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1. g00425598 Secondary fuel filters 1 Remove the used fuel filter with a 1U 8760 Chain Wrench Discard the used fuel filter 2 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 3 Apply clean diesel fuel to the new fuel filter gasket 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 4 Install the new fuel filter Spin the new fuel filter onto the fuel filter base until the gasket contacts the base Tighten the fuel filter by hand by one full turn Do not overtighten the fuel filter Use the rotation index marks that are on the fuel filter as a guide for proper tightening 5 Prime the fuel system See this Operation and Maintenance Manual Fuel System Prime topic Maintenance Section Replacing the Fuel Filter Elements During Engine Operation If the engine is equipped with duplex fuel filters the fuel filters can be changed while the engine is in operation If the filter is changed during rapid air movement an explosive vapor may be created The explosive vapor may result in personal injury or in death If rapid air movement exists s
2. g00799692 Illustration 50 Location of the cooling system drain plugs 1 Oil cooler 2 Jacket water pump 3 Engine block Note If the engine has a jacket water heater drain the coolant from the heater 3 Open the cooling system drain valves if equipped Remove the cooling system drain plugs 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 Cooling System NOTICE Use of commercially 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 72 Maintenance Section Cooling System Coolant DEAC Change SEBU7844 14 2 Close the cooling system dr
3. Table 41 Service Hours and Fuel Consumption for 3516B High Displacement Engines Interval Rated Upto Rated 1301 Rated 1601 1300 rpm to 1600 to 1800 rpm rpm 250 Service 44000 L 53000 L 64500 L Hours 11600 US 14000 US 17000 US gal of fuel gal of fuel gal of fuel 500 Service 88000 L 106000 L 129000 L Hours 23200 US 28000 US 34000 US gal of fuel gal of fuel gal of fuel 1000 176000 L 212000 L 258000 L Service 46500 US 56000 US 68000 US Hours gal of fuel gal of fuel gal of fuel 2000 352000 L 424000 L 516000 L Service 93000 US 112000 US 136000 US Hours gal of fuel gal of fuel gal of fuel 3000 528700 L 636700 L 773000 L Service 139500 US 168000 US 204000 US Hours gal of fuel gal of fuel gal of fuel 6000 1056000 L 1272000 L 1548000 L Service 279000 US 336000 US 408000 US Hours gal of fuel gal of fuel gal of fuel Top End 11000 9000 7500 Overhaul Service Service Service Hours Hours Hours 2000000 L 528000 US gal of fuel Major 22000 18000 15000 Overhaul Service Service Service Hours Hours Hours 4000000 L 1056000 US gal of fuel 1 Fuel consumption is based on a load factor of approximately 60 percent e For engines that operate at less than 50 percent load use the 50 percent load fuel consumption rate in order to determine the first top end the second top end and the overhaul hour intervals e Maintenance
4. 98 Every 2000 Service Hours Air Starting Motor Lubricator Bowl Clean 64 Crankshaft Vibration Damper Inspect 79 Driven Equipment Check cccceeeeeeteeeeees 80 Engine Mounts Check eeeeeeeeeeeeeeneeeeeeeeneees 88 Turbocharger Inspect n se 122 Every Year Cooling System Coolant Sample Level 2 Obtain eet ieta en ridea eel a T7 Every 3000 Service Hours or 3 Years Cooling System Coolant DEAC Change 71 Cooling System Coolant Extender ELC Add 74 Every 4000 Service Hours Auxiliary Water Pump Inspect ee 65 Engine Valve Lash Adjust ceeeeeeeeteeereeeees 96 Fuel Injector Inspect Adjust 2 0 0 0 96 Every 6000 Service Hours Air Shutoff Damper Remove Check 5 63 Cooling System Water Temperature Regulator Replace earo ereo iera a an aee oeat Canda 79 Every 6000 Service Hours or 6 Years Air Starting Motor Inspect seeen 63 Cooling System Water Temperature Regulator Ee E e EE EA 79 Electric Starting Motor Inspect n 81 Engine Speed Timing Sensor Clean Inspect 95 Prelube Pump Inspect ceeeeeteeteteees 120 Starting Motor Inspect i e 120 Water Pump Inspect ceceeeeeeeeeeeeeeeteeees 125 Every 8000 Service Hours or 3 Years Camshaft Roller Followers Inspect 05 69 Every 12 000 Service Hours or 6 Years
5. 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 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 112 Maintenance Section Marine Transmission Oil Level Check SEBU7844 14 101089872 Marine Transmission Oil Level Check SMCS Code 3300 535 OC Check the marine transmission oil level according to the instructions that are provided by the OEM of the transmission or the OEM of the vessel For the lubrication requirements of the transmission refer to the recommendations on the nameplate or the Owner s Manual for the transmission Marine Transmission Operation Maintenance Warranty and Parts Support For information on maintenance and operation of the marine
6. 0 cece 105 Marine Transmission Oil Level Check 112 Walk Around Inspection cceceeeeeeeeeeeeeees 124 Initial 250 Service Hours Engine Speed Timing Sensor Clean Inspect 95 Engine Valve Lash Adjust 0 ceeceeeeeeeeeeeeee 96 Fuel Injector Inspect Adjust 0 0 0 cceeeeeeeeeeees 96 Every 250 Service Hours Battery Electrolyte Level Check e 67 Belts Inspect Adjust Replace ceee 68 Cooling System Coolant Sample Level 1 ODAT reae e cece A E EANA 76 Cooling System Supplemental Coolant Additive SCAJ Test Add io et Ea 77 Engine Oil Sample Obtain a se 90 Engine Oil and Filter Change 91 Hoses and Clamps Inspect Replace 104 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Obtain cede dei del e aa 77 Every 500 Service Hours Air Shutoff Test ecccccccsececccceseeeheceeeetebecteeteneereet 61 Every 1000 Service Hours Air Starting Motor Lubricator Bowl Clean 64 Engine Clean ccccccccecceceeedecccceeeeedccneneeteceeeeeeees 81 Engine Crankcase Breather Clean aaisen 87 Engine Protective Devices Check esee 95 SEBU7844 14 59 Maintenance Section Maintenance Interval Schedule Fuel System Primary Filter Water Separator Clean Replace iee aeien E E a 97 Fuel System Secondary Filter Replace
7. 5 from hose tee 7 Inspect the hose tee for cracks If the tee is cracked discard 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 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 101786814 Engine Mounts Check SMCS Code 1152 535 Misalignment of the engine and the driven equipment will cause extensive damage Excessive vibration can lead to misa
8. SEBU7844 14 3 If the primary fuel filter is equipped with a drain valve open the drain valve in order to drain any fuel from the filter case Close the drain valve NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately Note Illustration 76 shows a Caterpillar Primary Fuel Filter If the engine has a different primary filter service the filter according to the instructions that are provided by the OEM of the filter Illustration 76 g00799801 1 Bolt 2 O ring seal 3 Case 4 Element 4 Remove bolt 1 O ring seal 2 case 3 and element 4 5 Wash the element and the case in clean nonflammable solvent Inspect the element for good condition Inspect the O ring seal for damage and deterioration Obtain new parts if necessary NOTICE Do not fill the fuel filters with fuel before installing them The fuel would not be filtered and could be contami nated Contaminated fuel will cause accelerated wear to fuel system parts 6 Install the element the case the O ring seal and the bolt Tighten the bolt to 25 5 N m 18 4 Ib ft Water Separator Service the water separator according to the instructions that are provided by the OEM of the water separator 100744357 Fuel System Primary Filter Water Separator Drain SMCS Code 1260 543 1263 543 Fuel leaked or spilled onto hot surfaces or electri cal components ca
9. 1000 070 Personal injury or death can result from high volt age Moisture can create paths of electrical conductiv ity Make sure that the electrical system is OFF Lock out the starting controls and tag the controls DO NOT OPERATE 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 Periodic cleaning of the engine is recommended 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 Caution must be used in order to prevent electrical components from being damaged by excessive water when you clean the engine Avoid electrical components such as the alternator the starter and the ECM 101553486 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 82 Maintenance Section Engine Air Cleaner Element Dual Element Clean
10. 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets of the cooling system filler cap are damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gaskets of the cooling system filler cap are not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure is stamped on the face of the cooling system filler cap If the cooling system filler cap does not maintain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 102482066 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Cat ELC Extended Life Coolant does not require the frequent additions of any supplemental cooling additives which are associated with the present conventional coolants The Cat ELC Extender only needs to be added once NOTICE Use only Cat Extended Life Coolant ELC Extender with Cat ELC Do NOT use conventional supplemental coolant addi tive SCA with Cat ELC Mixing Cat ELC with conven tional coolants and or conventional SCA reduces the Cat ELC service life Check the cooling system only when the engine is stopped and cool SEBU7844 14 75 Maintenance Section Cooling System Coolant Level Check Personal injury can result from hot coolant steam and alka
11. Caterpillar 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 Caterpillar 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 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 list 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 etc Insufficient maintenance of the fuel filters Oil Suction Screen Clean the oil suction screen after the oil has been drained Note A
12. Cooling System Coolant ELC Change 73 Overhaul Aftercooler Core Inspect Clean 00008 60 Overhaul Major cccceeeeeeeeeeeeenteeeeeeenneeeeeeeaas 112 Overhaul Top End ceeeeeeeeeeeeseeeeeeeenteeeeeeeas 114 Overhaul Considerations 118 60 Maintenance Section Aftercooler Core Inspect Clean SEBU7844 14 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 31 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 31 Hydrosolv Liquid Cleaners Part ee Number Description Size 1U 5490 Hydrosolv 4165 174 6854 Hydrosolv 100 19 L 5 US gallon 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
13. EUI Option Interval Rated Up To 1300 Rated 1301 To Rated 1601 To High High rpm 1600 rpm 1800 rpm Performance Performance D B e and Cr and E Ratings Ratings 250 Service 22700 L 27700 L 7200 US gal 32000 L 40500 L 29150 L Hours 6000 US gal 8500 US gal 10 700 US gal 7600 US gal 500 Service 45400 L 54400 L 64000 L 81000 L 58300 L Hours 12 000 US gal 14 400 US gal 17 000 US gal 21 400 US gal 15 200 US gal 1000 Service 89000 L 109000 L 128000 L 162000 L 116700 L Hours 23 500 US gal 28 800 US gal 34 000 US gal 42 800 US gal 30 800 US gal 2000 Service 178000 L 218000 L 257000 L 324000 L 233400 L Hours 47 000 US gal 57 600 US gal 68 000 US gal 85 600 US gal 61 600 US gal 3000 Service 267500 L 327500 L 386500 L 485500 L 350000 L Hours 70 500 US gal 84 000 US gal 102 000 US gal 128 400 US gal 92 500 US gal 6000 Service 535000 L 636000 L 774000 L 971000 L 700000 L Hours 141 000 US gal 168 000 US gal 204 000 US gal 256 250 US gal 185 000 US gal Top End 11 000 Service 9000 Service Hours 7500 Service 6000 Service 4500 Service Overhaul Hours Hours Hours Hours 976000 L 257 500 US gal 971000 L 525000 L 256 250 US gal 135 500 US gal Second Top 22 000 Service 18 000 Service Hours 15 000 Service n a n a End Overhaul Hours Hours 1952000 L 515 000 US gal n a n a Major Overhaul 33000 Service 27000 Service Hours 22500 Service 12000 Service 9000 Service Hours Hours Hours Hours 29
14. Horsepower e Range of rpm e Fuel consumption Fuel quality e Altitude e Maintenance intervals Selection of oil Selection of coolant e Environmental qualities e 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 Special Publication SEBU5898 Cold Weather Recommendations
15. Maintenance intervals Selection of oil Selection of coolant e Environmental qualities e 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 Recommendations Cleanliness Unless the equipment is cleaned regularly extended operation in a dirt
16. 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 2 If necessary drain some coolant in order to allow space for the addition of the SCA 3 Add the proper amount of SCA For the proper amount of SCA refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic For the proper concentration of SCA refer to Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations 4 Clean the cooling system filler cap Install the cooling system filler cap SEBU7844 14 79 Maintenance Section Cooling System Water Temperature Regulator Replace i03645060 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 te
17. Replace SEBU7844 14 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 Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer 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 Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air
18. S N TTB1 Up S N M8C1 Up S N TTC1 Up S N M8D1 Up S N S2D1 Up SEBU7844 14 121 Maintenance Section Starting Motor Inspect S N TTD1 Up S N S2E1 Up S N TTE1 Up S N S2F1 Up S N TTF1 Up S N B5G1 Up S N MRG5 Up S N PAG1 Up S N TTG1 Up S N MKH1 Up S N TTH1 Up S N S2J1 Up S N TTJ1 Up S N S2K1 Up S N S2L1 Up S N S2M1 Up S N S2N1 Up S N S2S51 Up S N S2T1 Up S N E3W1 Up S N S2W1 Up S N E3X1 Up S N S2X1 Up S N S2Y1 Up S N E3Z1 Up 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
19. 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 Caterpillar dealer if repair is needed or replacement is needed 103028045 Zinc Rods Inspect Replace SMCS Code 1388 040 1388 510 Corrosion in sea water circuits can result in the following issues premature deterioration of cooling system components leaks and possible cooling system contamination The corrosion may be caused by the lack of zinc rods in the sea water system Zinc rods are installed in the sea water cooling system of the engine in order to help prevent the corrosive oxidation that is caused by sea water Electrical current is conducted through the contact of the zinc rods with the cooling system components The zinc rods oxidize rather than the cooling system components Rapid deterioration of zinc rods may indicate the presence of uncontrolled electrical currents from improperly installed electrical attachments or improperly grounded electrical attachments The engineer for the operation must determine the interval for inspecting the zinc rods The interval for inspecting the zinc rods will depend on the size of the zinc rods and the number of zinc rods that are installed Table 42 Locations of the Zinc Rods Location Quantity Elbow of the Auxiliary Water Pump 1 Elbow of the Aftercooler 1 Ins
20. 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 in 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 SEBU7844 14 113 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 Salv
21. information on cleaning the core consult your Caterpillar dealer SEBU7844 14 61 Maintenance Section Air Shutoff Test 102566367 Air Shutoff Test Engines That Are Equipped with ADEM II or ADEM III Engine Control Modules SMCS Code 1078 081 hil fia WW r l mo wh Illustration 37 g01285348 Typical air shutoffs on a 3500B engine 1 Air shutoffs off Illustration 38 g01285609 Left hand side air shutoff in the OPEN position Illustration 39 g01285610 Right hand side air shutoff in the OPEN position Refer to the Troubleshooting Guide Air Shutoff System information in your Service Manual for further information about the electrical system for the air shutoff system Engines That Are Equipped with ADEM II Engine Control Modules Note Do not start the engine Ensure that the engine control is in the OFF position 1 Ensure that both air shutoff gates are latched in the OPEN position and ensure that both air shutoff switches are connected Turn on the power to the engine control panel Both air shutoff gates should remain open If both air shutoff gates do not remain open check the wiring for the air shutoff switches 2 With the power for the engine control panel in the ON position activate the EMERG
22. 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 and to Special Publica tion GECJ0003 Cat Shop Supplies and Tools for tools and supplies suitable to collect and contain flu ids on Caterpillar products Dispose of all fluids according to applicable regula tions and mandates Note Caterpillar recommends an S O S coolant analysis Level 1 78 Maintenance Section SEBU7844 14 Cooling System Supplemental Coolant Additive SCA Test Add Cooling Systems that Use Conventional Coolant This maintenance procedure is required for conventional coolants such as DEAC This maintenance is NOT required for cooling systems that are filled with Extended Life Coolant Test the Concentration of the 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 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 2 If necessary
23. of the service indicator Inspect the filter for cleanliness Clean the filter if necessary Use compressed air or a clean nonflammable solvent The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 lb in 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 88 Maintenance Section Engine Mounts Check SEBU7844 14 Illustration 65 g00597463 1 Loosen clamp 1 Slide the clamp down on tube 2 2 Loosen clamps 3 Remove both breathers as a unit Illustration 66 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 eee 6 Illustration 67 g00597466 4 Remove two clamps 6 Remove both breathers
24. small amounts of debris 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 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 engine 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 102209352 Engine Speed Timing Sensor Clean Inspect SMCS Code 1905 040 1905 070 1907 040 1907 070 An engine speed timing sensor is m
25. spindle 11 is 0 25 mm 0 010 inch The maximum clearance between bearing 15 and spindle 11 is 0 20 mm 0 008 inch If the rotor bearings and the spindle are not within specifications replace the parts Note The spindle and the filter body are replaced as a complete assembly The rotor assembly is replaced as a complete assembly Before you assemble the centrifugal oil filter thoroughly clean all of the parts and inspect all of the parts Replace parts that are damaged or worn NOTICE Ensure that all of the rotor components are thoroughly clean before assembling the rotor Failure to do so can cause an out of balance condition that can cause rapid wear to the bearings and the spindle 14 Install stand tube 12 on rotor base 17 15 Install a new paper liner 10 in rotor cover 8 Place O ring seal 13 on rotor base 17 Position rotor cover 8 on rotor base 17 16 Install stiffener plate 6 17 Use tool A to hold the rotor assembly and install nut 7 18 Install the rotor assembly on spindle 11 Install the rotor assembly carefully so the bearings are not damaged 19 Install O ring seal 14 on filter body 18 20 Install cover 9 and clamp 16 on filter body 18 Tighten clamp 16 and nut 5 21 Open valve 2 to centrifugal oil filter 1 SEBU7844 14 71 Maintenance Section Cooling System Coolant DEAC Change 22 Check the centrifugal oil filter for leaks Fee
26. 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 1 Open the drain valve that is on the bottom of the air tank Allow the moisture and sediment to drain 2 Close the drain valve 102256018 Auxiliary Water Pump Inspect SMCS Code 1371 040 1371 Refer to the Disassembly and Assembly Manual for the engine in order to perform the disassembly of the auxiliary water pump 66 Maintenance Section Auxiliary Water Pump Inspect SEBU7844 14 Impellers and seals require periodic inspection Impellers have a service life that is limited The service life depends on the engine operating conditions Inspect the components more frequently when the pump is exposed to debris sand or other abrasive materials Inspect the components if the pump is operating at a differential pressure of more than 103 kPa 15 psi There are different types of pumps Some pumps will have a cover that is bolted to the main pump body Some pumps will have a clamp that holds the front part of the pump body to the main part of the pump body The cover or the front part of the pump body must be removed in order to inspect the pump Pumps with a Cover 3 X O p e j O 1 Illustration 45 g01136356 1 Plug 2 Bolt 3 Cover 1 Rem
27. the heat exchanger 3 Turn the heat exchanger core upside down in order to remove debris 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 4 Back flush the core with cleaner Caterpillar recommends the use of Hydrosolv liquid cleaner Table 35 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 35 Hydrosolv Liquid Cleaners Part MPF 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 Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information SEBU7844 14 103 Maintenance Section Heat Exchanger Inspect 5 Steam clean the core in order to remove any residue Flush the tubes of the heat exchanger core Remove any other trapped debris 6 Wash the core with hot soapy water Rinse the core thoroughly with clean water 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
28. the outlet of the pump Place the hose in a suitable container Open the valve for the drain line The two marks on the valve must be turned so that one mark points to the pump and the second mark points to the drain line Operate the pump until the crankcase is empty Close the valve to the drain line Disconnect the hose d If the oil drain valve has a quick connect coupling attach the coupling Open the drain valve in order to drain the crankcase After the oil has drained close the drain valve Disconnect the coupling 3 Replace the engine oil filter elements before filling the crankcase with new oil 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 Replacing the Engine Oil Filters With the Engine Stopped Hot oil and components can cause personal in jury Do no
29. valve After the new filter elements are full of fuel either the main filter or the auxiliary filter may be used 103645042 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 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 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 Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bot
30. 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 Use fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance All of the following will affect the oil change interval 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 In the absence of scheduled oil sampling replace the engine oil and filters according to the following intervals If the engine has a standard oil sump change the oil after every 500 service hours If the engine has a deep oil sump change the oil after every 1000 service hours 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
31. 28000 L 773 578 US gal 1942000 L 1050000 L 512 500 US gal 275 000 US gal 1 Fuel consumption is based on a load factor of approximately 60 percent 2 Fuel consumption is based on a load factor of approximately 40 percent 108 Maintenance Section Maintenance Recommendations SEBU7844 14 Table 38 Maintenance Interval Schedule Service Hours and Fuel Consumption for 3512B Engines and 3512 Engines with EUI Option Interval Rated Up To 1300 Rated 1301 To Rated 1601 To High Performance High rpm 1600 rpm 1800 rpm B and C Performance Ratings D and E Ratings 250 Service 33400 L 41000 L 48500 L 60800 L 43750 L Hours 8800 US gal 10 800 US gal 12 800 US gal 21 400 US gal 11 500 US gal 500 Service 66800 L 82000 L 97000 L 121600 L 87500 L Hours 17 600 US gal 21 600 US gal 25 600 US gal 32 200 US gal 23 000 US gal 1000 Service 133500 L 164000 L 194000 L 243300 L 175000 L Hours 35 000 US gal 43 200 US gal 51 200 US gal 64 200 US gal 46 000 US gal 2000 Service 267000 L 328000 L 388000 L 486600 L 350000 L Hours 70 000 US gal 86 400 US gal 102 400 US gal 128 400 US gal 92 000 US gal 3000 Service 398000 L 491000 L 582000 L 729900 L 525000 L Hours 105 000 US gal 129 600 US gal 153 600 US gal 192 500 US gal 138 000 US gal 6000 Service 796000 L 982000 L 1164000 L 1460000 L 1050000 L Hours 210 000 U
32. 286567 Damper assembly 3 Plug 4 Seal ring 5 Housing 6 Spring 7 Plunger 1 The body of the damper should not be loosened or removed from the air shutoff when the plunger is removed In order to remove the plunger without loosening or removing the damper unscrew the plug with the following tools a 6 35 mm 0 25 inch Allen wrench and an open end wrench 2 Check the seal ring for damage or wear If necessary replace the seal ring 3 Inspect the internal parts of the vibration damper for wear or damage Clean the components with 138 8440 component cleaner E Illustration 42 g01286606 Damper plunger 4 Remove the plunger from the spring Visually inspect the exposed end of the plunger for dirt fouling damage and wear If distance A is less than 18 3 mm 0 72 inch or if a visual inspection reveals dirt fouling damage or wear on the active end of the plunger replace the plunger Insert the tapered end of a clean undamaged plunger into the spring Install the open end of the spring into the plug Apply 9S 3263 thread lock or apply 9S 4030 thread lock onto the threads of the plug Screw the assembly into the damper body The thread lock should cure for a minimum of 1 hour before the air shutoff is used 101076477 Air Starting Motor Inspect SMCS Code 1451 040 If the starting motor fails the engine may not start in an emergency situation A scheduled inspection of the starting m
33. 3500B SERIES II and 3500C MARINE PROPULSION ENGINES Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU7844 14 00 2009 Caterpillar CATERPILLAR All Rights Reserved 56 Maintenance Section Maintenance Recommendations SEBU7844 14 Maintenance Recommendations 102909163 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 High Pressure Fuel Lines If Equipped 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 The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head These fuel lines are different from fuel lines on other fuel systems This is because of the following differences e The hi
34. 4 Remove the drain plug 5 Steam clean the core in order to remove any residue Flush the fins of the aftercooler 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
35. Air Cleaner Elements Illustration 61 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 62 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 SEBU7844 14 87 Maintenance Section Engine Air Cleaner Service Indicator Inspect 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 following information e Date of cleaning e Number of cleanings
36. ENCY STOP switch Both of the air shutoff gates should close If both air shutoff gates close proceed to step 3 If both air shutoff gates do not close check the wiring for the air shutoff switches and check the wiring for the solenoids Activate the EMERGENCY STOP switch again When both air shutoff gates close proceed to step 3 3 Turn the power to the engine control panel to the OFF position Ensure that the EMERGENCY STOP switch is in the RUN position Latch only the right side air shutoff gate to the OPEN position Turn the power for the engine control panel to the ON position The right side air shutoff gate should close If the right side air shutoff closes proceed to step 4 If the right side air shutoff gate does not close check the air shutoff switch for the right side air shutoff and check the wiring for the right side air shutoff When the right side air shutoff closes proceed to step 4 62 Maintenance Section Air Shutoff Test SEBU7844 14 Turn the power for the engine control panel to the OFF position Latch only the left side air shutoff gate to the OPEN position Turn the power for the engine control panel to the ON position The left side air shutoff gate should close If the left side air shutoff gate closes the test is complete If the left side air shutoff gate does not close check the switch and the wiring for the left side air shutoff Note Testing is only complete when the engi
37. ICE 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 cooling lines are clamped properly and ensure that the cooling lines are tight Check for leaks Check the condition of all pipes e Inspect the water pumps 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 when the engine cools and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pumps and the installation of water pumps and or seals refer to two articles in the Disassembly and Assembly Manual Water Pump Remove and Water Pump Install 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 in
38. LE WITH WARM OIL side 4 The engine oil level should be between ADD mark 5 and FULL mark 6 90 Maintenance Section Engine Oil Sample Obtain SEBU7844 14 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 engin
39. S gal 259 200 US gal 307 200 US gal 385 000 US gal 276 000 US gal Top End 11 000 Service 9000 Service Hours 7500 Service 6000 Service Hours 4500 Service Overhaul Hours Hours Hours 1460000 L 385 000 US gal 787500 L 206 250 US gal Second Top 22000 Service 18000 Service Hours 15000 Service n a n a End Overhaul Hours Hours 2920000 L 770 000 US gal n a n a Major Overhaul 33000 Service 27000 Service Hours 22500 Service 12000 Service 9000 Service Hours Hours Hours Hours 4380000 L 1 155 000 US gal 2920000 L 1575000 L 770 000 US gal 412 500 US gal 1 Fuel consumption is based on a load factor of approximately 60 percent 2 Fuel consumption is based on a load factor of approximately 40 percent 109 Maintenance Section Maintenance Recommendations SEBU7844 14 Table 39 Maintenance Interval Schedule Service Hours and Fuel Consumption for 3516B Engines and 3516 Engines with EUI Option Interval Rated Up To Rated 1301 To Rated 1601 To High High High 1300 rpm 1600 rpm 1800 rpm Performance Performance Performance A Rating B and C D and E Ratings Ratings 250 Service 44000 L 53000 L 64500 L 97000 L 81000 L 58300 L Hours 11 600 US gal 14 000 US gal 17 000 US gal 25 600 US gal 21 400 US 15 200 US gal gal 500 Service 88000 L 106000 L 129000 L 194000 L 162000 L 116600 L Hours 23 200 US gal 28 000 US gal 34 000
40. Store the box in a dry location 101397712 Engine Air Cleaner Service Indicator Inspect SMCS Code 7452 040 A service indicator may be mounted on the air cleaner element or in a remote location ian Illustration 63 g00736586 1 Service indicator Some engines may be equipped with a different service indicator Observe the service indicator Clean the air cleaner element or replace the air cleaner element when the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position e The air restriction reaches 6 kPa 25 inches of H20 Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three pushes Check the movement of the yellow core when the engine is accelerated to the engine rated rpm The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the fitting for the service indicator may be plugged Illustration 64 g00351792 Porous filter A porous filter is part of a fitting that is used for mounting
41. 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 Stop the engine Allow the engine to cool 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suitable clean container The coolant can be reused 3 Drain the coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose 7 Install the hose clamps with a torque wrench Note Refer to the Specifications SENR3130 Torque Specifications in order to locate the proper torques 8 Refill the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler cap s gaskets Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks 101048507 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 a warning lamp does not illuminate replace the bulb immediately If the alarm does not sound investigate the problem and co
42. US gal 51 300 US gal 42 800 Us 30 400 US gal gal 1000 176000 L 212000 L 258000 L 388000 L 324000 L 233300 L Service 46 500 US gal 56 000 US gal 68 000 US gal 102 500 US 85 600 US 61 600 US gal Hours gal gal 2000 352000 L 424000 L 516000 L 777000 L 648000 L 466600 L Service 93 000 US gal 112 000 US gal 136 000 US 205 300 US 171 200 US 123 200 US gal Hours gal gal gal 3000 528700 L 636700 L 773000 L 1165000 L 972000 L 700000 L Service 139 500 US 168 100 US gal 204 000 US 308 000 US 257 000 US 185 000 US gal Hours gal gal gal gal 6000 1056000 L 1272000 L 1548000 L 2330000 L 1942000 L 1400000 L Service 279 000 US 336 000 US gal 408 000 US 615 500 US 512 500 US 370 000 US gal Hours gal gal gal gal Top End 11000 Service 9000 Service 7500 Service 5000 Service 6000 Service 4500 Service Overhaul Hours Hours Hours Hours Hours Hours 1942000 L 512 500 US gal 1050000 L 275 000 US gal Second 22000 Service 18000 Service 15000 Service n a n a n a Top End Hours Hours Hours Overhaul eee 3884000 L 1 025 000 US gal n a n a n a Major 33000 Service 27000 Service 22500 Service 10000 Service 12000 9000 Service Overhaul Hours Hours Hours Hours Service Hours Hours 5826000 L 1 537 500 US gal 3884000 L 1 025 000 US gal 2100000 L 550 000 US gal 1 Fuel consumption is based on a load factor of approximately 60 percent 2 Fuel consumption is based on a load factor of approxi
43. 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 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 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 con
44. able 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 could result Visually inspect the air cleaner elements before cleaning Inspect
45. age 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 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 th
46. ain valves if equipped 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 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the cooling system 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 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the cooling system drain valves if equipped Remove the cooling system drain plugs Allow the water to drain Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the cooling system filler cap Start the engine Operate the engine for a minimum of 90 minutes with a coolant temperature of at least 82 C 180 F Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the cooling system drain valves if equipped Remove the cooling sy
47. alve lash is NOT necessary Perform the valve lash setting when the engine is cold After the engine has been shutdown 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 this Operation and Maintenance Manual Specifications topic Product Information Section 101225237 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 Fuel System topic Adjust the lash for the fuel injector if necessary SEBU7844 14 97 Maintenance Section Fuel System Prime 101398238 Fuel System Prime SMCS Code 1250 548 1258 548 1 Open the fuel supply valve Ensur
48. 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 102654935 Air Starting Motor Lubricator Bowl Clean SMCS Code 1451 070 If the engine is equipped with an air starting motor use the following procedure 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 1 Ensure that the air supply to the lubricator is OFF Illustration 43 g01333332 1 Filler plug 2 Bowl 3 Drain valve 2 Slowly loosen filler plug 1 in order to release the pressure from the lubricator 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 for tools and supplies suitable to collec
49. and results of the test are successful reconnect the right side air shutoff Reset both air shutoffs Turn the power for the engine control panel to the ON position Reset both air shutoffs Start the engine Disconnect only the left side air shutoff Both air shutoff gates should close The engine should shut down If the engine does not shut down use the EMERGENCY STOP switch to stop the engine Check the wiring for both air shutoffs Use the above procedure in order to retest the left side air shutoff When the procedure in 6 is followed and the results of the test are successful reconnect the right side air shutoff Reset both air shutoffs Testing is complete only when the engine successfully passes steps 1 through 6 Reset both air shutoffs Ensure that the EMERGENCY STOP switch has been reset Operate the engine normally SEBU7844 14 63 Maintenance Section Air Shutoff Damper Remove Check 102567801 Air Shutoff Damper Remove Check SMCS Code 1078 011 1078 535 Illustration 40 g01286554 Typical air shutoff back view 1 Air shutoff gate 2 Damper assembly The vibration damper on the air shutoff minimizes the vibration of the air shutoff gate when the engine is operating and the air shutoff gate is in the latched position The components of the damper assembly must be removed in order to ensure correct performance of the damper aff Illustration 41 g01
50. arry 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 Alternator Belt Adjustment Illustration 47 g00960176 1 Adjusting nuts 2 Mounting bolt 3 Mounting bolt 4 Mounting bolt 1 Remove the drive belt guard 2 Loosen mounting bolts 2 3 and 4 Loosen adjusting nuts 1 3 Turn adjusting nuts 1 in order to increase or decrease the drive belt tension 4 Tighten adjusting nuts 1 Tighten mounting bolts 2 3 and 4 5 Reinstall the drive belt guard If new drive belts are installed check the drive belt tension again after 30 minutes of engine operation at the rated rpm SEBU7844 14 69 Maintenance Section Camshaft Roller Followers Inspect 102756549 Camshaft Roller Followers Inspect SMCS Code 1209 040 For instructions on disassembly and assembly of the valve lifter group see the Service Manual Disassembly and Assembly module See Reuse and Salvage Guidelines SEBF8146 Visual Inspection of Camshafts and inspect the following components for wear at each metal to metal contact point e Rollers for the valve lifters e Camshaft Inspect each roller for wear excessive movement and end play If excessive wear or other signs of deterioration are found replace the damaged components 102576503 Centrifugal Oil Filter Inspect SMCS Code 1328 040 Hot oil and c
51. ase 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 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 Tables 37 38 and 39 list average ranges of fuel consumption and service hours for standard displacement engines These tables are based on a load factor of approximately 60 percent SEBU7844 14 107 Maintenance Section Maintenance Recommendations Standard Displacement Engines Table 37 Maintenance Interval Schedule Service Hours and Fuel Consumption for 3508B Engines and 3508 Engines with
52. 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 SEBU7844 14 57 Maintenance Section Maintenance Recommendations 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 provided 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 ae SR 6 Illustration 36 g01075639 Use the example above The current flow from the welder to the ground clamp of the welder will n
53. cause a battery explosion resulting in personal injury 1 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 2 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 3 Tape the leads in order to help prevent accidental starting 4 Proceed with necessary system repairs Reverse the steps in order to reconnect all of the cables 102229322 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspection Inspect the alternator belt and any accessory 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 reduces the service life of the components 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 c
54. ce Manual Refill Capacities and Recommendations article for more information 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 102158408 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Climbing equipment may be required to access this service point Refer to the Operation and Maintenance Manual Mounting and Dismount ing topic for safety information Engines That Are Equipped With a Sight Gauge A ATT Illustration 52 g00750429 1 Filler cap 2 Sight gauge If the engine is equipped with a sight gauge observe the position of the coolant in the sight gauge At normal operating temperature the proper coolant level is in the upper half of the sight gauge If the coolant level is low add the proper coolant mixture Engines That Are Not Equipped With a Sight Gauge 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 Check the coolant level when the engine is stopped and cool Check the coolant level only after the engine has been stopped and the cooling system filler cap is cool enough to touch with your bare
55. cing the Engine Oil Filters During Engine Operation If the engine is equipped with duplex oil filters the engine oil filter elements can be changed while the engine is in operation This is useful if the oil filter elements require more frequent replacement than the engine oil This filter contains hot pressurized oil that can cause burns and fire hazards which may result in bodily injury or death Follow the instructions given in this Operation and Maintenance Manual and stop the engine if rapid air movement exists to blow the oil 1 Open the FILL valve for a minimum of five minutes in order to fill the oil filter elements that will not be serviced The oil filters that will not be serviced must be full of engine oil Close the FILL valve 2 Move the control valve to the AUX RUN position in order to change the main oil filter elements Move the selector valve to the MAIN RUN position in order to change the auxiliary oil filter elements 3 Allow the oil pressure gauge for the oil filter that is being changed to reach a ZERO pressure reading 94 Maintenance Section Engine Oil and Filter Change SEBU7844 14 4 Perform Step 1 through Step 8 of Replacing the Engine Oil Filters With the Engine Stopped 5 Open the FILL valve for a minimum of five minutes in order to fill the new oil filter elements 6 Close the FILL valve Rotate the control valve to the RUN pos
56. 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 The secondary air cleaner element is not serviceable or washable The secondary air cleaner element should be removed and discarded for 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 55 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 dirt out 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 SEBU7844 14 83 Maintenance Section Engine Air C
57. 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 Caterpillar 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 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 list of circumstances indicate that the unit injectors should be inspected more frequently Use of fuels that are not recommended in this Operation and Maintenance Manual Refill Capacities and Recommendations 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 etc Insufficient maintenance of the fuel filters Oil Suction Screen Clean the oil suction screen after the oil has been drained SEBU7844 14 117 Maintenance Section Overhaul Top End Note Approximately 1 L 1 qt of oil will remain in t
58. d 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 has been operated at normal operating temperature STOP the engine 2 Drain the oil according to the equipment on the engine Note Drain the oil into a suitable container DO NOT drain the oil into the bilge sump Dispose of the oil according to local regulations 92 Maintenance Section Engine Oil and Filter Change SEBU7844 14 Illustration 70 g00574534 Oil drain plug Note If a suction device is used in order to remove the oil from the oil pan ensure that the suction device is clean This will prevent dirt from entering into the oil pan Be careful not to strike the engine oil suction tubes or the piston cooling jets a If the engine does not have a drain valve or a pump remove an oil drain plug Allow the oil to drain After the oil has drained clean the drain plug and clean the fitting for the drain plug Install the drain plug Tighten the drain plug to 145 15 N m 105 10 Ib ft b If the engine has an oil drain valve open the valve After the oil has drained close the valve c If the engine has a pump for removing dirty oil connect a hose to
59. d overhaul for a general C or D load profile Applications that have frequent cycling of the engine will increase the wear rate of the valve in the exhaust bypass Applications that have extended periods of operation at the opening position of the valve will increase the wear rate of the valve The valve stem should be inspected periodically for wear of the valve stem A reduced service interval may be required if the inspection reveals heavy wear of the valve This will ensure proper operation of the exhaust bypass Use the following steps in order to inspect the exhaust bypass 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 Drain the cooling system to a sufficient level below the exhaust bypass in order to remove the cooling lines that attach to the exhaust bypass Refer to the maintenance section of this Operation and Maintenance Manual Cooling System Coolant Change for instructions on draining the cooling system Illustration 81 g01174063 1 Exhaust bypass 2 Boost line 3 Coolant line 2 Disconnect the boost line 2 and the two coolant lines 3 from the exhaust bypass 1 The coolant lines 3 attach to both sides of the exhaust bypass 1 Illustration 82 g01173813 1 E
60. diment Metal oxides Sulfamic acid ot Citric acid Diatomic Phosphoric acid organisms Complexing Seaweed agents Chips of wood Sodium Gross fouling and fibers polyphosphates Mussels Barnacles Bacteria Biological growth Nematodes Protozoa si tes Paraffinic or Oily films Naphtha based Residue Asphalt h Fats solvent such as Kerosene 04 1 Cleaners should be mixed at a maximum concentration of 4 percent by weight The temperature of the cleaning solution should be less than 60 C 140 F 2 The addition of surfactants to the cleaning solution may ease cleaning 3 Do not mix the solvent with water for cleaning Dry the plates with a cloth or rinse the plates with water 4 Gaskets that are made from natural rubber butyl rubber and EPDM rubber will swell in these solvents Do not allow the solvent to contact the gasket more than half an hour 1 Drain the heat exchanger 2 Disassemble the heat exchanger and remove the plates Keep the plates in order 3 Clean the plates with a cleaning solution and a soft brush Pressurized water may also be used Do not use steel wool or a wire brush which may scratch the plate Any iron scratches on the plates can lead to corrosion of the plates Rinse the plates with water 4 Assemble the heat exchanger 102121526 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Inspect all hoses for leaks that are caused by the following conditions
61. ditions malfunction of the solenoid and malfunction of the electric starting system Inspect the electrical system for the following conditions 122 Maintenance Section Turbocharger Inspect SEBU7844 14 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 102349288 Turbocharger Inspect SMCS Code 1052 040 Avoid contact with hot surfaces Exhaust piping and engine components become hot during en gine operation and cool slowly after engine shut down Any contact with hot surfaces can cause se vere burns 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 bea
62. drain some coolant in order to allow space for the addition of the SCA 3 Add the proper amount of SCA For the proper amount of SCA refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic The proper concentration of SCA depends on the type of coolant that is used For the proper concentration of SCA refer to Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations 4 Clean the cooling system filler cap Install the cooling system filler cap Cooling Systems that Use Water and SCA Test the Concentration of the SCA Test the concentration of the SCA with a 298 5311 Coolant Nitrite Test Kit for SCA or perform an S O S Coolant Analysis The test kit includes the following items a tool for the testing 30 ampoules for testing nitrite instructions and a case 294 7420 Test Kit contains the refill ampoules for the 298 5311 Coolant Nitrite Test Kit Use the instructions that are included with the test kit in order to properly conduct the testing Refer to this Operation and Maintenance Manual Maintenance Interval Schedule for the times at which the procedures should be conducted Test the concentration of the SCA more frequently if more frequent testing is indicated by the results of the S 0 S Coolant Analysis NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration Add the SCA If Necessary
63. e Cracking e Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps 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 carefully Tighten all connections to the rec ommended torque Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps 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 SEBU7844 14 105 Maintenance Section Instrument Panel Inspect Replace the Hoses and the Clamps Pressurized
64. e 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 102624457 Overhaul Top End SMCS Code 7595 020 TE Refer to this Operation 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 Caterpillar dealer can provide these services and components Your Caterpillar 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 SEBU7844 14 115 Maintenance Section Overhaul Top End First 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
65. e 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 magnetic particle inspection process to check for cracks 114 Maintenance Section Overhaul Top End SEBU7844 14 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 remo
66. e oil sample and analysis include the total amount of engine oil that has been added since the previous oil change This will help to provide the most accurate analysis 103542996 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 in order to monitor the condition of the engine and the maintenance requirements of the engine 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 well 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 Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency
67. e that the engine will not start during the priming procedure Turn the start switch to the OFF position a gt ed 1 ea wey fol as oe mnm z T N O Illustration 75 g00736817 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 i01076701 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 side and the outlet side of the fuel filter As the fuel filter element becomes plugged the difference in pressure between th
68. e 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 101539891 Fuel System Primary Filter Water Separator Clean Replace SMCS Code 1260 070 PY 1260 510 PY 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 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 Note After cleaning or replacing the element it may be necessary to prime the fuel system before the engine will start See this Operation and Maintenance Manual Fuel System Prime topic Maintenance Section Primary Filter 1 Stop the engine Turn the start switch to the OFF position Disconnect the battery 2 Shut off the fuel tank supply valve to the engine 98 Maintenance Section Fuel System Primary Filter Water Separator Drain
69. eaking The paint on the damper is discolored from heat The engine has had a failure because of a broken crankshaft The crankshaft bearings are showing excessive wear There is a large amount of gear train wear that is not caused by a lack of oil 80 Maintenance Section Driven Equipment Check SEBU7844 14 Dampers With Sampling Ports Illustration 54 g00819045 Some dampers have ports for fluid samples If the damper has no external damage collect a sample of the damper fluid The fluid should be analyzed in order to check for a loss of viscosity Use the results of the analysis to determine if the damper should be rebuilt or replaced Kits for fluid samples are available from the address that follows Return the kits to the same address for analysis Hasse amp Wrede GmbH Georg Knorr Strake 4 12681 Berlin Germany Phone 49 30 9392 3135 Fax 49 30 9392 7 3135 Alternate phone 49 30 9392 3156 Alternate fax 49 30 9392 7 3156 The typical limit for the degradation of the damper fluid viscosity that is used by Hasse amp Wrede GmbH is 20 percent for the majority of applications The reports from Hasse amp Wrede should indicate that the fluid samples meet this viscosity limit Dampers Without Sampling Ports Some dampers do not have a port for a fluid sample These dampers must be rebuilt or the dampers must be replaced when one of the following criteria has been met e The damper has been op
70. ealers 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 102259851 Sea Water Strainer Clean Inspect SMCS Code 1371 040 1371 070 The sea water strainer must be clean in order to allow proper engine cooling Check the sea water strainer for plugging Inspect the sea water strainer more frequently if the vessel is being operated in water which is shallow or dirty Refer to the OEM recommendations for more information about inspecting and cleaning the sea water strainer 102618737 Starting Motor Inspect If equipped SMCS Code 1451 040 1453 040 S N M8A1 Up S N TTA1 Up S N M8B1 Up
71. eals 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 56 g00281692 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 in order to 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 Primary 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 reco
72. eck the right side air shutoff Check the wiring for the right side air shutoff Retest the air shutoff When the procedure in 3 is followed and the engine fails to start proceed to 4 4 Reset the EMERGENCY STOP switch to the RUN position Set the power for the engine control panel to the ON position Activate the EMERGENCY STOP switch Both air shutoff gates should close Set power for the engine control panel to the OFF position Reset the EMERGENCY STOP switch to the RUN position Reset the left side air shutoff to the OPEN position Turn the power for the engine control panel to the ON position Select START RUN on the engine control panel The engine should fail to start If the engine does not start proceed to 5 If the engine starts turn off the engine Check the left side air shutoff Check the wiring for the left side air shutoff Retest the left side air shutoff When the procedure in step 4 is followed and the engine fails to start proceed to 5 Turn the power for the engine control panel to the ON position Reset both air shutoffs Start the engine Disconnect only the right side air shutoff Both air shutoff gates should close The engine should shut down If the engine does not shut down use the EMERGENCY STOP switch to stop the engine Check the wiring for both air shutoffs Use the above procedure in order to retest the right side air shutoff When the procedure in step 5 is followed
73. em Durablity 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 102 Maintenance Section Heat Exchanger Inspect SEBU7844 14 102259870 Heat Exchanger Inspect SMCS Code 1379 040 Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The heat exchanger and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove the filler cap slowly to relieve pressure only when the engine is stopped and the filler cap for the heat exchanger is cool enough to touch with your bare hand Cooling System Conditioner contains alkali Avoid contact with skin and eyes NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life 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 Publicat
74. emperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 102871204 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 This can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive torsional vibrations 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 Caterpillar 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 The damper is dented cracked or l
75. ensor b Extend sliphead 2 by a minimum of 4 mm 0 16 inch c Coat the threads of the sensor with 4C 5597 Anti Seize Compound Note The sliphead is designed to contact a tooth during the first revolution of the speed timing wheel For the maximum allowable clearance between the sliphead and the tooth refer to the engine s Specifications manual d Install the sensor Tighten the locknut to 40 5 N m 30 4 lb ft 101878914 Engine Valve Lash Adjust SMCS Code 1102 1209 025 Note For procedures on adjusting the valve lash and adjusting the valve bridge see Testing and Adjusting Valve Lash and Valve Bridge Adjustment Consult your Caterpillar dealer for assistance Valve Bridge Adjust the valve bridge Perform the procedure for both valve bridges for each cylinder After the valve bridge is adjusted for each cylinder proceed with the valve lash adjustment Engine Valve Lash NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust ment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could 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 v
76. er elements require more frequent replacement than the engine oil Refer to Replacing the Engine Oil Filters During Engine Operation The oil change interval can be affected by several factors e Air fuel ratio e Ambient air conditions e Engine application e Fuel type e Oil type e Size of the oil sump The S 0 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 the interval that is listed in Table 34 Table 34 Engine Oil Change Intervals Engine Sump Capacity Oil Change Interval Engines With a Shallow Sump 3508B 104 L 27 US gal Every 250 Service H 3512B 152 L 40 US gal RAS 3512C 3516B 204 L 53 US gal 3516C Engines With a Standard Sump 3508B 227 L 60 US gal Every 500 Service Hours 3512B 318 L 84 US gal 3512C 3516B 405 L 107 US gal 3516C Engines With a Deep Sump 3508B 443 L 117 US gal Every 1000 Service H 3512B 625 L 165 US gal RAEES 3512C 3516B 807 L 213 US gal 3516C Drain the Oil Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Do not drain the oil when the engine is cold As the oil cools waste particles settle on the bottom of the oil pan The waste particles are not removed when the col
77. erated for 20000 hours e The engine is undergoing a major overhaul Removal and Installation Refer to the Disassembly and Assembly Manual Vibration Damper Remove and Install article or consult your Caterpillar 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 i00935098 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 Requirements for ventilation SEBU7844 14 81 Maintenance Section Electric Starting Motor Inspect 101076519 Electric Starting Motor Inspect SMCS Code 1453 040 If the starting motor fails the engine may not
78. g the bolts pry cover 2 loose or tap the cover with a rubber mallet in order to relieve any spring pressure Section view of the engine oil filter Illustration 72 g00799721 2 Cover 6 O ring seal 7 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 5 Clean cover 2 spring 7 O ring seal 6 and retainer 8 Clean the inside of the oil filter housing 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 6 Ensure that the new oil filter elements are in good condition Install the new oil filter elements 7 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 8 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 9 Start the engine according to this Operation and Maintenance Manual Starting The Engine procedure Operation Section Check for oil leaks Repla
79. g 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 MPGM 68 Maintenance Section Battery or Battery Cable Disconnect SEBU7844 14 101492654 Battery or Battery Cable Disconnect SMCS Code 1401 1402 029 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
80. gh pressure fuel lines are constantly charged with high pressure e The internal pressures of the high pressure fuel lines are higher than other types of fuel system Before any service or repair is performed on the engine fuel lines perform the following tasks 1 Stop the engine 2 Wait for ten minutes Do not loosen the high pressure fuel lines in order to remove air pressure from the fuel system 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 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
81. gine Stopped Canister 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 2 Tar 4 ae Illustration 77 g01411122 1 Bolts 2 Cover 3 Plug 4 Drain valve 5 Drain 3 Connect a hose to drain 5 Place the other end of the hose into a suitable container in order to collect the fuel 4 Open drain valve 4 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 2 is removed Prepare to catch the fuel 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 aler
82. gine 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 ten 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 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 SEBU7844 14 95 Maintenance Section Engine Protective Devices Check Aluminum debris may indicate problems with the bearings of the front gears If you find aluminum debris inspect the crankshaft vibration damper and the idler gear bearings Due to normal wear and friction it is not uncommon to find
83. hand 76 Maintenance Section Cooling System Coolant Sample Level 1 Obtain SEBU7844 14 Remove the cooling system filler cap slowly in order to relieve any pressure Maintain the coolant within 13 mm 0 5 inch below the bottom of the filler pipe Add Coolant Note For the proper coolant mixture to use see this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section 1 Stop the engine Allow the engine to cool 2 Remove the cooling system filler cap slowly in order to relieve any pressure Pour the proper coolant mixture into the filler pipe Illustration 53 g00103639 Gaskets 3 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets are damaged replace the old cooling system filler cap with a new cooling system filler cap Install the cooling system filler cap 4 Start the engine Inspect the cooling system for leaks 102837191 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 that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any
84. he crankcase if the engine oil filters were replaced during engine operation 1 If the engine oil filters were replaced during engine operation operate the engine at low idle Ensure that the oil level is at the FULL mark on the LOW IDLE side of the oil level gauge 2 Add oil if necessary Remove the oil filler cap Fill the crankcase through the oil filler tube only Use the following procedure in order to fill the crankcase if the engine oil filters were replaced with the engine stopped 1 Remove the oil filler cap Fill the crankcase through the oil filler tube only For the amount of oil to use see this Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section Clean the oil filler cap Install the oil filler cap NOTICE To 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 two minutes before cranking again 3 Start the engine according to this Operation and Maintenance Manual Starting The Engine procedure Operation Section Operate the engine at low idle for two minutes This will ensure that the lubrication system has oil and that the oil filters are filled with oil Inspect the en
85. he housing after the sump has been completely 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 top end overhaul e Electronic unit injectors 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 Camshaf
86. in plugs NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with clean water Install the cooling system 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 Ensure that the engine will not start when the cooling system is drained Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 5 Open the cooling system drain valves if equipped Remove the drain plugs Allow the coolant to drain Flush the cooling system with clean water Close the cooling system drain valves if equipped Install the drain plugs 6 Repeat Steps 3 4 and 5 Fill the Cooling System 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 Cat ELC Extended Life Coolant After filling the cooling system do not install the cooling system filler cap 2 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 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 5 inch below the bottom of the filler pipe
87. ine at the intervals that are recommended in this Operation and Maintenance Manual Consider the graph in Illustration 80 Illustration 80 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 80 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 e Delaying an overhaul until a breakdown increases the chance of a catastrophic failure This type of failure requires more parts labor and cleanup e 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 engine exhibits symptoms of excessive wear or failure It is not less costly to wait A planned overhau
88. intervals must be reduced for engines that operate in a severe service application and for engines that operate in excess of the engine rating definition Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals SEBU7844 14 111 Maintenance Section Maintenance Recommendations 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 Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine When an engine s 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 Severe Operation Severe operation is the use of an engine that exceeds current published standards for that engine Caterpillar maintains standards for the following engine parameters e
89. ion NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Shell and Tube Heat Exchanger The interval for the maintenance of the shell and tube heat exchanger depends on the operating environment of the vessel and on the operating time The sea water that is circulated through the heat exchanger and the amount of operating time of the vessel affects the following items e Cleanliness of the tubes for the heat exchanger e Effectiveness of the heat exchanger system Operating in water that contains the following will adversely affect the heat exchanger system silt sediment salt and algae In addition intermittent use of the vessel will adversely affect the heat exchanger system The following items indicate that the heat exchanger may require cleaning e Increased coolant temperature e Engine overheating e Excessive pressure drop between the water inlet and the water outlet An operator that is familiar with the normal operating temperature of the coolant can determine when the coolant temperature is out of the normal range Inspection and maintenance of the heat exchanger are required if the engine is overheating Cleaning the Shell and Tube Heat Exchanger Refer to the Disassembly and Assembly Manual for the engine 1 Drain the heat exchanger 2 Remove
90. irt 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 SEBU7844 14 85 Maintenance Section Engine Air Cleaner Element Single Element Clean Replace 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 59 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 NOTICE Caterpillar recommends certified air filter cleaning ser vices that are avail
91. istent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar 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 SEBU7844 14 77 Maintenance Section Cooling System Coolant Sample Level 2 Obtain e 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 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 and Recommendations or consult your Caterpillar dealer 101987714 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 inc
92. ition for the oil filter that was serviced Fill the Crankcase NOTICE Only use oils that are recommended by Caterpillar For the proper oil to use refer to this Operation and Maintenance Manual Refill Capacities and Recom mendations topic Maintenance Section NOTICE If the engine is equipped with an auxiliary 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 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 Use the following procedure in order to fill t
93. l Ensure that the engine will not start when the cooling system is drained 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap g00799692 Illustration 51 Location of the cooling system drain plugs 1 Oil cooler 2 Jacket water pump 3 Cylinder block 3 Open the cooling system drain valves if equipped Remove the cooling system drain plugs 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 74 Maintenance Section Cooling System Coolant Extender ELC Add SEBU7844 14 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 Cooling 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 cooling system drain valves if equipped Clean the drain plugs and install the dra
94. l 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 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 costly 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
95. l 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 Change topic 102418058 Engine Oil Level Check SMCS Code 1348 535 FLV The most accurate check of the engine oil level is obtained when the engine is stopped ae Tr I Illustration 68 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 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 Rae ENGINE STOPPED WITH OIL COLD ms a 00 m 3g ENGINE AT LOW IDLE WITH WARN OTL Illustration 69 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 ID
96. l the centrifugal oil filter for excessive vibration 102576516 Cooling System Coolant DEAC Change SMCS Code 1350 044 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 for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 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 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 Stop the engine and allow the engine to cool Ensure that the engine will not start when the cooling system is drained 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap
97. leaner Element Dual Element Clean Replace Cleaning the Primary Air Cleaner Elements NOTICE 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 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 are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the s
98. let system and the elbows for cracks and for loose clamps 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 SEBU7844 14 125 Maintenance Section Water Pump Inspect e 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 for good condition Inspect the closed crankcase ventillation CCV filter if equipped If the restriction indicator is visible service the CCV e Check the condition of the gauges Replace any gauge that is damaged Replace any gauge that can not be calibrated Inspect the exhaust system for leaks Inspect the gaskets and the exhaust bellows joint If a leak is found make repairs 102624237 Water Pump Inspect SMCS Code 1361 040 A failed water pump might cause severe engine overheating problems that 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 disassembly and assembly procedure If it is necessary to remove the water pump refer to two articles in the Disassembly and Assembly Manual Water Pump Remove
99. li At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes 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 for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 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 Cat ELC Extender 3 Add Cat ELC Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenan
100. lignment Excessive 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 Ensure that the mounting bolts are tightened to the proper torque For standard torques see Specifications SENR3130 Torque Specifications SEBU7844 14 89 Maintenance Section Engine Oil Filter Differential Pressure Check 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 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 differentia
101. mately 80 percent 3 Fuel consumption is based on a load factor of approximately 40 percent 110 Maintenance Section Maintenance Recommendations SEBU7844 14 High Displacement Engines Table 40 Service Hours and Fuel Consumption for 3512B High Displacement Engines Interval Rated Upto Rated 1301 Rated 1300 rpm to 1600 1601 to rpm 1800 rpm 250 Service 33400 L 41000 L 48500 L Hours 8800 US 10800 US 12800 US gal of fuel gal of fuel gal of fuel 500 Service 66800 L 82000 L 97000 L Hours 17600 US 21600 US 25600 US gal of fuel gal of fuel gal of fuel 1000 Service 133500 L 164000 L 194000 L Hours 35000 US 43200 US 51200 US gal of fuel gal of fuel gal of fuel 2000 Service 267000 L 328000 L 388000 L Hours 70000 US 86400 US 102400 gal of fuel gal of fuel US gal of fuel 3000 Service 398000 L 491000 L 582000 L Hours 105000 US 129600 US 153600 gal of fuel gal of fuel US gal of fuel 6000 Service 796000 L 982000 L 1164000 L Hours 210000 US 259200 US 307200 gal of fuel gal of fuel US gal of fuel Top End 11000 9000 7500 Overhaul Service Service Service Hours Hours Hours 1500000 L 395000 US gal of fuel Major 22000 18000 15000 Overhaul Service Service Service Hours Hours Hours 3000000 L 790000 US gal of fuel 1 Fuel consumption is based on a load factor of approximately 60 percent
102. mmended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements 84 Maintenance Section SEBU7844 14 Engine Air Cleaner Element Single Element Clean Replace Inspecting the Primary Air Cleaner Elements Illustration 57 g00281693 Inspect the clean dry primary air cleaner element Use a 60 watt 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 If it is necessary in order 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 58 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dir
103. mperature regulator that fails in the closed position 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 t
104. n cause a fire NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately Drain the primary filter water separator on a daily basis before starting the engine For specific instructions for draining the primary filter water separator see the service information that is provided by the OEM of the primary filter water separator 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 102828884 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Note If the engine is equipped with duplex fuel filters the fuel filter elements can be changed while the engine is in operation Refer to Replacing the Fuel Filter Elements During Engine Operation 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 elements whenever the following conditions occur e The fuel filter differential pressure gauge registers 103 kPa 15 psi SEBU7844 14 99 Maintenance Section Fuel System Secondary Filter Replace e The fuel filters have been used for 1000 service hours Replacing the Fuel Filter Elements with the En
105. nd 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 wheel 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 SEBU7844 14 123 Maintenance Section Turbocharger Inspect 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 Inspect the Exhaust Bypass The exhaust bypass is a wear component that is sensitive to the load cycles of the engine Replacement of the exhaust bypass is predicted at the top en
106. ne successfully passes step 1 through step 4 5 Operate the engine normally Ensure that the air shutoff gates continue to be latched Engines That Are Equipped with ADEM III Engine Control Modules Note Do not start the engine Ensure that the engine control is in the OFF position 1 Ensure that both air shutoff gates are latched in the OPEN position Ensure that both air shutoff switches are connected Turn the power for the engine control panel to the ON position The air shutoff gates should remain in the OPEN positions If the air shutoff gates do not remain in the OPEN positions check the wiring for the air shutoffs When step 1 has been successfully completed proceed to step 2 While the power for the engine control panel is in the ON position activate the EMERGENCY STOP switch Both air shutoff gates should close If the air shutoff gates do not close check the wiring for the air shutoffs and the wiring for the solenoids Both air shutoff gates must close before proceeding to step 3 Turn the power for the engine control panel to the OFF position Reset the EMERGENCY STOP switch to the RUN position Reset the right side air shutoff to the OPEN position Turn the power for the engine control panel to the ON position Select Run Start on the engine control panel The engine should fail to start If the engine does not start proceed to 4 If the engine starts turn off the engine Ch
107. ngs un til all pressure in the system has been relieved 2 Ensure that the air supply to the lubricator is OFF Slowly loosen filler plug 4 in order to release pressure from the lubricator bowl 3 Remove filler plug 4 Pour oil into the lubricator bowl Use nondetergent SAE 10W oil for temperatures that are greater than 0 C 32 F Use air tool oil for temperatures that are below 0 C 32 F 4 Install filler plug 4 Adjust the Lubricator Note Adjust the lubricator with a constant rate of air flow After the adjustment the lubricator will release oil in proportion to variations of the air flow 1 Ensure that the fuel supply to the engine is OFF NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 2 Operate the air starting motor Observe the drops of oil that are released in dome 1 Note Some lubricators have an adjustment screw rather than a knob 3 If necessary adjust the lubricator in order to release from one to three drops of oil per second To increase the rate turn knob 2 counterclockwise To decrease the rate turn the knob clockwise 100351324 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
108. of the heat exchanger and maintenance of the heat exchanger are required if the engine is overheating Your Caterpillar dealer has the equipment and the personnel in order to measure the pressure drop across the heat exchanger Consult your Caterpillar dealer or refer to the Service Manual for service information for the heat exchanger Cleaning the Plate Type Heat Exchanger Refer to the Disassembly and Assembly Manual for the engine The heat exchanger must be disassembled in order to be cleaned The Disassembly and Assembly Manual will contain instructions for cleaning the heat exchanger prior to reassembly The following general guidelines are for cleaning a plate type heat exchanger Refer to Table 36 for types of cleaners NOTICE Do not use hydrochloric acid to clean stainless steel plates Do not use hydrofluoric acid to clean titanium plates Water that contains more than 300 ppm of chlorine should not be used to prepare cleaning solutions Do not use Ketones such as Acetone and Methyle tyketone Do not use esters such as Ethylacetate and Butylac etate Do not use Halogenated hydrocarbons such as Chlorothene and Carbon Tetrachloride Do not use Aromatics such as Benzene and Toluene 104 Maintenance Section Hoses and Clamps Inspect Replace SEBU7844 14 Table 36 Problem Source Cleaners Calcium carbonate Scaling Calcium sulphate Silicates Corrosion products Nitric acid Se
109. of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure 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 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 Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine SEBU7844 14 91 Maintenance Section Engine Oil and Filter Change 102419365 Engine Oil and Filter Change SMCS Code 1318 510 If the engine is equipped with duplex oil filters the engine oil filter elements can be changed while the engine is in operation This is useful if the oil filt
110. omponents can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life 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 for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Table 32 Required Tools Tool Ace Part Description Qty A 185 3630 Strap Wrench Assembly 1 B 8T 0890 Puller Group 1 Cc 8T 5096 Dial Indicator Group 1 N A 2 U a 3 Illustration 48 g00810377 1 Centrifugal oil filter 2 Valve 3 Camshaft cover 70 Maintenance Section Centrifugal Oil Filter Inspect SEBU7844 14 5 Hii 7 9 Illu
111. or rect interpretation that could lead to concerns by both dealers and customers 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 Caterpillar Commercial Diesel Engines Fluids Recommendations or consult your Caterpillar dealer 102839449 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 NOTICE Excessive supplemental coolant additive 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 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair
112. ot damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure is stamped on the face of the cooling system filler cap If the cooling system filler cap does not maintain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 102576535 Cooling System Coolant ELC Change SMCS Code 1350 044 NL 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 for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Use only clean water to flush the cooling system when Cat ELC Extended Life Coolant is drained and replaced Drain the 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 1 Stop the engine and allow the engine to coo
113. ot 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 electrical 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 58 Maintenance Section Maintenance Interval Schedule SEBU7844 14 103638169 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
114. other coolant instead of Cat ELC This includes the following types of 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 Table 33 Recommended Interval Type of Coolant Level 1 Level 2 Every 250 Cat DEAC Hours Yearly 2 Cat ELC Optional Yearly 1 This is the recommended interval for coolant samples for all conventional heavy duty coolant antifreeze This is also the recommended interval for coolant samples of commercial coolants that meet the Cat EC 1 specification for engine coolant 2 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 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 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 you must establish a consistent trend of data In order to establish a pertinent history of data perform cons
115. otor 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 64 Maintenance Section Air Starting Motor Lubricator Bowl Clean SEBU7844 14 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 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 Removal
116. ounted in the flywheel housing The speed timing sensor provides information about engine speed and the position of the crankshaft to the ECM Illustration 73 g00760464 1 Remove engine speed timing sensor 1 Inspect the condition of the end of the magnet Look for signs of wear and contaminants 2 Clean any debris from the face of the magnet nl Illustration 74 g01115363 3 Check the tension of the sliphead Gently extend sliphead 2 for a minimum of 4 mm 0 16 inch Then push back the sliphead When the sliphead has the correct tension at least 22 N 5 Ib of force is required to push in the sliphead from the extended position 96 Maintenance Section Engine Valve Lash Adjust SEBU7844 14 NOTICE The sliphead must be fully extended when the speed timing sensor is installed so that the sensor maintains the correct clearance with the speed timing wheel If the correct clearance is not maintained the signal from the sensor will not be generated Do not install the sensor between the teeth of the speed timing wheel Damage to the sensor would re sult Before installing the sensor ensure that a tooth of the wheel is visible in the mounting hole for the sen sor 4 Install the engine speed timing sensor a Ensure that a tooth on the speed timing wheel is visible in the mounting hole for the s
117. ove plug 1 and drain the water out of the pump 2 Remove bolts 2 and cover 3 3 Inspect the priming impeller the priming impeller wear plates and the impeller for wear or damage Inspect the pump housing for wear damage or buildup 4 Inspect the pump shaft and the impeller for excessive axial movement 5 If wear or damage is found replace the components which are worn or damaged Use the proper repair kit for the pump Pumps with a Clamp Illustration 46 g01136382 1 Plug Clamp 2 3 Clamp 4 Front part of the pump body 1 Remove plug 1 and drain the water out of the pump 2 Remove the water line and clamp 2 if necessary 3 Loosen clamp 3 and remove the front part of the pump body 4 4 Inspect the impeller the wear plates and the wear ring for wear or damage Inspect the pump housing for wear damage or buildup 5 Inspect the pump shaft and the impeller for excessive axial movement 6 If wear or damage is found replace the components which are worn or damaged Use the proper repair kit for the pump SEBU7844 14 67 Maintenance Section Batteries Replace 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 pro
118. 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 120 Maintenance Section Prelube Pump Inspect SEBU7844 14 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 greatest value Schedule an overhaul with your Caterpillar dealer Overhaul programs vary between d
119. pect the Zinc Rods 1 Remove the zinc rod 2 Inspect the zinc rod Ensure that the zinc rod will remain effective until the next scheduled inspection a If the zinc rod has deteriorated excessively install a new zinc rod g00481100 Illustration 84 b Tap the zinc rod lightly with a hammer If the zinc rod breaks install a new zinc rod 3 If the zinc rod will be reused scrape the layer of oxidation from the zinc rod before installation The layer of oxidation reduces the effectiveness of the zinc rod 126 SEBU7844 14 Maintenance Section Zinc Rods Inspect Replace Replace the Zinc Rods 1 Use pliers to unscrew the old zinc rod from the plug If not enough material remains or the zinc rod has broken off drill the zinc from the plug 2 Clean the plug Illustration 85 g00748510 1 Shoulder 2 Threads 3 External threads of the plug Note Do not apply adhesive or sealant to the threads of the zinc rod 2 3 Apply 9S 3263 Thread Lock Compound to the shoulder 1 of a new zinc rod Apply the compound only to the shoulder of the zinc rod Install the zinc rod onto the plug 4 Coat the external threads of the plug 3 with 5P 3413 Pipe Sealant Install the zinc rod See Specifications SENR3130 Torque Specifications for the torque for the plug
120. per 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 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 102601752 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 clothin
121. pproximately 1 L 1 qt of oil will remain in the housing after the sump has been completely 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 top end overhaul e Electronic unit injectors 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 p
122. psi for cleaning purposes 7 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 8 Inspect the core in order to ensure cleanliness Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 9 Install the heat exchanger Refer to the Service Manual for the procedure For more information on cleaning the core consult your Caterpillar dealer Plate Type Heat Exchanger The interval for the maintenance of the plate type heat exchanger depends on the operating environment of the vessel and on the operating time The sea water that is circulated through the heat exchanger and the amount of operating time of the vessel affects the following items e Cleanliness of the heat exchanger plates e Effectiveness of the heat exchanger system Operating in water that contains the following will adversely affect the heat exchanger system silt sediment salt and algae In addition intermittent use of the vessel will adversely affect the heat exchanger system The following items indicate that the heat exchanger may require cleaning e Increased coolant temperature e Engine overheating e Excessive pressure drop between the water inlet and the water outlet An operator that is familiar with the normal operating temperature of the coolant can determine when the coolant temperature is out of the normal range Inspection
123. refer to this Operation and Maintenance Manual Maintenance Recommendations When Required Batteries Replace 0 cccceeeceeeeecceeceeeeeeeeeeetees 67 Battery or Battery Cable Disconnect 68 Centrifugal Oil Filter Inspect 0 0 0 eee 69 Engine Air Cleaner Element Dual Element Clean Replace cccccecceceeeeceeceeeeeeeeeeeeeeneeees 81 Engine Air Cleaner Element Single Element Clean Replace ccccceeceeeeeseeeeeeeeeseeeeeeeseennaeees 84 Fuel System Prime cc cceeceeeeeeeeeeeeeeeeeeeeeeneeees 97 Heat Exchanger Inspect ieee 102 Maintenance Recommendations 008 105 Sea Water Strainer Clean Inspect 120 Zinc Rods Inspect Replace esseeees 125 Daily Air Starting Motor Lubricator Oil Level Check 65 Air Tank Moisture and Sediment Drain 65 Cooling System Coolant Level Check 75 Driven Equipment Inspect Replace Lubricate 80 Engine Air Cleaner Service Indicator Inspect 87 Engine Oil Filter Differential Pressure Check 89 Engine Oil Level Check cceeeeceeeceeeeeseeeeeeeees 89 Fuel System Fuel Filter Differential Pressure CHOC cies soak eee ed EA catia ines ee 97 Fuel System Primary Filter Water Separator Dra Resear per err a E in pier E E aae 98 Fuel Tank Water and Sediment Drain 101 Instrument Panel Inspect
124. ring 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 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 a
125. rovide these services and components e Camshaft followers e Cylinder head assembly e Scavenge oil pump e Engine wiring harness e Exhaust manifold seals 116 Maintenance Section Overhaul Top End SEBU7844 14 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 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 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 Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the
126. rrect 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 help to establish the trends of engine performance A gauge reading that is abnormal may indicate a problem with operation or a problem with the gauge 103483500 Maintenance Recommendations SMCS Code 1000 Overhaul Intervals Some factors that are important for 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 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 106 SEBU7844 14 Maintenance Section Maintenance Recommendations e The wear metal analysis of the lube oil e An incre
127. s if equipped 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 this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section 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 coolant antifreeze After filling the cooling system do not install the cooling system filler cap 2 Start the engine Operate the engine in order to purge the air from the cavities of the engine block Allow the coolant to warm and allow the coolant level to stabilize Stop the engine SEBU7844 14 73 Maintenance Section Cooling System Coolant ELC Change 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 5 inch below the bottom of the filler pipe 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets of the cooling system filler cap are damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gaskets of the cooling system filler cap are n
128. 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 Problems with the electric starting motor can be caused by the following conditions malfunction of the solenoid and malfunction of the electric starting system Inspect the electrical system for the following conditions e Loose connections e Corrosion e Wires that are worn or frayed e Cleanliness Make repairs if necessary 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 101646701 Engine Clean SMCS Code
129. stem drain plugs Allow the water to drain NOTICE 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 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 Flush the cooling system with clean water until the water that drains is clean Close the cooling system drain valves if equipped Clean the cooling system drain plugs and install the cooling system drain plugs 6 Flush the cooling system with clean water until the water that drains is clean Close the cooling system drain valves if equipped Clean the cooling system drain plugs and install the cooling system drain plugs 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 cooling system drain valve
130. stration 49 g008 10333 4 Bearing 5 Nut 6 Stiffener plate 7 Nut 8 Rotor cover 9 Cover 10 Paper liner 11 Spindle 12 Stand tube 13 O ring 14 O ring 15 Bearing 16 Clamp 17 Rotor base 18 Filter body 1 Close valve 2 to centrifugal oil filter 1 2 Loosen clamp 16 and nut 5 Remove cover 9 from filter body 18 3 Remove O ring seal 14 from the body 4 Remove the rotor assembly from spindle 11 Lift the rotor assembly carefully so the bearings are not damaged 5 Use tool A to hold the rotor assembly and remove nut 7 6 Remove stiffener plate 6 7 Use tool B to remove rotor cover 8 from rotor base 17 Remove O ring seal 13 from the base Remove paper liner 10 from the rotor cover Properly dispose of the paper liner Use a plastic scraper to clean out the inside of rotor cover 8 8 Remove stand tube 12 from rotor base 17 and clean the stand tube 9 Clean the nozzles in rotor base 17 Do not enlarge the nozzles 10 Inspect bearings 4 and 15 for excessive wear 11 Inspect spindle 11 for excessive wear 12 If there is minimal wear to bearing 4 bearing 15 and spindle 11 got to step 14 If there is considerable wear to bearing 4 bearing 15 and spindle 11 go to step 13 13 Use tool C to measure the clearances between the bearing 4 and bearing 15 and spindle 6 The maximum clearance between bearing 4 and
131. t allow hot oil or components to contact skin Perform the following procedure after the oil has been drained Note Use this procedure if the engine oil filters do not have a control valve AASA i s Illustration 71 g00799719 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 SEBU7844 14 93 Maintenance Section Engine Oil and Filter Change 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 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 Prepare to catch the oil in a suitable container Clean up any spilled oil with absorbent pillows or towels 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 removin
132. t and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 3 Place a suitable container under bowl 2 and open drain valve 3 in order to drain the oil from the bowl 4 Remove bowl 2 Clean the bowl with warm water 5 Dry the bowl Inspect the bowl for cracks If the bowl is cracked replace the damaged bowl with a new bowl Inspect the gasket If the gasket is damaged replace the gasket 6 Install the bowl 7 Make sure that drain valve 3 is closed 8 For instructions on filling the lubricator see this Operation and Maintenance Manual Air Starting Motor Lubricator Oil Level Check topic SEBU7844 14 65 Maintenance Section Air Starting Motor Lubricator Oil Level Check 102654969 Air Starting Motor Lubricator Oil Level Check SMCS Code 1451 535 NOTICE Never allow the lubricator bowl to become empty The air starting motor will be damaged by a lack of lubrica tion Ensure that sufficient oil is in the lubricator bowl Illustration 44 g01333366 1 Observe the oil level in sight gauge 3 If the oil level is less than 1 2 add oil to the lubricator bowl A WARNING 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 fitti
133. t 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 101553508 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 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 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 d
134. t followers e Connecting rods e Connecting rod bearings Cylinder head assembly Cylinder liners e Scavenge oil pump e 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 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 control module Exhaust bellow shields 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 118 Maintenance Section Overhaul Considerations SEBU7844 14 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 engine parameters e Horsepower e Range of rpm e Fuel consumption Fuel quality e Altitude e
135. t to the spring force Gradually loosen but do not remove bolts 1 Before removing bolts 1 pry cover 2 loose in order to relieve any spring pressure Remove cover 2 Remove the O ring seal on the inside of the cover Remove the fuel filter elements 6 Clean cover 2 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 2 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 Spin On Filter 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 100 Maintenance Section Fuel System Secondary Filter Replace SEBU7844 14 O n ED ih P 2 L N it d aie Ee EL TIA RI L GP 44 Illustration 78
136. 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 e Pressurized air e Vacuum cleaning 86 Maintenance Section SEBU7844 14 Engine Air Cleaner Element Single Element Clean Replace 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 60 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 and oil Note Refer to Inspecting the Air Cleaner Elements Inspecting the
137. tom 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 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 Refer to Special Publication SENR9620 Improving Fuel Syst
138. top the engine in order to change the filter Filter contains hot pressurized fluid when engine is running Follow instructions on control valve to avoid per sonal injury Duplex Fuel Filters Q2 5 82 5 O O Sle a Illustration 79 g01411130 4 Control valve 5 Fill valve _ Open FILL valve 5 for a minimum of five minutes in order to fill the fuel filters that will not be serviced The fuel filters that will not be serviced must be full of fuel Close the FILL valve 2 If the main filter will be serviced rotate control valve 4 to the AUX RUN position If the auxiliary filters will be serviced rotate control valve 4 to the MAIN RUN position 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 SEBU7844 14 101 Maintenance Section Fuel Tank Water and Sediment Drain 3 See Replacing the Fuel Filter Elements with the Engine Stopped Perform Step 3 through Step 9 from the Canister instructions 4 Open fill valve 5 for a minimum of five minutes in order to fill the new elements Close the fill
139. transmission consult your Caterpillar dealer and or the OEM dealer of the transmission All support for the warranty of the transmission will be the responsibility of the OEM All parts support for the transmission will be the responsibility of the OEM This parts support includes both the installation of parts and the resolution of any service problems 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
140. val 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 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 possibl
141. xhaust Bypass 4 Nut 5 Housing 3 Remove the nuts 4 that fasten the exhaust bypass 1 to the housing 5 4 Remove the exhaust bypass 1 from the housing 5 124 Maintenance Section Walk Around Inspection SEBU7844 14 Illustration 83 g01173915 5 Inspect the valve stem 6 for heavy wear 6 Replace the exhaust bypass 1 if the valve stem is excessively worn 102622549 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 thoroughly inspect the engine compartment before starting the engine Look for items such as leaks loose bolts 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 NOT
142. y 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 Extended operation at low idle 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 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 SEBU7844 14 119 Maintenance Section Overhaul Considerations 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 Inspecting the alignment of the driven equipment Most owners will save money by overhauling the eng

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