caterpillar diesel engines equipped with air to air aftercooling ATAAC require a minimum of 30 percent glycol to prevent water pump cavitation Table 19 Coolant Service Life Service Life 2 Coolant Type 12000 Service Hours or Cat ELC Six Years Commercial coolant that meets the Caterpillar EC 1 Specification 6000 Service Hours or Six Years 3000 Service Hours or Cat DEAC Three Years Commercial Heavy Duty Coolant Antifreeze that meets ASTM D6210 3000 Service Hours or Two Years Commercial Heavy Duty Coolant Antifreeze that meets ASTM D4985 3000 Service Hours or One Year Cat SCA 3000 Service Hours or Two Years Commercial 3000 Service Hours or supplemental coolant One Year additiven 0 Use the interval that occurs first 2 Refer to the Operation and Maintenance Manuals Maintenance Interval Schedule for the correct interval for replacement of the water temperature regulator for the cooling system 3 Cat ELC Extender must be added at 6000 service hours or one
83. le death If fluid is injected into your skin it must be treated immediately by a doctor familiar with this type of injury Inspect all of the components in the air circuit for the starting motor Inspect all of the air lines and connections for leaks If damaged teeth are found the air circuit for the starting motor must be examined in order to determine the cause of the problem Electric Starting Motor If the starting motor fails the engine may not start in an emergency situation A scheduled inspection of the starting motor is recommended The starting motor pinion and the flywheel ring gear must be in good condition in order for the engine to start properly The engine will not start if the starting motor pinion does not engage the flywheel ring gear The teeth of the starting motor pinion and the flywheel ring gear can be damaged because of irregular engagement Inspect the starting motor brushes and remove dust build up from the starting motor every 2 years Inspect the starting motor for proper operation Listen for grinding when the engine is started Inspect the teeth of the starting motor pinion and the flywheel ring gear Look for patterns of wear on the teeth Look for teeth that are broken or chipped If damaged teeth are found the starting motor pinion and the flywheel ring gear must be replaced Problems with the electric starting motor can be caused by the following conditions malfunction of the solenoi
84. magnetic particle inspection process to check for cracks 100 Maintenance Section Overhaul Top End SEBU8666 07 Replace the crankshaft vibration damper if any of the following conditions occur e Engine failure due to a broken crankshaft e Excessive wear of the front bearing for the crankshaft e Excessive wear of the gear train that is not caused by a lack of lubrication Inspect the gears of the gear train and inspect the gear train bushings for the following conditions e Worn gear teeth e Unusual fit e Unusual wear In addition to the inspection of components inspect the alignment of the driven equipment See the Application and Installation Guide for the engine or see the literature that is provided by the OEM of the driven equipment Cleaning of Components Clean the oil cooler core and the aftercooler core Then pressure test both of these cores For instructions on cleaning the cores see this Operation and Maintenance Manual Aftercooler Core Inspect Clean topic Clean the oil suction screen Also remove side covers in order to clean the oil sump For instructions on removal and installation of components see the Service Manual Disassembly and Assembly module Obtain a Coolant Analysis For conventional heavy duty coolant antifreeze check the concentration of supplemental coolant additive SCA regularly The concentration of SCA can be checked with an S O S coolant analysis Level
85. ment The air cleaner differential pressure is measured from the turbocharger air inlet As the air filter element becomes plugged the difference in pressure between the two sides of the air cleaner element will increase The nominal air filter differential pressure during normal engine operation is approximately 3 kPa 12 inches of H O To avoid the derating of engine operation replace the air filter element before reaching the maximum differential pressure of 6 2 kPa 25 inches of H O For instructions on replacement of the air filter elements see this Operation and Maintenance Manual Engine Air Cleaner Element Replace topic 104041218 Engine Air Cleaner Element Dual Element Clean Replace SMCS Code 1051 1054 037 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Cat deal
86. ments for ventilation 101664717 Engine Clean SMCS Code 1000 070 Personal injury or death can result from high volt age Moisture could create paths of electrical conduc tivity Make sure the unit is off line disconnected from utility and or other generators locked out and tagged Do Not Operate NOTICE Water or condensation can cause damage to gen erator components Protect all electrical components from exposure to water SEBU8666 07 71 Maintenance Section Engine Air Cleaner Differential Pressure Check NOTICE Accumulated grease and oil on an engine is a fire haz ard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumulates on the engine Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits e Easy detection of fluid leaks e Maximum heat transfer characteristics e Ease of maintenance Note For more information on cleaning and drying electric generators refer to Special Instruction SEHS9124 Cleaning and Drying of Electric Set Generators Engine Air Cleaner Differential Pressure Check SMCS Code 1051 7452 040 Observe the air cleaner differential pressure frequently during engine operation Inlet Air Restriction Air Cleaner Differential Pressure This gauge indicates the difference in air pressure between the inlet side and the engine side of the air filter ele
87. mercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the cooling system drain Clean the cooling system drain plugs and install the drain plugs NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Open the water inlet for the separate circuit aftercooler Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pt of cleaner per 15 L 4 US gal of the cooling system capacity Install the radiator filler cap 4 Start the engine Operate the engine for a minimum of 30 minutes with a coolant temperature of at least 82 C 180 F 5 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler Ensure that the engine will not start when the cooling system is drained Loosen the radiator filler cap slowly in order to relieve any pressure Remove the radiator filler cap Open the coolant drain Remove the cooling system drain plugs Allow the water to drain NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to com
88. mixing bottle Move the bottle in a circular motion in order to mix the solution 5 Add 1 drop of NITRITE TEST SOLUTION A to the mixing bottle Move the bottle in a circular motion in order to mix the solution 6 Repeat 5 until the solution changes color from red to light gray green or blue Record the number of drops of NITRITE TEST SOLUTION A that were required to cause the color change 7 Use Table 23 to interpret the results Table 23 Number of Concentration Maintenance Drops of SCA Required Less than 25 Less than the Add SCA recommended Retest the concentration of coolant SCA 25 to 30 The None recommended concentration of SCA More than 30 More than the Remove the recommended coolant concentration of Replace with SCA water only Retest the coolant Add the SCA If Necessary Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly Note Always dispose of fluids according to local regulations 2 If necessary drain some coolant in order to allow space for the addition of the SCA SEBU8666 07 69 Maintenance Section Cooling System Water Temperature Regulator Replace NOTICE Excessive supplemental coolant addit
89. n order to completely rebuild the engine For the major overhaul all of the bearings seals gaskets and components that wear are disassembled The parts are cleaned and inspected If necessary the parts are replaced The crankshaft is measured for wear The crankshaft may require regrinding Alternatively the crankshaft may be replaced with a Caterpillar replacement part Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications Replacement of Components Replace the following components during the major overhaul e Camshaft bearings e Connecting rod bearings Crankshaft seals Crankshaft thrust washers Electronic unit injectors e Gear train bushings e Gear train bearings e Main bearings Piston rings SEBU8666 07 99 Maintenance Section Overhaul Major Inspection Reconditioning or Exchanging of Components Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts Recondition the worn components or exchange the components if necessary Your Caterpillar dealer can provide these services and components e Camshaft followers e Camshaft thrust washers e Connecting rods e Crankshaft vibration
90. nce Manual Refill Capacities and Recommendations Maintenance Section 104047604 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Note Obtaining a Coolant Sample Level 1 is optional if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems filled with Cat ELC should have a Coolant Sample Level 2 obtained at the recommended interval Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC including the following coolants e Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat DEAC Diesel Engine Antifreeze Coolant e Commercial heavy duty coolant antifreeze SEBU8666 07 67 Maintenance Section Cooling System Coolant Sample Level 2 Obtain Table 22 Recommended Interval Type of Coolant Level 1 Level 2 Cat DEAC Conventional heavy duty coolant Every 250 j 1 service hours Every year Commercial coolant that meets the requirements of the Caterpillar EC 1 standard Cat ELC or conventional Optional EC 1 coolant Every year 1 The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same p
91. ne protective devices will ensure that the alarms and shutoffs activate at the setpoints Ensure that the engine protective devices are functioning properly NOTICE During testing abnormal operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately 104041349 Engine Valve Lash Inspect Adjust SMCS Code 1102 025 Note For procedures on adjusting the valve lash and adjusting the valve bridge see Systems Operation Testing and Adjusting Valve Lash and Valve Bridge Adjustment Consult your Cat dealer for assistance SEBU8666 07 83 Maintenance Section Fuel Injector Inspect Adjust Engine Valve Lash NOTICE Only qualified service personnel should perform this maintenance Refer to the Systems Operation Testing and Adjusting Manual Valve Lash and Valve Bridge Adjustment article or consult your Caterpillar dealer for the complete valve lash adjustment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency coul
92. ng System 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the coolant drain Clean the drain plugs and install the drain plugs NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Open the water inlet for the separate circuit aftercooler Fill the cooling system with clean water Install the radiator filler cap Operate the engine until the temperature reaches 49 C 120 F to 66 C 150 F 4 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler Ensure that the engine will not start when the cooling system is drained Loosen the radiator filler cap slowly in order to relieve any pressure Remove the radiator filler cap 5 Open the coolant drain Remove the drain plugs Allow the coolant to drain Flush the cooling system with clean water Close the coolant drain Install the drain plugs 6 Repeat Steps 3 4 and 5 Fill the Cooling System Note For information about the proper coolant to use see Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations For the capacity of the cooling system see this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks
93. ng eyes and the lifting fixtures obsolete If alterations are made ensure that proper lifting devices are provided Consult your Cat dealer for information regarding fixtures for proper lifting or Illustration 30 Catalyst Module 1 Remove exhaust bellows insulation and exhaust bellows from below the module 2 Remove condensation drain line 3 Remove four bolts 1 4 Attach lifting equipment to the lifting eyes 2 5 Lift module from the locomotive 6 Lower new module into the locomotive 7 Remove lifting equipment 8 Install four bolts 1 For proper torque specifications refer to Specifications SENR3130 Torque Specifications 9 Install condensation line 10 Install exhaust bellows and exhaust bellows insulation 902798676 104035015 Cooling System Coolant DEAC Change SMCS Code 1350 044 Clean the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e The coolant is foaming e Oil or fuel has entered the cooling system and the coolant is contaminated Drain the Cooling System 1 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler Ensure that the engine will not start when the cooling system is drained SEBU8666 07 63 Maintenance Section Cooling System Coolant DEAC Change 2 Loosen the radiator filler cap slowly in order to
94. ngine Inspect the air lines for leaks 100823916 Instrument Panel Inspect SMCS Code 7451 040 Inspect the instrument panel for good condition Perform the self test All of the warning lamps should illuminate If the alarm does not sound investigate the problem and correct the problem Check the condition of all of the gauges If a gauge is broken repair the gauge or replace the gauge immediately Frequently monitor the gauges during normal operation Record the data in a log Compare the new data to the data that was previously recorded Comparing the new data to the recorded data will establish the normal gauge readings for the engine A gauge reading that is abnormal may indicate a problem with operation or a problem with the gauge 92 Maintenance Section Instrument Panel Inspect SEBU8666 07 Record the Performance of the Engine Records of engine performance are an important element of a maintenance program Record information about the engine operation on a daily basis This will help to reveal the trends of the engine performance The data on engine performance can help to predict problems with operation Also the data can provide your Caterpillar dealer with information that is useful for recommending optimum operation Table 25 is offered for use as a log for engine performance Make several copies of Table 25 for continued use Retain the recorded information for reference SEBU8666 07 93 Ma
95. ngine Oil Filter Differential Pressure Check 77 Engine Oil Level Check ccceeecceeeeeeeesteeeeeeees 77 Fuel System Fuel Filter Differential Pressure Check aa aean a et aeae ane eraa 84 Fuel Tank Water and Sediment Drain 86 Fumes Disposal Filter Service Indicator Check 89 Hoses and Clamps Inspect Replace 89 Instrument Panel Inspect eeeeeeeeeeeeeeeees 91 Walk Around Inspection s eeeeeeeeeeeeeeees 109 Initial 250 Service Hours Engine Valve Lash Inspect Adjust 0 0 0 eee 82 Speed Sensor Clean Inspect ccceeeees 107 Every 250 Service Hours Cooling System Coolant Sample Level 1 Obtain 4a ed eae 66 Cooling System Supplemental Coolant Additive SCA Test Add 000 cccccceeeecececeeeeeeeeeeetseeesenees 68 Engine Oil Sample Obtain a se 78 Every 1000 Service Hours Catalyst Module Check seeen 61 Every 1000 Service Hours or Every 92 Day FRA Inspection Cooling System Coolant Sample Level 2 Obtain secies iiia sndls 67 Engine Crankcase Breather Clean 00 76 Engine Oil and Filter Change n se 79 Engine Protective Devices Check iesse 82 Fuel System Primary Filter Water Separator Element Replace ceccceeeeeeeeeeteeeeeneees 84 Fuel System Secondary Filter Replace 85 Fumes Disposal Filter Element Replace 87 Every 20
96. nsult your Caterpillar dealer 102624456 Overhaul Major SMCS Code 7595 020 MJ Refer to this Operation and Maintenance Manual Maintenance Recommendations in order to determine the maintenance interval for a major overhaul The need for a major overhaul is determined by several factors e An increase of oil consumption e An increase of crankcase blowby e The total amount of fuel consumption e The service hours of the engine e The wear metal analysis of the lube oil e An increase in the levels of noise and vibration An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced An increase in the levels of noise and vibration indicates that rotating parts require service Note It is possible for oil analysis to indicate a decrease of wear metals in the lube oil The cylinder liners may be worn so that polishing of the bore occurs Also the increased use of lube oil will dilute the wear metals Monitor the engine as the engine accumulates service hours Consult your Caterpillar dealer about scheduling a major overhaul Note The driven equipment may also require service when the engine is overhauled Refer to the literature that is provided by the OEM of the driven equipment A major overhaul includes all of the work that is done for the top end overhaul A major overhaul includes additional parts and labor Additional parts and labor are required i
97. of 80 percent or more for extended periods of time perform the following decrease the interval between oil changes by 20 percent and increase the API service classification of the oil Refer to Caterpillar Publication PEHJ0191 CAT S O S Fluid Analysis in order to understand optimizing oil change intervals The S O S oil analysis program analyzes used oil in order to determine if the oil change interval is suitable for your specific engine In the absence of S O S oil analysis change the engine oil and filters according to Table 24 Table 24 3512C HD Locomotive Engine Oil Change Interval Sump Capacity Oil Change Interval 3512C 308 L 81 3 US gal Every 1000 HD Service Hours or Every 92 Day FRA Inspection Drain the Oil Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin 80 Maintenance Section Engine Oil and Filter Change SEBU8666 07 Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed when the cold oil is drained Drain the crankcase when the oil is warm This method allows proper draining of the waste particles that are suspended in the oil Failure to follow this recommended procedure will allow the waste particles to be recirculated through the engine lubrication system with the new oil 1 After the engine ha
98. or exchange the components if necessary Your Caterpillar dealer can provide these services and components e Camshaft followers e Connecting rods Cylinder head assembly Cylinder liners e Engine wiring harness Exhaust bellows Fuel transfer pump e Oil pump e Pistons e Piston pins e Prelube pump Spacer plate SEBU8666 07 97 Maintenance Section Overhaul In Frame e Turbochargers Inspection of Components Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts e Camshaft e Camshaft bearings Crankshaft Crankshaft thrust washers Crankshaft vibration damper Driven equipment alignment e Engine control module Front gear train e Gear train bushings and bearings e Rear gear train Inspect the camshaft for damage to the journals and the lobes Inspect the following components for signs of wear and or for signs of fatigue e Camshaft bearings e Camshaft followers Inspect the crankshaft for any of the following conditions e Deflection e Damage to the journals e Bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the following components e Rod bearing e Main
99. or good condition Inspect the engine to frame ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check the condition of the gauges Replace any gauges which are cracked Replace any gauges that can not be calibrated 110 Maintenance Section Water Pump Inspect SEBU8666 07 104342954 Water Pump Inspect SMCS Code 1361 040 A failed water pump might cause severe engine overheating problems Severe overheating problems could result in cracks in the cylinder head a piston seizure or other potential damage to the engine Visually inspect the water pump for leaks If leaking of the water pump seals is observed replace all of the water pump seals Refer to two articles in the Disassembly and Assembly Manual Water Pump Disassemble and Water Pump Assemble for the procedure If removal of the water pump is necessary refer to two articles in the Disassembly and Assembly Manual Water Pump Remove and Water Pump Install Inspect the water pump for wear cracks pin holes and proper operation Refer to the Parts Manual for the correct part numbers for your engine or consult your Cat dealer if repair is needed or replacement is needed
100. or use in ALL Cat diesel engines that are covered by this Special Publication Commercial alternative diesel engine oils are as a group second choice oils Cat DEO ULS or oils that meet the Cat ECF 3 specification and the API CJ 4 oil category are required for use in nonroad Tier 4 United States Environmental Protection Agency U S EPA certified engines that are equipped with aftertreatment devices Cat DEO ULS or oils that meet the Cat ECF 3 specification and the API CJ 4 are required for use in the applications listed below If oils meeting the Cat ECF 3 specification and the API CJ 4 specifications are not available oils meeting ACEA E9 may be used ACEA E9 oils meet the chemical limits designed to maintain aftertreatment device life ACEA E9 oils are validated using some but not all ECF 3 and API CJ 4 standard engine performance tests Consult your oil supplier when considering use of an oil that is not Cat ECF 3 or API CJ 4 qualified e Nonroad EU Stage IIIB and IV type approved engines that are equipped with aftertreatment devices e Nonroad Japan Step 4 approved engines that are equipped with aftertreatment devices Cat DEO ULS and oils meeting the Cat ECF 3 specification and the API CJ 4 and ACEA E9 oil categories have the following chemical limits e 1 percent maximum sulfated ash e 0 12 percent maximum phosphorous e 0 4 percent maximum sulfur The chemical limits were developed in order to maintain the expected after
101. osal Filter Element Replace Closed Crankcase Ventilation CCV SMCS Code 1074 2 is 5 b oM Typical example of the Closed Crankcase Ventilation CCV system Illustration 53 g02260233 1 Fumes from crankcase breather 2 Oil drain to crankcase The Closed Crankcase Ventilation CCV system requires the replacement of the fumes disposal filter The service interval of the CCV will be affected by the following items e Engine load e Concentration of soot e Condition of the engine The CCV is equipped with a service indicator If the fumes disposal filter becomes plugged prior to the normal service interval increased restriction of the filter will cause the vacuum to become positive When the pressure continues to rise the service indicator will show through the cap The service indicator indicates the need for the fumes disposal filter to be changed Reset the service indicator by using the following procedure 88 Maintenance Section Fumes Disposal Filter Element Replace SEBU8666 07 Resetting the Service Indicator Illustration 54 g02260276 1 Remove plastic cover 3 2 Push down on service indicator 4 3 Replace cover 3 4 Replace the fumes disposal filter by using the following procedure Replacing the Fumes Disposal Filter Hot oil and hot components can cause
102. ostly repairs The use of out of spec parts can also contribute to increased fuel consumption and reduction of engine efficiency New parts are not necessary if the old parts can be reused repaired or salvaged Otherwise the old parts can be replaced or exchanged Your Caterpillar dealer can provide the parts that are needed to rebuild the engine at the least possible cost Overhaul Programs An economical way to obtain most of the parts that are needed for overhauls is to use Caterpillar remanufactured parts Caterpillar remanufactured parts are available at a fraction of the cost of new parts These parts have been rebuilt by Caterpillar and certified for use The following components are examples of the remanufactured parts e Cylinder heads e Oil Pumps e Turbochargers e Water pumps Consult your Caterpillar dealer for details and for a list of the remanufactured parts that are available Your Caterpillar dealer may be offering a variety of overhaul options A Flat Rate Overhaul guarantees the maximum price that you will pay for an overhaul Flat rate prices on preventive maintenance programs or major repair options are available from many servicing dealers for all Caterpillar engines Consult your Caterpillar dealer in order to schedule a before failure overhaul Overhaul Recommendation Caterpillar recommends a scheduled overhaul in order to minimize downtime A scheduled overhaul will provide the lowest cost and the g
103. pillar Commercial Diesel Engines Fluids Recommendations or consult your Caterpillar dealer 68 Maintenance Section SEBU8666 07 Cooling System Supplemental Coolant Additive SCA Test Add 102017557 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and eyes Do not drink cooling system coolant additive Note Caterpillar recommends an S O S coolant analysis Level 1 Test the Concentration of the SCA Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Follow the instructions that are provided in the kit Water and SCA NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Use the instructions that follow 1 Fill the syringe to the 1 0 ml mark with the coolant 2 Dispense the 1 0 mL coolant sample from the syringe into the empty mixing bottle 3 Add tap water to the mixing bottle in order to bring the level up to the 10 ml mark Place the cap on the bottle and shake the bottle 4 Add 2 to 3 drops of the NITRITE INDICATOR SOLUTION B to the
104. pletely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 6 Flush the cooling system with clean water until the water that drains is clean Close the coolant drain Clean the cooling system drain plugs and install the cooling system drain plugs 64 Maintenance Section Cooling System Coolant ELC Change SEBU8666 07 Cleaning a Cooling System that has Heavy Deposits or Plugging Note For the following procedure to be effective there must be an active flow through the cooling system components 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the coolant drain Clean the cooling system drain plugs and install the cooling system drain plugs NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Open the water inlet for the separate circuit aftercooler Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pt of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the radiator filler cap 4 Start the engine Operate the engine for a minimum of 90 minutes with a coolant temperature of at least 82 C 180 F 5 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler Ensure t
105. pplemental Coolant Additive SCA addition that is associated with the present conventional coolant The Extender only needs to be added once Check the cooling system only when the engine is stopped and cool 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Extender 3 Add Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations in the Maintenance Section for the capacity of the cooling system for your engine Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations information for the Caterpillar ELC Extender additions 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 102077612 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Check the level of the coolant in the cooling system Add coolant if necessary See the service literature that is provided by the OEM of the locomotive for instructions on performing these procedures e Checking the coolant level e Adding coolant to the cooling system For the correct coolant to use see this Operation and Maintena
106. pplier of grease is used Some greases are not chemically compatible Consult your supplier in order to determine if the greases are compatible If you are in doubt about the compatibility of the old grease and the new grease purge all of the old grease from the joint Note All Caterpillar greases are compatible with each other For more information about choosing the correct lubricating grease refer to Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations 54 Maintenance Section Maintenance Recommendations SEBU8666 07 Maintenance Recommendations 104032319 System Pressure Release SMCS Code 1250 1300 1350 5050 Coolant System Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure To relieve the pressure from the coolant system turn off the engine Allow the cooling system pressure cap to cool Remove the cooling system pressure cap slowly in order to relieve pressure Fuel System To relieve the pressure from the fuel system turn off the engine Engine Oil To relieve pressure from the lubricating system turn off the engine 103642798 Welding on Engines with Electronic Controls SMCS Code 1000 NOTICE Because the strength of the frame may decrease some manufacturers do not recommend welding onto a chassis frame or rail Consult the OEM
107. prevent crankshaft or bearing damage crank en gine with fuel off to fill all filters before starting Do Not crank engine for more than 30 seconds 2 Close the fuel supply line and crank the engine until the oil pressure gauge indicates 70 kPa 10 psi Open the fuel supply line Allow the starting motor to cool for 2 minutes before cranking again 3 Start the engine according to the instructions that are provided by the OEM of the locomotive Operate the engine at low idle for 2 minutes Operating the engine for 2 minutes will ensure that the lubrication system has oil and that the oil filters are filled with oil Inspect the engine for oil leaks Ensure that the oil level is at the FULL mark on the LOW IDLE side of the oil level gauge 4 Stop the engine and allow the oil to drain back into the sump for a minimum of 10 minutes 5 Remove the oil level gauge and check the oil level Maintain the oil level to the FULL mark on the ENGINE STOPPED side of the oil level gauge 100626013 Engine Protective Devices Check SMCS Code 7400 535 Alarms and shutoffs must function properly Alarms provide timely warning to the operator Shutoffs help to prevent damage to the engine It is impossible to determine if the engine protective devices are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices A calibration check of the engi
108. ps NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Cooling System Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved _ Stop the engine N Allow the engine to cool o Before servicing a coolant hose slowly loosen the filler cap for the cooling system in order to relieve any pressure D Remove the filler cap for the cooling system a Drain the coolant from the cooling system to a level that is below th
109. r Adjustment topic Adjust the lash for the fuel injector if necessary 103651102 Fuel System Prime SMCS Code 1250 548 1258 548 1 Open the fuel supply valve Ensure that the engine will not start during the priming procedure Turn the start switch to the OFF position Illustration 49 g01959336 1 Fuel priming pump plunger 2 Turn the fuel priming pump plunger counterclockwise in order to release the lock plate from the retainer 3 Operate the fuel priming pump until the air in the fuel system has been pumped through the fuel return line back to the fuel tank 4 Press the fuel priming pump plunger to the locking position Turn the fuel priming pump plunger clockwise in order to engage the lock plate in the retainer Note Enable the starting system only after all maintenance has been completed Priming Procedure for Dry Starting If the air cannot be completely purged from the fuel system and the engine will not start see Special Instruction SEHS9586 3500 EUI Fuel Priming Procedure 84 Maintenance Section Fuel System Fuel Filter Differential Pressure Check SEBU8666 07 101076701 Fuel System Fuel Filter Differential Pressure Check SMCS Code 1261 535 Observe the fuel filter differential pressure frequently during engine operation Fuel Filter Differential Pressure Restriction This gauge indicates the difference in fuel pressure between the inlet sid
110. rained This oil will pour out of the oil housing when cover 1 is removed Prepare to catch the oil in a pan Clean up any spilled oil with absorbent towels or pillows DO NOT use absorbent particles to clean up the oil 1 Remove the cover 1 2 Remove the screen assembly 2 according to the instructions in the Service Manual Disassembly and Assembly module Discard the used O ring seals 3 Inspect the screen assembly 2 Obtain a new screen assembly if necessary 4 Wash the screen assembly 2 in clean nonflammable solvent Allow the screen assembly 2 to dry before installation 5 Install the screen assembly 2 and install new O ring seals according to the instructions in the Service Manual Disassembly and Assembly module 6 Install the cover 1 102 Maintenance Section Overhaul Top End SEBU8666 07 7 Remove side covers in order to gain access to the sump Clean the bottom of the sump with absorbent towels or pillows When the bottom of the sump is clean install the side covers Replacement of Components Replace the following components during the top end overhaul e Electronic unit injectors e Turbocharger cartridge Inspection Reconditioning or Exchanging of Components Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publ
111. rd the old tee and obtain a new tee for installation 5 Turn the breathers upside down in order to inspect the condition of the breather elements Clean the breather elements with clean nonflammable solvent If the breather elements remain contaminated after the cleaning discard the breathers and obtain new breathers Do not attempt to disassemble the breathers Allow the breather elements to dry before installation SEBU8666 07 77 Maintenance Section Engine Mounts Check Note Coat the rubber parts with clean engine oil or petroleum jelly in order to make installation easier 6 Place clamps 6 over the parts of hose tee 7 that will receive breathers 5 Install the breathers into the tee Tighten the clamps to the torque that is listed in the Service Manual Specifications 7 Coat O ring seals 4 with clean engine oil Place the O ring seals on the valve covers 8 Place clamps 3 around the parts of the breathers that will be attached to the valve covers Install both breathers as a unit Tighten the clamps 9 Place clamp 1 on the part of the hose tee that will receive tube 2 Install the tube into the hose tee Tighten the clamp to the torque that is listed in the Service Manual Specifications 103651127 Engine Mounts Check SMCS Code 1152 535 Misalignment of the engine and the driven equipment will cause extensive damage Excessive vibration can lead to misalignment Excessive
112. re being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean primary air cleaner elements e Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 34 g00281692 SEBU8666 07 73 Maintenance Section Engine Air Cleaner Element Single Element Clean Replace Note When the primary air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter This air flow will help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Primar
113. reatest value Schedule an overhaul with your Caterpillar dealer Overhaul programs vary between dealers To obtain specific information about the types of overhaul programs and services consult your Caterpillar dealer i01879911 Prelube Pump Inspect SMCS Code 1319 040 Inspect the prelube pump for the following conditions e Cracks e Pin holes e Proper operation e Wear Perform a pressure check on the prelube pump Inspect the hoses and the fittings for leaks Inspect the prelube pump for leaks Replace all of the seals if a leak is observed Inspect the wiring for the following conditions e Damage e Fraying Ensure that the wiring is in good condition Inspect the electrical connections Ensure that the electrical connections are secure Inspect the brushes Replace the brushes if necessary If repair or replacement is necessary see the Service Manual or see literature that is provided by the OEM of the pump Consult your Caterpillar dealer for assistance SEBU8666 07 107 Maintenance Section Speed Sensor Clean Inspect 102650343 Speed Sensor Clean Inspect SMCS Code 1907 040 1907 070 xD mn e o Illustration 59 g00293337 Typical engine speed timing sensor 1 Remove the engine speed timing sensor from the flywheel housing Check the condition of the
114. refully Tighten all connections to the rec ommended torque NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components SEBU8666 07 91 Maintenance Section Instrument Panel Inspect Note High pressure fuel lines may be installed between the high pressure fuel pump and the fuel injectors High pressure fuel lines are constantly charged with high pressure Do not check the high pressure fuel lines with the engine or the starting motor in operation Wait for 10 minutes after the engine stops before you perform any service or repair on high pressure fuel lines Waiting for 10 minutes will to allow the pressure to be purged 1 Drain the fuel from the fuel system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose with a new hose 5 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 6 Carefully inspect the engine for any spilled fuel Make sure that no fuel remains on or close to the engine Note Fuel must be added to the fuel system ahead of the fuel filter 7 Refill the fuel system Refer to this Operation an
115. relieve any pressure Remove the radiator filler cap Note For the location of the coolant drain see the service literature that is provided by the OEM of the locomotive ed yy S Illustration 31 ONG gt O B g00831734 Location of the cooling system drain plugs 1 Oil cooler 2 Jacket water pump 3 Cylinder block Note If the engine has a jacket water heater drain the coolant from the heater 3 Open the coolant drain Remove cooling system drain plug 1 Remove cooling system drain plug 2 Remove cooling system drain plug 3 Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools Outside U S A 309 675 6277 Inside U S A 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL COSA Geneva Switzerland 41 22 849 40 56 Clean the Cooling System NOTICE Use of com
116. rval operating conditions fuel type oil type and size of the oil sump Scheduled oil sampling analyzes used oil in order to determine if the oil change interval is suitable for your specific engine Refer to this Operation and Maintenance Manual Engine Oil and Filter Change in order to determine the oil change interval that is suitable for your specific engine To determine the maintenance intervals for the overhauls refer to this Operation and Maintenance Manual Maintenance Recommendations When Required Batteries Replace 00 cccceceeeeeeecceeceeeeeeteeeetees 59 Battery or Battery Cable Disconnect 60 Engine Air Cleaner Element Dual Element Clean Replace 2 ccccccceeeeeeccceeeeeeeeeeeeeetenenees 71 Engine Air Cleaner Element Single Element Clean Replace 2 cccccceceeeeeeeeeeeeceeeeeeeeeeeteeeeees 73 Fuel System Prime ssssessssesesrrreerrrrrsererrneersnnes 83 Fuel System Primary Filter Water Separator ET E EEIE TE PE E TE heeds 85 Maintenance Recommendations cceeeee 94 Daily Air Tank Moisture and Sediment Drain 59 Battery Electrolyte Level Check seese 60 Belts Inspect Adjust Replace cee 61 Cooling System Coolant Level Check 66 Driven Equipment Inspect Replace Lubricate 70 Engine Air Cleaner Differential Pressure Check 71 Engine Air Precleaner Clean i c 76 E
117. s been operated at normal operating temperature STOP the engine 2 Drain the oil according to the equipment on the engine See the literature that is provided by the OEM of the locomotive NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice 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 a Open the oil drain After the oil has drained close the oil drain b If a suction device is inserted into the oil pan ensure that the device is clean A clean suction device will prevent dirt from entering into the oil pan Be careful not to strike the engine oil suction tubes or the piston cooling jets c If a suction device that attaches to the oil drain is used ensure that the suction device is clean Attach the suction device to the oil drain Open the oil drain After the oil has drained close the oil drain and remove the suction device d If the oil drain valve has a quick connect coupler attach the coupling Open the drain valve in order to drain the crankcase After the oil has drained close the drain valve D
118. t the specifications These fuels are distilled from crude oil Diesel fuels from other sources could exhibit detrimental properties that are not defined or controlled by this specification Refer to Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations for additional information that relates to diesel fuel Cooling System Coolant Recommendations The following two types of coolants may be used in Caterpillar diesel engines Preferred Caterpillar Extended Life Coolant ELC or a commercial extended life coolant that meets the Caterpillar EC 1 specification Acceptable Caterpillar Diesel Engine Antifreeze Coolant DEAC or a commercial heavy duty coolant antifreeze that meets ASTM D4985 or ASTM D6210 specifications NOTICE Do not use a commercial coolant antifreeze that only meets the ASTM D3306 or equivalent specification This type of coolant antifreeze is made for light duty automotive applications Use only the coolant antifreeze that is recommended Caterpillar recommends a 1 1 mixture of water and glycol This mixture will provide optimum heavy duty performance as a coolant antifreeze Note Cat DEAC does not require a treatment with an SCA at the initial fill However a commercial heavy duty coolant antifreeze that only meets the ASTM D4985 specification WILL require a treatment with an SCA at the initial fill A commercial heavy duty coo
119. terpillar experience has shown that adding oil products to Tier 4 engine fuels U S EPA Tier 4 certified to Euro IV Stage IV certified engine fuels or to the fuels of engines equipped with exhaust aftertreatment devices will generally cause the need for more frequent ash service intervals and or cause loss of performance Adding oil products to the fuel may raise the sulfur lev el of the fuel and may cause fouling of the fuel system and loss of performance Note Do not use API CF 4 oils in Caterpillar diesel engines Viscosity of Engine Oil The proper SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start up The proper SAE viscosity grade of oil is determined by the maximum ambient temperature during engine operation To determine the oil viscosity that is required for starting a cold soaked engine refer to the minimum temperature in Table 17 To select the oil viscosity for operation at the highest anticipated ambient temperature refer to the maximum temperature in the Table Use the highest oil viscosity that is available in order to meet the required temperature during start up Table 17 Engine Oil Viscosities for Ambient Temperatures Ambient Temperature Viscosity Grade Minimum Maximum SAE OW 20 40 C 40 F 10 C 50 F SAE OW 30 40 C 40 F 30 C 86 F SAE OW 40 40 C 40 F 40 C 104 F SAE 5W 30 30 C
120. the coolant from the cooling system to a level that is below the water temperature regulator housing 104041214 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 The crankshaft vibration damper limits the torsional vibration of the crankshaft The visconic damper has a weight that is located inside a fluid filled case Damage to the crankshaft vibration damper or failure of the damper can increase torsional vibrations Torsional vibration can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive torsional vibrations 70 Maintenance Section Driven Equipment Check SEBU8666 07 A damper that is hot may be the result of excessive torsional vibration worn bearings or damage to the damper Use an infrared thermometer to monitor the temperature of the damper during operation Follow the instructions that are included with the infrared thermometer If the temperature reaches 100 C 212 F consult your Cat dealer Inspect the damper for evidence of dents cracks and leaks of the fluid If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous and smooth If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace all of the seals Inspect the damper and repair or replace the damper for any of the following reasons
121. tors Your Caterpillar dealer can provide these services and components The wear of unit injectors is affected by the following considerations e Quality of the fuel e Quality of the filtration of the fuel The wear of the unit injectors can result in elevated levels of exhaust emissions and or poor engine performance The misfire of a single cylinder is not typically attributed to normal wear This condition can be repaired by replacing the faulty unit injector The following lists of circumstances indicate that the unit injectors should be inspected more frequently e Use of fuels that are not recommended in this Operation and Maintenance Manual Refill Capacities and Recommendations e Extreme ambient temperatures that reduce the ability of the fuel to provide lubrication Frequent plugging of the fuel filters Insufficient maintenance of the fuel tank or the fuel storage tank that can allow excessive water sediment and other foreign matter Insufficient maintenance of the fuel filters Oil Suction Screen Clean the oil suction screen after the oil has been drained mor FWD Illustration 57 g02251853 Top view of a typical 3500 engine oil pan with an oil housing and oil suction screen 1 Cover 2 Oil suction screen Note Approximately 1 L 1 qt of oil will remain in the oil housing after the sump has been d
122. treatment devices life performance and service intervals Use of oils other than Cat DEO ULS or oils that do not meet the Cat ECF 3 specification and the API CJ 4 oil category and or ACEA E9 category for EU and Japan specific applications listed above in aftertreatment equipped engines can negatively affect performance of the aftertreatment devices can contribute to Diesel Particulate Filter DPF plugging and or can cause the need for more frequent DPF ash service intervals Refer to your engine specific Operation and Maintenance Manual and refer to your aftertreatment device documentation if available for additional guidance Typical aftertreatment systems include the following e Diesel Particulate Filters DPF e Diesel Oxidation Catalysts DOC e Selective Catalytic Reduction SCR e Lean NOx Traps LNT Other systems may apply Cat DEO ULS is recommended for all pre Tier 4 engines that use Ultra Low Sulfur Diesel ULSD or Low Sulfur Diesel LSD fuels SEBU8666 07 49 Maintenance Section Refill Capacities Cat DEO ULS may be used in these applications if an oil analysis program is followed The oil change interval may be affected by the fuel sulfur level NOTICE Ultra Low Sulfur Diesel ULSD fuel 0 0015 percent 15 ppm mg kg sulfur is required by regulation for use in engines certified to nonroad Tier 4 standards U S EPA Tier 4 certified and that are equipped with exhaust aftertreatment systems
123. uld result Visually inspect the air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean air cleaner elements SEBU8666 07 75 Maintenance Section Engine Air Cleaner Element Single Element Clean Replace e Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 38 g00281692 Note When the air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon
124. ump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Cat dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination e Never collect samples from expansion bottles e Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see this Operation and Maintenance Manual Refill Capacities
125. vals 96 Maintenance Section Overhaul In Frame SEBU8666 07 Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases The oil consumption rate brake specific oil consumption is measured in grams per kW h lb per bhp The brake specific oil consumption BSOC depends on the engine load Consult your Cat dealer for assistance in determining the typical oil consumption rate for your engine When engine oil consumption has risen to three times the original oil consumption rate due to normal wear an engine overhaul should be scheduled There may be a corresponding increase in blowby and a slight increase in fuel consumption 102994813 Overhaul In Frame SMCS Code 1000 020 The maintenance intervals that are listed in this Operation and Maintenance Manual Maintenance Interval Schedule are expressed in service hours A more accurate figure to use is fuel consumption Fuel consumption corresponds more accurately to the engine load Refer to this Operation and Maintenance Manual Maintenance Recommendations in order to determine the maintenance interval for an in frame overhaul Typically an in frame overhaul does not require the engine to be removed Instead the service is performed with the engine in place If the customer requires a minimum disruption in the production of po
126. vibration of the engine and the driven equipment can be caused by the following conditions e Improper mounting e Loose bolts e Deterioration of the isolators Note Refer to the Specifications SENR3130 in order to locate the proper torques Ensure that the isolators are free of oil and contamination Inspect the isolators for deterioration Ensure that the bolts for the isolators are tightened to the proper torque Replace any isolator that shows deterioration For more information see the literature that is provided by the OEM of the isolators Also see the Application and Installation Guide for the engine Consult your Caterpillar dealer for assistance 102110431 Engine Oil Filter Differential Pressure Check SMCS Code 1308 535 Observe the oil filter differential pressure frequently during engine operation Oil Filter Differential Pressure Restriction This gauge indicates the difference in pressure between the inlet side and the outlet side of the engine oil filters As the oil filter elements become plugged oil filter differential pressure will increase paad The nominal oil filter differential pressure during normal engine operation is approximately 60 kPa 9 psi Replace the oil filter elements when the oil filter differential pressure reaches 103 kPa 15 psi For instructions on replacement of the oil filter elements see this Operation and Maintenance Manual Engine Oil and Filter C
127. w dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJ0003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 86 Maintenance Section Fuel Tank Water and Sediment Drain SEBU8666 07 Illustration 52 g01959325 1 Drain 2 Drain valve 3 Plug 4 Cover 5 Bolts 3 Connect a hose to drain 1 Place the other end of the hose into a suitable container in order to collect the fuel 4 Open drain valve 2 Remove plug 3 Allow the fuel to drain Clean the plug and install the plug Close the drain valve Remove the hose from the drain Note Some fuel will remain in the housing after the fuel has been drained This fuel will pour out of the housing when cover 4 is removed Prepare to catch the fuel
128. wer the engine can be replaced with a rebuilt model of identical specifications Note The generator or the driven equipment may also require service when the in frame overhaul is performed An in frame overhaul includes all of the work that is done for a top end overhaul Additionally some other components that wear are replaced Some components are inspected for good condition Some components are reconditioned or replaced if necessary Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications If you elect to perform an in frame overhaul without the services of a Caterpillar dealer be aware of the following recommendations For instructions on removal and installation of components see the Service Manual Disassembly and Assembly module Replacement of Components Replace the following worn components with new components during the in frame overhaul e Connecting rod bearings e Crankshaft seals e Electronic unit injectors e Main bearings e Piston rings Inspection Reconditioning or Exchanging of Components Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts Recondition the worn components
129. wing conditions may result in a hazardous situation Hoses which are cracked Hoses which are soft Outer covering that is chafed or cut Exposed wire that is used for reinforcement Outer covering that is ballooning locally Flexible part of the hose that is kinked or crushed Armoring that is embedded in the outer covering Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps Inspect all clamps for the following conditions Replace any clamp which exhibits signs of any of the following conditions e Cracking e Looseness e Damage Inspect all couplings for leaks Replace any coupling which exhibits signs of leaks Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen which can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Replace hoses that are cracked or soft Replace hoses that show signs of leakage Replace hoses that show signs of damage Replace hose clamps that are cracked or damaged Tighten or replace hose clamps which are loose 90 Maintenance Section Hoses and Clamps Inspect Replace SEBU8666 07 Replace the Hoses and the Clam
130. y Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements Inspecting the Primary Air Cleaner Elements Illustration 35 g00281693 Inspect the clean dry primary air cleaner element Use a 60 W blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element for tears and or holes Inspect the primary air cleaner element for light that may show through the filter material To confirm the result compare the primary air cleaner element to a new primary air cleaner element that has the same part number Do not use a primary air cleaner element that has any tears and or holes in the filter material Do not use a primary air cleaner element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will not be used the primary air cleaner element can be stored for future use Illustration 36 g00281694 Do not use paint a waterproof cover or plastic as a

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