3512 industrial engine-maintenance intervals

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SAFETY.CAT.COM

3512 INDUSTRIAL

ENGINESMaintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU6759-02-01)

© 2007 CaterpillarAll Rights Reserved



63Maintenance Section

Maintenance Interval Schedule

i01226639

Maintenance Interval Schedule

SMCS Code: 1000; 7500

Before performing any operation or maintenanceprocedures, ensure that the Safety Information,warnings, and instructions are read andunderstood.

Before each consecutive interval is performed, allof the maintenance requirements from the previousinterval must be performed.

When Required

Maintenance Recommendations .......................... 64Batteries - Replace ............................................... 67Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 75Engine Air Cleaner Element (Single Element) -Inspect/Replace .................................................. 78

Fuel System - Prime ............................................. 86Fuel System Primary Filter/Water Separator Element

- Replace ............................................................. 88

Daily

Air Starting Motor Lubricator Oil Level - Check .... 66Cooling System Coolant Level - Check ................ 72Driven Equipment - Inspect/Replace/Lubricate ... 75Engine Air Cleaner Service Indicator - Inspect ..... 79Engine Air Precleaner - Clean .............................. 80

Engine Oil Level - Check ...................................... 82Fuel System Pr imary Filter/Water Separator -Drain ................................................................... 88

Fuel Tank Water and Sediment - Drain ................. 89Instrument Panel - Inspect .................................... 90Walk-Around Inspection ...................................... 100

Initial 250 Service Hours

Engine Valve Lash - Inspect/Adjust ...................... 86Fuel Injector - Inspect/Adjust ................................ 86Magnetic Pickups - Clean/Inspect ........................ 93

Every 250 Service Hours

Alternator and Fan Belts - Inspect/Adjust/Replace ............................................................... 66

Battery Electrolyte Level - Check .......................... 68Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 73Engine Oil Sample - Obtain .................................. 82Engine Oil and Filter - Change ............................. 83Fuel System Primary Filter - Clean/Inspect/

Replace ............................................................... 87Fuel System Secondary Filter - Replace .............. 88Hoses and Clamps - Inspect/Replace .................. 89


Cooling System Coolant Analysis (Level II) -Obtain ................................................................. 71

Engine - Clean ...................................................... 75Engine Crankcase Breather - Clean ..................... 80

Engine Protective Devices - Check ...................... 85


Actuator Contr ol Linkage - Lubricate .................... 65 Air Starting Motor Lubricator Bowl - Clean ........... 65Crankshaft Vibration Damper - Inspect ................. 74Driven Equipment - Check .................................... 75Engine Mounts - Check ........................................ 81Engine Valve Lash - Inspect/Adjust ...................... 86Fuel Injector - Inspect/Adjust ................................ 86Turbocharger - Inspect .......................................... 99

Every 3000 Service Hours or 2 Years

Cooling System Coolant (DEAC) - Change .......... 68


Cooling System Coolant Extender (ELC) - Add .... 72


Overhaul (Top End) ............................................... 95Overhaul Considerations ...................................... 96


Alternator - Inspect ............................................... 66

Cooling System Coolant (ELC) - Change ............. 70Cooling System Water Temperature Regulator -

Replace ............................................................... 74Magnetic Pickups - Clean/Inspect ........................ 93Starting Motor - Inspect ........................................ 99Water Pump - Inspect ......................................... 101

Every 18 000 Service Hours

Overhaul (Major) ................................................... 93Overhaul Considerations ...................................... 96



64Maintenance SectionMaintenance Recommendations

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MaintenanceRecommendations

SMCS Code: 1000

Service Hours and FuelConsumption

Table 32

Service Hours and Fuel Consumptionfor 3512 Engines

Interval Fuel Consumption

250 servicehours

43,750 L (11,500 US gal)

500 service

hours

87,500 L (23,000 US gal)

1000 servicehours

175,000 L (46,000 US gal)

2000 servicehours

350,000 L (92,000 US gal)

3000 servicehours

525,000 L (138,000 US gal)

Top end overhaul(4000 service

hours)

787,500 L (206,250 US gal)

6000 servicehours

1,050,000 L (276,000 US gal)

Major overhaul(18,000 service

hours)

1,575,000 L (412,500 US gal)

Severe Operation

Severe operation is the use of an engine thatexceeds current published standards for that engine.Caterpillar maintains standards for the followingengine parameters:

• Horsepower

• Range of rpm

• Fuel consumption

• Fuel quality

• Altitude

• Maintenance intervals

• Selection of oil

• Selection of coolant

• Environmental qualities

• Installation

Refer to the standards for your engine or consult your Caterpillar dealer in order to determine if your engine

is operating within the defined parameters.

Severe operation can accelerate component wear.Engines that are operating under severe conditionsmay need more frequent maintenance intervals for the following reasons:

• Maximum reliability

• Retention of full service life

Because of individual applications, it is not possibleto identify all of the factors which can contribute tosevere operation. Consult your Caterpillar dealer

about the maintenance that is needed for your specific engine.

The following factors can contribute to severeoperation: environment, improper operatingprocedures, and improper maintenance practices.

Environmental Factors

Extreme Ambient Temperatures

Extended operation in environments that areextremely cold or hot can damage components. Valvecomponents can be damaged by carbon buildup if the engine is frequently started and stopped in verycold temperatures. Extremely hot inlet air reducesthe perfor mance capabilities of the engine.

Note: Refer to this Operation and MaintenanceManual, “Cold Weather Operations” topic (OperationSection), or refer to Supplement, SEBU5898, “ColdWeather Recommendations”.

Cleanliness

Unless the equipment is cleaned regularly, extendedoperation in a dirty environment and in a dusty

environment can damage components. Built up mud,dirt, and dust can encase components. This canmake maintenance difficult. The buildup can containcorrosive chemicals. Corrosive chemicals and saltcan damage some components.

Altitude

Engines are set to operate within a certain altitude.Operating above this altitude can cause enginedamage. Adjustments are necessary for operationat higher altitudes.




Actuator Control Linkage - Lubricate

Improper Operating Procedures

• Extended operation at low idle

• Minimum cool down periods after high load factor operation

• Operating the engine at loads that are greater thanthe rated load

• Operating the engine at speeds that are greater than the rated rpm

• Use of the engine for an application that is notapproved

Improper Maintenance Practices

• Extension of maintenance intervals

• Not using recommended fuel, lubricants, andcoolant/antifreeze

i00855723

Actuator Control Linkage -Lubricate

SMCS Code: 1265-086

g00426785Illustration 21

(1) Grease Fitting

Apply grease to the grease fittings (1).

Use a hand grease gun and lubricate the greasefittings with MPGM.

Check the Linkage

Use the following procedure to check the linkage for binding.

1. Stop the engine.

2. Move the linkage by hand.

If the linkage binds, repair the linkage.

For information on adjustment, removal, andreplacement, see the Service Manual. Consult your Caterpillar dealer for assistance.

i00691569

Air Starting Motor Lubricator Bowl - Clean

SMCS Code: 1451-070

1. Ensure that the air supply to the lubricator is OFF.


(1) Plug(2) Bowl(3) Drain

Note: Always dispose of fluids according to localregulations.

2. Open drain (3). Drain the oil into a suitablecontainer. Dispose of the used oil.

3. Remove bowl (2). Clean the bowl with warm water.

4. Dry the bowl. Inspect the bowl for cracks. If thebowl is cracked, replace the damaged bowl with anew bowl.

5. Install the bowl. Close drain (3).

6. Remove plug (1). Fill bowl (2) with oil. Usenondetergent “10W” oil for temperatures thatare greater than 0°C (32°F). Use air tool oil for temperatures that are below 0°C (32°F). Install oilfiller plug (1).

7. If necessary, adjust the lubricator in order torelease two drops of oil per 30 seconds. For instructions, see this Operation and MaintenanceManual, “Air Starting Motor Lubricator Oil Level -Check” topic (Maintenance Section).




Air Starting Motor Lubricator Oil Level - Check

i00691572

Air Starting Motor Lubricator Oil Level - Check

SMCS Code: 1451-535

NOTICENever allow the lubricator bowl to become empty. Theair starting motor will be damaged by a lack of lubrica-tion. Ensure that sufficient oil is in the lubricator bowl.


(1) Dome(2) Knob(3) Sight gauge(4) Plug

1. Observe the oil level in sight gauge (3). If the oillevel is less than 1/2, add oil to the lubricator bowl.

2. Ensure that the air supply to the lubricator is OFF.

3. Remove plug (4). Pour oil into the lubricator bowl.Use “10W” oil for temperatures that are greater than 0°C (32°F). Use air tool oil for temperaturesthat are below 0°C (32°F).

4. Install plug (4).

Adjust the Lubricator

Note: Adjust the lubricator with a constant rate of air

flow. After the adjustment, the lubricator will releaseoil in proportion to variations of the air flow.

1. Ensure that the fuel supply to the engine is OFF.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

2. Operate the air starting motor. Observe the dropsof oil that are released in dome (1).

Note: Some lubr icators have an adjustment screwrather than a knob.

3. If necessary, adjust the lubricator in order torelease two drops of oil per 30 seconds. Toincrease the rate, turn knob (2) counterclockwise.

To decrease the rate, turn the knob clockwise.

i00839754

Alternator - Inspect

SMCS Code: 1405-040

Inspect the alternator for the following conditions:

• Loose connections

• Proper charging of the battery

Observe the ammeter during engine operation inorder to ensure proper battery performance and/or proper performance of the electrical system.

Make repairs, if necessary. See the Service Manualfor service procedures. Consult your Caterpillar dealer for assistance.

i00738285

Alternator and Fan Belts -Inspect/Adjust/Replace

SMCS Code: 1357-025; 1357-040; 1357-510; 1405

Inspection

To maximize the engine performance, inspect thedrive belt for wear and for cracking. Check the drivebelt tension. Adjust the drive belt tension in order tominimize belt slippage. Belt slippage will decreasethe life of the drive belt.

Check the drive belt tension according to theinformation in the Service Manual, “SystemsOperation/Testing and Adjusting”.

Replacement

For applications that require multiple drive belts,replace the drive belts in matched sets. Replacingone drive belt of a matched set will cause the newdrive belt to carry more load because the older drivebelts are stretched. The additional load on the newdrive belt could cause the new drive belt to fail.




Batteries - Replace

Alternator Belt Adjustment


(1) Adjusting nuts(2) Mounting bolt

1. Remove the drive belt guard.

2. Loosen mounting bolt (2) and 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 bolt(2). Refer to the Operation and MaintenanceManual for the proper torques.

5. Reinstall the drive belt guard.

If new drive belts are installed, check the drive belt

tension again after 30 minutes of engine operation atthe rated rpm.

Fan Drive Belt Adjustment

1. Loosen the mounting bolt for the pulley.

2. Loosen the adjusting nut for the pulley.

3. Move the pulley in order to adjust the belt tension.

4. Tighten the adjusting nut.

5. Tighten the mounting bolt.

i01041029

Batteries - Replace

SMCS Code: 1401-510

Batteries give off combustible gases which canexplode. 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 inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

1. Turn the key start switch to the OFF position.Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect thecharger.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the ground plane. Disconnectthe 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 abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before connecting the cables, ensure that thekey start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE “+” battery terminal.

8. Connect the cable from the ground plane to theNEGATIVE “-” battery terminal.



68Maintenance SectionBattery Electrolyte Level - Check

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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 batteriesmay not fully r echarge. Ensure a full charge in order to help prevent the battery from freezing. If batteriesare properly charged, ammeter reading should bevery near zer o.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on or

near batteries.

1. Remove the f iller caps. Maintain the electrolytelevel to the “FULL” mark on the battery.

If the addition of water is necessary, use distilledwater. If distilled water is not available use cleanwater that is low in minerals. Do not use artificiallysoftened water.

2. Check the condition of the electrolyte with the1U-7298 Coolant/Battery Tester (°C) or the1U-7297 Coolant/Battery Tester (°F).

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• A mixture of 0.1 L (0.11 qt) of baking soda and1 L (1 qt) of clean water

• 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 theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fitproperly. Coat the clamps and the terminals with5N-5561 Silicone Lubricant, petroleum jelly or MPGM grease.

i00849995

Cooling System Coolant(DEAC) - Change

SMCS Code: 1350-044

Clean the cooling system before the recommendedmaintenance interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• Oil has entered the cooling system and the coolantis contaminated.

• Fuel has entered the cooling system and thecoolant is contaminated.

Drain the Cooling System

1. Stop the engine and allow the engine to cool.Ensure that the engine will not start when thecooling system is drained.

2. Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.


Locations of the drain plugs

(1) Jacket water pump

(2) Cylinder block

3. Open the cooling system drain valves (if equipped). If the cooling system is not equippedwith drain valves, remove drain plugs (1) and (2).

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.




Cooling System Coolant (DEAC) - Change

For information regarding the disposal and therecycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Service TechnologyGroup:

Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Clean the Cooling System

1. After the cooling system has been drained, flushthe cooling system with clean water in order toremove any debris.

2. Close the cooling system drain valves (if equipped). Clean the drain plugs and install thedrain plugs.

NOTICEUse 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.

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add .5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

4. Start the engine. Operate the engine for a

minimum of 30 minutes with a coolant temperatureof at least 82 °C (180 °F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap. Open the cooling system drainvalves (if equipped) or remove drain plugs (1) and(2). See Illustration 25.

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

6. Allow the water to drain. Flush the cooling systemwith clean water until the water that drains isclean. Close the cooling system drain valves (if equipped). Clean the drain plugs and install thedrain plugs.

Cleaning a Cooling System thathas Heavy Deposits or Plugging

Note: For the following procedure to be effective,there must be an active flow through the coolingsystem components.


2. Close the cooling system drain valves (if equipped). Clean drain plugs and install drainplugs (1) and (2). See Illustration 25.

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. 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.

4. Start the engine. Operate the engine for aminimum of 90 minutes with a coolant temperatureof at least 82 °C (180 °F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap. Open the cooling system drainvalves (if equipped) or remove drain plugs (1) and(2). See Illustration 25. Allow the water to drain.

NOTICE

Improper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

6. Flush the cooling system with clean water untilthe water that drains is clean. Close the coolingsystem drain valves (if equipped). Clean the drainplugs and install the drain plugs.

Fill the Cooling System

NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.



70Maintenance SectionCooling System Coolant (ELC) - Change

Note: For infor mation about the proper coolantto use, see this Operation and MaintenanceManual, “Coolant Recommendations” (MaintenanceSection). For the capacity of the cooling system,see this Operation and Maintenance Manual, “RefillCapacities” (Maintenance Section).

1. Fill the cooling system with coolant/antifreeze. Donot install the cooling system filler cap.

2. Start the engine. Operate the engine in order topurge the air from the cavities of the engine block.

Allow the coolant to warm and allow the coolantlevel to stabilize. Stop the engine.

3. Check the coolant level. Maintain the coolant tothe proper level on the sight gauge (if equipped).If a sight gauge is not equipped, maintain thecoolant within 13 mm (.5 inch) below the bottom of the filler pipe.

4. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets of the cooling system filler cap aredamaged, discard the old cooling system filler capand install a new cooling system filler cap. If thegaskets of the cooling system filler cap are notdamaged, use a 9S-8140 Pressurizing Pump inorder 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 systemfiller 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.

i00850204

Cooling System Coolant (ELC)- Change

SMCS Code: 1350-044-NL

Use only clean water to flush the cooling systemwhen Extended Life Coolant (ELC) is drained andreplaced.

Drain the Cooling System

1. Stop the engine and allow the engine to cool.Ensure that the engine will not start when thecooling system is drained.



Locations of the cooling system drain plugs

(1) Jacket water pump(2) Cylinder block

3. Open the cooling system drain valves (if equipped). If the cooling system is not equippedwith drain valves, remove drain plugs (1) and (2).

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and the

recycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Service TechnologyGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Clean the Cooling System


2. Close the cooling system drain valves (if equipped). Clean the drain plugs and install thedrain plugs.

NOTICEFill 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 thecooling system filler cap. Operate the engine untilthe temperature reaches 49 °C (120 °F) to 66 °C(150 °F).




Cooling System Coolant Analysis (Level II) - Obtain

4. Stop the engine and allow the engine to cool.Ensure that the engine will not start when thecooling system is drained. Loosen the coolingsystem filler cap slowly in order to relieve anypressure. Remove the cooling system filler cap.

5. Open the cooling system drain valves (if equipped). If the cooling system is not equippedwith drain valves, remove drain plugs (1) and (2).See Illustration 26. Allow the coolant to drain.Flush the cooling system with clean water. Closethe 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 Extended Life Coolant(ELC). See the Operation and MaintenanceManual, “Refill Capacities” for the correct coolingsystem capacity. Do not install the cooling systemfiller cap.

2. Start the engine. Operate the engine in order topurge the air from the cavities of the engine block.

Allow the ELC to warm and allow the coolant levelto stabilize. Stop the engine.

3. Check the coolant level. Maintain the coolant tothe proper level on the sight gauge (if equipped).If a sight gauge is not equipped, maintain thecoolant within 13 mm (.5 inch) below the bottom of the filler pipe.

4. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets of the cooling system filler cap aredamaged, discard the old cooling system filler capand install a new cooling system filler cap. If thegaskets of the cooling system filler cap are notdamaged, 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 systemfiller 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.

i01065859

Cooling System CoolantAnalysis (Level II) - Obtain

SMCS Code: 1350

For conventional heavy-duty coolant/antifreeze,check the concentration of supplemental coolantadditive (SCA) regularly. The concentration of SCAcan be checked with an S·O·S coolant analysis (LevelI). A more detailed coolant analysis is recommendedperiodically.

For example, considerable deposits are found in thewater jacket areas on the external cooling system,but the concentrations of coolant additives werecarefully maintained. The coolant water probablycontained minerals which were deposited on theengine over time.

A coolant analysis can be conducted in order to verifythe condition of the water that is being used in thecooling system. A full water analysis may be obtainedfrom the following sources:

• Caterpillar dealer

• Local water utility company

• Agricultural agent

• Independent laboratory

Caterpillar recommends an S·O·S coolant analysis(Level II). This is a comprehensive chemicalevaluation of the coolant. This analysis is also acheck of the overall condition of the inside of thecooling system. The following services are provided:

• Full Level I analysis

• Identification of the source of metal corrosion andof contaminants

• Identification of buildup of the impurities that causecorrosion

• Identification of buildup of the impurities that causescaling

• Determination of possible electrolysis within theengines’ cooling system

A report of the results of the analysis is provided.Maintenance recommendations are based on theresults.

For more information about S·O·S coolant analysis,consult your Caterpillar dealer.



72Maintenance SectionCooling System Coolant Extender (ELC) - Add

i00259474

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352-544-NL

Caterpillar Extended Life Coolant (ELC) doesnot require the frequent Supplemental Coolant

Additive (SCA) additions associated with the presentconventional coolants. The Extender only needs tobe added once.

Check the cooling system only when the engine isstopped and cool.

1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. It may be necessary to drain enough coolant fromthe cooling system in order to add the Extender.

3. Add Extender according to the requirements for your engine’s cooling system capacity. Refer tothe Operation and Maintenance Manual, “RefillCapacities” in the Maintenance Section for thecapacity of the cooling system for your engine.Refer to the Operation and Maintenance Manual,“Cooling System Specifications” information for the Caterpillar ELC Extender additions.

4. Clean the cooling system filler cap. Inspect thecooling system filler cap gaskets. Replace thecooling system filler cap if the cooling systemfiller cap gaskets are damaged. Install the coolingsystem filler cap.

i00855831

Cooling System Coolant Level- Check


Climbing equipment may be required to accessthis service point. Refer to the Operation andMaintenance Manual, “Mounting and Dismount-ing” topic for safety information.


(1) Sight gauge

NOTICEOverfilling the overflow tank (if equipped) will result indamage to the cooling system.

If the cooling system has an overflow tank, maintainthe coolant level in the tank below 1/2 full in order toavoid damage to the cooling system.

Observe the coolant level in the sight gauge. Atnormal operating temperature, the coolant should bein the upper half of the sight gauge. If the coolantlevel is low, add the proper coolant mixture.

Add Coolant

Note: For the proper coolant mixture to use, seethis Operation and Maintenance Manual, “CoolantRecommendations” topic (Maintenance Section).

1. Stop the engine. Allow the engine to cool.

2. Remove the cooling system filler cap slowly inorder to relieve any pressure. Pour the proper coolant mixture into the filler pipe.


Filler cap gaskets




Cooling System Supplemental Coolant Additive (SCA) - Test/Add

3. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets are damaged, replace the old coolingsystem 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.

i01065856

Cooling System SupplementalCoolant Additive (SCA) -Test/Add

SMCS Code: 1352-045; 1395-081

This maintenance procedure is required for

conventional coolants such as DEAC and for mixtures of water and SCA. This maintenance isNOT required for cooling systems that are filledwith Extended Life Coolant.

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and eyes. Do not drink cooling systemcoolant additive.

Note: Test the concentration of the SCA or obtain an

S·O·S coolant analysis (Level I).

Test the Concentration of the SCA

Coolant/Antifreeze and SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit or the 4C-9301 CoolantConditioner Test Kit. Follow the instructions that are

on the label of the test kit.

Water and SCA

NOTICEDo not exceed the recommended eight percent sup-plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Follow the instructionsthat are in this Operation and Maintenance Manual,“Water/Supplemental Coolant Additive (SCA)” topic(Maintenance Section).

S·O·S Coolant Analysis (Level I)

Level I is a basic analysis of the coolant. Thefollowing items are tested: SCA concentration, glycolconcentration, pH, and conductivity.

The results are reported, and recommendationsare made according to the results. Consult your Caterpillar dealer for information on the benefits of managing your equipment with an S·O·S analysis.

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 systemcomponents are cool. Loosen the cooling system

pressure cap slowly in order to relieve the pres-sure.

1. Remove the cooling system filler cap slowly.

Note: Always dispose of fluids according to localregulations.

2. If necessary, drain some coolant in order to allowspace for the addition of the SCA.

NOTICEExcessive supplemental coolant additive concentra-

tion can form deposits on the higher temperature sur-faces of the cooling system, reducing the engine’sheat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components.

Excessive supplemental coolant additive concentra-tion could also result in blockage of the heat exchang-er, overheating, and/or accelerated wear of the water pump seal.

Do not exceed the recommended amount of supple-mental coolant additive concentration.

3. Add the proper amount of SCA. The concentrationof the SCA depends on the type of coolant thatis used.

a. For cooling systems that use conventionalcoolant/antifreeze, see this Operationand Maintenance Manual, “ConventionalCoolant/Antifreeze Cooling SystemMaintenance” topic (Maintenance Section).



74Maintenance SectionCooling System Water Temperature Regulator - Replace

b. For cooling systems that use only a mixtureof water and SCA, see this Operation andMaintenance Manual, “Water/SupplementalCoolant Additive (SCA)” topic (MaintenanceSection).

4. Clean the cooling system filler cap. Install thecooling system filler cap.

i00912898

Cooling System Water Temperature Regulator -Replace

SMCS Code: 1355-510

Replace the water temperature regulator before

the water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime.

A water temperature regulator that fails in apartially opened position can cause overheating or overcooling of the engine.

A water temperature regulator that fails in the closedposition can cause excessive overheating. Excessiveoverheating could result in cracking of the cylinder head or piston seizure problems.

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup inside thecylinders. This excessive carbon buildup could resultin an accelerated wear of the piston rings and wear of the cylinder liner.

NOTICEFailure to replace your water temperature regulator on a regularly scheduled basis could cause severeengine damage.

Caterpillar engines incorporate a shunt design coolingsystem 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 headdamage. Ensure that the new water temperature reg-ulator is installed in the original position. Ensure thatthe water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket or cylinder head surface.

Refer to the Ser vice Manual for the replacementprocedure of the water temperature regulator, or consult your Caterpillar dealer.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling system to

a level that is below the water temperature regulator housing.

i00767300

Crankshaft Vibration Damper - Inspect

SMCS Code: 1205-040

The crankshaft vibration damper limits the torsionalvibration of the crankshaft. The visconic damper hasa weight that is located inside a fluid filled case.

Damage to the crankshaft vibration damper or failureof the damper can increase torsional vibrations. Thiscan result in damage to the crankshaft and to other engine components. A deteriorating damper cancause excessive gear train noise at variable pointsin the speed range.

A damper that is hot may be the result of excessivefriction. This could be due to misalignment. Use aninfrared thermometer to monitor the temperatureof the damper during operation. If the temperaturereaches 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 hasthe following characteristics: transparent, viscous,smooth, and difficult to remove from surfaces.

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 leaking.

• The paint on the damper is discolored from heat.

• The engine has had a failure because of a brokencrankshaft.

• An analysis of the oil has revealed that the frontbearing of the crankshaft is badly worn.

• There is a large amount of gear train wear that isnot caused by a lack of oil.




Driven Equipment - Check

Removal and Installation

Refer to the Ser vice Manual or consult your Caterpillar dealer for information about damper replacement.

i00449093

Driven Equipment - Check

SMCS Code: 3279-535

To minimize bearing problems and vibration of theengine crankshaft and the driven equipment, thealignment between the engine and driven equipmentmust be maintained properly.

Check the alignment according to the instructionsthat are provided by the following manufacturers:

• Caterpillar

• OEM of the coupling

• OEM of the driven equipment

i00935098

Driven Equipment -Inspect/Replace/Lubricate

SMCS Code: 3279-040

Observe the driven equipment during operation. Lookfor the following items:

• Unusual noise and vibration


• Damaged parts

Perform any maintenance that is recommendedby the OEM of the driven equipment. Refer to theliterature of the OEM of the driven equipment for thefollowing service instructions.

• Inspection

• Lubricating grease and lubricating oil requirements

• Specifications for adjustment

• Replacement of components

• Requirements for ventilation

i00737417

Engine - Clean

SMCS Code: 1000-070

NOTICE Accumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides the followingbenefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

i00174810

Engine Air Cleaner Element(Dual Element) - Clean/Replace

SMCS Code: 1051; 1054-037

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged air

cleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning 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 enginewear. Your Caterpillar dealer has the proper air cleaner elements for your application. Consult your Caterpillar dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily for accumulation of dirt and debris. Remove any dirtand debris, as needed.

• Operating conditions (dust, dirt and debris) mayrequire more frequent service of the air cleaner element.



76Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

• The air cleaner element may be cleaned up tosix times if the element is properly cleaned andinspected.

• The air cleaner element should be replaced at leastone time per year. This replacement should be

performed regardless of the number of cleanings.

Replace the dirty paper air cleaner elements withclean air cleaner elements. Before installation, theair cleaner elements should be thoroughly checkedfor tears and/or holes in the filter material. Inspectthe 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 primaryair cleaner element and a secondary air cleaner element. The primary air cleaner element can beused up to six times if the element is properly cleanedand inspected. The primary air cleaner elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

The secondary air cleaner element is not serviceableor washable. The secondary air cleaner elementshould be removed and discarded for every threecleanings of the primary air cleaner element. Whenthe engine is operating in environments that aredusty or dirty, air cleaner elements may require morefrequent replacement.


(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 beremoved and discarded for every three cleaningsof the primary air cleaner element.

Note: Refer to “Cleaning the Primary Air Filter 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 bodywith a clean, dry cloth.

5. Remove the tape for the turbocharger air inlet.Install the secondary air cleaner element. Install aprimary air cleaner element that is new or cleaned.

6. Install the air cleaner cover.

7. Reset the ser vice indicator.

Cleaning the Primary Air Cleaner Elements

The primary air cleaner element can be used upto six times if the element is properly cleaned andinspected. When the primary air cleaner element iscleaned, check for rips or tears in the filter material.The primary air cleaner element should be replacedat least one time per year. This replacement shouldbe performed regardless of the number of cleanings.

Use clean pr imary air cleaner elements while dirtyelements are being cleaned.

NOTICEDo 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. Enginedamage could result.

Visually inspect the primary air cleaner elementsbefore 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 four common methods that are used toclean primary air cleaner elements:

• Pressurized water

• Pressurized air

• Vacuum cleaning

• Washing with nonsudsing detergent




Engine Air Cleaner Element (Dual Element) - Clean/Replace

Pressurized Water

Pressurized water will clean the primary air cleaner element unless carbon and oil have accumulated onthe surface of the primary air cleaner element. Themaximum water pressure for cleaning purposes must

be below 275 kPa (40 psi). Do not use a spray nozzle.

Note: When the primary air cleaner element iscleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the water flows inside theelement along the length of the filter in order to helpprevent damage to the paper pleats. Do not aim thestream of water directly at the primary air cleaner element. Dirt could be forced further into the pleats.

Note: Refer to “Drying the Primary Air Cleaner

Elements”. Refer to “Inspecting the Primary Air Cleaner Elements”.

Pressurized Air

Pressurized air can be used to clean primary air cleaner elements that have not been cleaned morethan two times. Pressurized air will not removedeposits of carbon and oil. Use filtered, dry air with amaximum pressure of 207 kPa (30 psi).


Note: When the primary air cleaner elements arecleaned, 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 elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the streamof air directly at the primary air cleaner element. Dirtcould be forced further into the pleats.

Note: Refer to “Inspecting the Primary Air Cleaner Elements”.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningprimary air cleaner elements which require dailycleaning because of a dry, dusty environment.Cleaning with pressurized air is recommended prior

to vacuum cleaning. Vacuum cleaning will not removedeposits of carbon and oil.

Note: Refer to “Inspecting the Primary Air Cleaner Elements”.

Washing the Primary Air Cleaner

Elements with Nonsudsing Detergent

Do not wash air cleaner elements in anyflammable solution such as diesel fuel or gaso-

line. Doing so can cause fire or an engine runawayand can result in personal injury.

Washing with nonsudsing detergent is effective for cleaning primary air cleaner elements that havedeposits of carbon or oil. Use a cleaning agent thatis specifically manufactured for cleaning primary air cleaner elements. Cleaning with pressurized water,pressurized air, or a vacuum is recommended prior to washing with nonsudsing detergent.

1. Place the primary air cleaner element into a washtank so that the gasket is up. The wash tank

should be equipped with a rack so that the primaryair cleaner element does not sit on the bottom of the wash tank.

Note: Caterpillar does not recommend a processfor washing the primary air cleaner element whichincludes agitation. Agitation may cause carbonparticles to be distributed.

2. Fill the wash tank with the cleaning agentand warm water to a maximum temperatureof 60°C (140°F). Follow the manufacturersrecommendations for the cleaning agent. Allowthe primary air cleaner element to soak for six

hours.

3. Drain the wash tank. Do not use the cleaningagent more than one time. Remove the primaryair cleaner element from the wash tank. Rinse theprimary air cleaner element with the method for using pressurized water.

Note: Refer to “Drying the Primary Air Cleaner Elements”. Refer to “Inspecting the Primary Air Cleaner Elements”.



78Maintenance SectionEngine Air Cleaner Element (Single Element) - Inspect/Replace

Drying the Primary Air Cleaner Elements

The oven method may be used in order to dryprimary air cleaner elements. If an oven is used,do not expose the primary air cleaner elements totemperatures that exceed 82°C (160°F).

Note: Do not use compressed air in order to dry theprimary air cleaner elements.

Primary air cleaner elements may be allowed toair dry. Allow two days for the primary air cleaner elements to air dry before the elements are inspectedand installed.

Inspecting the Primary Air Cleaner

Elements


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 tearsand/or holes. Inspect the primary air cleaner elementfor light that may show through the filter material. If itis necessary in order to confirm the result, comparethe 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 hasany tear s and/or holes in the filter material. Do not

use an primary air cleaner element with damagedpleats, gaskets or seals. Discard damaged primaryair cleaner elements.

Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes inspectionwill not be used, the primary air cleaner element canbe stor ed for future use.


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. Restricted air flowmay result. To protect against dirt and damage, wrap

the primary air cleaner elements in Volalite CorrosionInhibited (VCI) paper.

Place the primary air cleaner element into a boxfor storage. For identification, mark the outside of the box and mark the primary air cleaner element.Include the following information:

• Date cleaned

• Number of cleanings

Store the box in a dry location.

For more detailed information on cleaning the primaryair cleaner element, refer to Special Publication,SEBF8062, “Procedure to Inspect and Clean Air Filters”.

i00736823

Engine Air Cleaner Element (Single Element) -Inspect/Replace

SMCS Code: 1054-040; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.




Engine Air Cleaner Service Indicator - Inspect

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 enginewear. Your Caterpillar dealer has the proper air

cleaner elements for your application. Consult your Caterpillar dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily for accumulation of dirt and debris. Remove any dirtand debris, as needed.

• Operating conditions (dust, dirt and debris) mayrequire more frequent service of the air cleaner element.

• The air cleaner element may be cleaned up tosix times if the element is properly cleaned andinspected.

• The air cleaner element should be replaced at leastone time per year. This replacement should beperformed regardless of the number of cleanings.

Replace the dirty paper air cleaner elements withclean air cleaner elements. Before installation, theair cleaner elements should be thoroughly checkedfor tears and/or holes in the filter material. Inspectthe gasket or the seal of the air cleaner element for damage. Maintain a supply of suitable air cleaner elements for replacement purposes.


(1) Cover (2) Element(3) Air inlet

1. Remove the air cleaner cover. Remove the air cleaner element.

2. Cover the air inlet with tape in order to keep dirtout.

3. Clean the inside of the air cleaner cover and bodywith 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. If necessary, reset the air cleaner service indicator.

i00823657

Engine Air Cleaner ServiceIndicator - Inspect

SMCS Code: 7452-040

A service indicator may be mounted on the air cleaner element or in a remote location.


(1) Service indicator

Some engines may be equipped with a differentservice indicator.

Observe the service indicator. Clean the air cleaner element or replace the air cleaner element when thefollowing conditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

• The air restriction reaches 6 kPa (25 inches of H2O).

Test the Service Indicator

Service indicators are important instruments.

• Check for ease of resetting. The service indicator should reset in less than three pushes.

• Check the movement of the yellow core when theengine is accelerated to the engine rated rpm.The yellow core should latch approximately at thegreatest vacuum that is attained.



80Maintenance SectionEngine Air Precleaner - Clean

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If the newservice indicator will not reset, the fitting for theservice indicator may be plugged.


Porous filter

A porous filter is part of a fitting that is used for mounting of the service indicator. Inspect the filter for cleanliness. Clean the filter, if necessary. Usecompressed air or a clean, nonflammable solvent.

The service indicator may need to be replacedfrequently in environments that are severely dusty, if necessary. Replace the service indicator annuallyregardless of the operating conditions. Replace theservice indicator when the engine is overhauled, andwhenever major engine components are replaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 N·m (18 lb in).

i01190885

Engine Air Precleaner - Clean

SMCS Code: 1055-070


Typical precleaner

(1) Wing nut(2) Cover (3) Body

Remove wing nut (1) and cover (2). Check for anaccumulation of dirt and debris in body (3). Clean thebody, if necessary.

After cleaning the precleaner, install cover (2) andwing nut (1).

Note: When the engine is operated in dusty

applications, more frequent cleaning is required.

i01225429

Engine Crankcase Breather -Clean

SMCS Code: 1317-070

If the crankcase breather is not maintained on aregular basis, the crankcase breather will becomeplugged. A plugged crankcase breather will causeexcessive crankcase pressure that may cause

crankshaf t seal leakage.




Engine Mounts - Check


1. Loosen clamp (1). Slide the clamp down on tube(2).

2. Loosen clamps (3). Remove both breathers as aunit.


3. Remove O-ring seals (4) from the valve covers.Inspect the O-ring seals for good condition. Obtainnew O-ring seals, if necessary.


4. Remove two clamps (6). Remove both breathers(5) from hose tee (7).

Inspect the hose tee for cracks. If the tee iscracked, discard the old tee and obtain a new teefor installation.

5. Turn the breathers upside-down in order to inspectthe condition of the breather elements.

Clean the breather elements with clean,nonflammable solvent. If the breather elementsremain contaminated after the cleaning, discardthe breathers and obtain new breathers. Do notattempt to disassemble the breathers.

Allow the breather elements to dry beforeinstallation.

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 breathersinto the tee. Tighten the clamps to the torque thatis listed in the Service Manual, “Specifications”.

7. Coat O-ring seals (4) with clean engine oil. Placethe O-ring seals on the valve covers.

8. Place clamps (3) around the parts of the breathersthat will be attached to the valve covers. Installboth breathers as a unit. Tighten the clamps.

9. Place clamp (1) on the part of the hose tee thatwill receive tube (2). Install the tube into the hosetee. Tighten the clamp to the torque that is listed

in the Service Manual, “Specifications”.

i00855827

Engine Mounts - Check

SMCS Code: 1152-535

Misalignment of the engine and the driven equipmentwill cause extensive damage. Excessive vibrationcan lead to misalignment. Excessive vibration of theengine and the driven equipment can be caused bythe following conditions:

• Improper mounting

• Loose bolts

• Deterioration of the isolators

Ensure that the mounting bolts are tightenedto the proper torque. For standard torques, seethis Operation and Maintenance Manual, “TorqueSpecifications” (Maintenance Section).



82Maintenance SectionEngine Oil Level - Check

Ensure that the isolators are free of oil andcontamination. Inspect the isolators for deterioration.Ensure that the bolts for the isolators are tightened tothe proper tor que.

Replace any isolator that shows deterioration. For

more information, see the literature that is providedby the OEM of the isolators. Also see the Applicationand Installation Guide for the engine. Consult your Caterpillar dealer for assistance.

i01071237

Engine Oil Level - Check


The most accurate check of the oil level isobtained when the engine is stopped. Perform thismaintenance on a surface that is as level as possible.


(1) Oil filler (2) Oil level gauge


(3) “ENGINE STOPPED WITH OIL COLD” side(4) “ENGINE AT LOW IDLE WITH WARM OIL” side(5) “ADD” mark(6) “FULL” mark

1. Ensure that oil level gauge (1) is seated.

a. If the engine is stopped, remove the oil levelgauge. Observe the oil level on “ENGINESTOPPED WITH OIL COLD” side (3).

b. If the engine is operating, reduce the enginespeed to low idle. Remove the oil level gauge

and observe the oil level on “ENGINE AT LOWIDLE WITH WARM OIL” side (4).

The oil level should be between “ADD” mark(5) and “FULL” mark (6).

NOTICEEngine damage can occur if the crankcase is filledabove the “FULL” mark on the oil level gauge (dip-stick).

An overfull crankcase can enable the crankshaft todip into the oil. This will reduce the power that is de-veloped and also force air bubbles into the oil. Thesebubbles (foam) can cause the following problems: re-duction of the oil’s ability to lubricate, reduction of oilpressure, inadequate cooling of the pistons, oil blow-ing out of the crankcase breathers, and excessive oilconsumption.

Excessive oil consumption will enable deposits to formon the pistons and in the combustion chamber. De-posits in the combustion chamber lead to the followingproblems: guttering of the valves, packing of carbonunder 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.

2. If necessary, remove oil filler cap (2) and addoil. For the correct oil to use, see this Operationand Maintenance Manual, “Engine Oil” topic(Maintenance Section). Do not fill the crankcaseabove the “FULL” mark on the oil level gauge.Clean the oil filler cap. Install the oil filler cap.

3. Record the amount of oil that is added. For thenext oil sample and analysis, include the totalamount of oil that has been added since theprevious oil change. This will help to provide themost accurate oil analysis.

i01070756

Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regularly scheduled intervals in order to monitor the condition of the engine and themaintenance requirements of the engine.




Engine Oil and Filter - Change

Obtain the Sample and the Analysis

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components tocontact 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, providethe following information:

• Engine model

• Service hours on the engine

• The number of hours that have accumulated sincethe last oil change

• The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of theoil in the crankcase, obtain a warm, well mixed oilsample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 8T-9190 Fluid Sampling Bottle Group isrecommended for use with the sampling valve. Thebottle group includes the parts that are needed for obtaining oil samples. Instructions are also provided.

NOTICEDo not use the same vacuum sampling pump for ex-tracting oil samples that is used for extracting coolant

samples.

A small residue of either type sample may remain inthe pump and may cause a false positive analysis for the sample being taken.

Always use a designated pump for oil sampling and adesignated pump for coolant sampling.

Failure to do so may cause a false analysis whichcould lead to customer and dealer concerns.

If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEHP6001,“How To Take A Good Oil Sample”. Consult your Caterpillar dealer for complete information andassistance in establishing an S·O·S program for your engine.

i00854772

Engine Oil and Filter - Change

SMCS Code: 1318-510

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

The S·O·S oil analysis program analyzes used oil inorder to determine if the oil change interval is suitablefor your specific engine.

Drain the Oil

Do not drain the oil when the engine is cold. As the oilcools, suspended waste particles settle on the bottom

of the oil pan. The waste particles are not removedwhen the cold oil is drained. Drain the crankcasewhen the oil is warm. This draining method allowsthe waste particles that are suspended in the oil tobe drained properly.

Failure to follow this recommended procedure willallow the waste particles to be recirculated throughthe engine lubrication system with the new oil.

1. After the engine has been operated at normaloperating temperature, STOP the engine.

2. Drain the oil according to the equipment on the

engine.

Note: Drain the oil into a suitable container. Disposeof the oil according to local regulations.



84Maintenance SectionEngine Oil and Filter - Change


Oil drain

a. Open oil drain (1). After the oil has drained,close the oil drain.

b. If a suction device is inserted into the oil pan,ensure that the suction device is clean. Thiswill prevent dirt from entering into the oil pan.Be careful not to strike the engine oil suctiontubes or the piston cooling jets.

c. If a suction device that attaches to the oil drainis used, ensure that the suction device is clean.

Attach the suction device to the oil drain. Openthe oil drain. After the oil has drained, close theoil drain and remove the suction device.

Replace the Oil Filter Elements


Oil filters

1. Remove the oil filter with a 1U-8760 ChainWrench.


Mounting base and gasket

2. Clean the sealing surface of the mounting base.Ensure that all of the old gasket is removed.

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

3. Apply clean engine oil to the gasket of the newoil filter.

NOTICEDo not fill the oil filters with oil before installing them.This oil would not be filtered and could be contaminat-ed. Contaminated oil can cause accelerated wear toengine components.

4. Place the oil filter in position. Tighten the oil filter until the gasket contacts the base. Tighten theoil filter by hand for an additional 3/4 turn (270degrees). Do not overtighten the oil filter.

Inspect the Used Oil Filter Elements

1. Cut the used oil filter element open with a4C-5084 Oil Filter Cutter. Spread apart the pleatsand inspect the filter material for metal debris.

An excessive amount of debris in the element mayindicate early wear or a pending failure.

2. Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are foundin the filter.




Engine Protective Devices - Check

Ferrous metals may indicate wear on the steel andthe cast iron parts of the engine. Nonferrous metalsmay indicate wear on the aluminum parts, the brassparts, or the bronze parts of the engine. Parts thatmay be affected include the following components:main bearings, rod bearings, turbocharger bearings,

and cylinder heads.

Due to normal wear and friction, it is not uncommonto find small amounts of debris in the oil filter. If anexcessive amount of debris is found, consult your Caterpillar dealer in order to arrange for further oilanalysis.

Fill the Crankcase

NOTICEOnly use oils that are recommended by Caterpillar.For the proper oil to use, refer to this Operation and

Maintenance Manual, “Engine Oil” topic (MaintenanceSection).

NOTICEIf the engine is equipped with an auxiliary oil filter system, extra oil must be added when filling thecrankcase. If equipped with an auxiliary oil filter system that is not supplied by Caterpillar, follow therecommendations of the OEM.

NOTICEEngine damage can occur if the crankcase is filledabove the “FULL” mark on the oil level gauge (dip-stick).

An overfull crankcase can enable the crankshaft todip into the oil. This will reduce the power that is de-veloped and also force air bubbles into the oil. Thesebubbles (foam) can cause the following problems: re-duction of the oil’s ability to lubricate, reduction of oilpressure, inadequate cooling of the pistons, oil blow-ing out of the crankcase breathers, and excessive oilconsumption.

Excessive oil consumption will enable deposits to formon the pistons and in the combustion chamber. De-posits in the combustion chamber lead to the followingproblems: guttering of the valves, packing of carbonunder the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil levelgauge, dr ain some of the oil immediately.

1. Remove the oil filler cap. Fill the crankcasethrough the oil filler tube only.

For the amount of oil to use, see this Operationand Maintenance Manual, “Refill Capacities” topic(Maintenance Section).

2. Clean the oil filler cap. Install the oil filler cap.

NOTICETo 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.

3. Close the fuel supply line and crank the engineuntil the oil pressure gauge indicates 70 kPa(10 psi). Open the fuel supply line.

Allow the starting motor to cool for two minutesbefore cranking again.

4. Follow the Operation and Maintenance Manual,“Starting The Engine” procedure (OperationSection).

Operate the engine at low idle for two minutes.

This will ensure that the lubrication system has oiland that the oil filters are filled with oil.

Inspect the engine for oil leaks. Ensure that theoil level is at the “FULL” mark on the “ENGINE

AT LOW IDLE WITH WARM OIL” side of the oillevel gauge.

5. Stop the engine and allow the oil to drain back intothe sump for a minimum of ten minutes.

6. Remove the oil level gauge and check the oil level.

Maintain the oil level to the “FULL” mark on the“ENGINE STOPPED WITH OIL COLD” side of the oil level gauge.

i00626013

Engine Protective Devices -Check

SMCS Code: 7400-535

Alarms and shutoffs must function properly. Alarms

provide timely warning to the operator. Shutoffs helpto prevent damage to the engine. It is impossibleto determine if the engine protective devices arein good working order during normal operation.Malfunctions must be simulated in order to test theengine pr otective devices.

A calibration check of the engine protective deviceswill ensure that the alarms and shutoffs activateat the setpoints. Ensure that the engine protectivedevices are functioning properly.



86Maintenance SectionEngine Valve Lash - Inspect/Adjust

NOTICEDuring testing, abnormal operating conditions must besimulated.

The tests must be performed correctly in order to pre-

vent possible damage to the engine.

To prevent damage to the engine, only authorizedservice personnel or your Caterpillar dealer shouldperform the tests.

Visual Inspection

Visually check the condition of all gauges, sensorsand wiring. Look for wiring and components thatare loose, br oken, or damaged. Damaged wiringor components should be repaired or replacedimmediately.

i01071128

Engine Valve Lash -Inspect/Adjust

SMCS Code: 1102-025

Note: For procedures on adjusting the valvebridge and adjusting the engine valve lash, see theService Manual, “Systems Operation/Testing and

Adjusting” module. Consult your Caterpillar dealer for assistance.

Valve Bridge

Check the valve bridge and adjust the valve bridge,if necessary. Perform the procedure for both valvebridges for each cylinder. After the valve bridge ischecked for each cylinder, proceed with the valvelash adjustment, if necessary.

Engine Valve Lash

NOTICE

Only qualified service personnel should perform thismaintenance. Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

The valve bridge adjustment must be performedbefore making a valve lash adjustment. If the valvelash is within the tolerance, an adjustment of thevalve lash is NOT necessary.

Perform the valve lash setting when the engine is

cold. After the engine has been shut down and thevalve covers are removed, the engine is consideredcold. Before performing maintenance, prevent theentry of foreign matter into the top of the cylinder head and the valve mechanism. Thoroughly cleanthe area around the valve mechanism covers.

For the valve lash setting, see this Operation andMaintenance Manual, “Engine Description” topic(Product Information Section).

i01225410

Fuel Injector - Inspect/AdjustSMCS Code: 1290-025

Note: Perform this procedure when the engine valvelash is inspected.

NOTICEThe 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 fromthe 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 thefuel injector, if necessary.

i00850285

Fuel System - Prime

SMCS Code: 1250-548; 1258-548

1. Open the fuel supply valve. Ensure that the enginewill not start during the priming procedure. Turn

the start switch to the OFF position.




Fuel System Primary Filter - Clean/Inspect/Replace


(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 thefuel system has been pumped through the fuelreturn line back to the fuel tank.

4. Press the fuel priming pump plunger to the lockingposition. Turn the fuel priming pump plunger clockwise in order to engage the lock plate in theretainer.

Note: Enable the starting system only after allmaintenance has been completed.

i00735594

Fuel System Primary Filter -Clean/Inspect/Replace

SMCS Code: 1260-510; 1260-571

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off when

changing fuel filters or water separator elements.Clean up fuel spills immediately.

1. Stop the engine. Ensure that the engine will notstart during this procedure.

2. Shut off the fuel supply valve to the engine.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

NOTICEUse a suitable container to catch any fuel that mightspill. Clean up any spilled fuel immediately.

g00330404

Illustration 46(1) Filter case(2) Nut

3. Loosen nut (2). Hold filter case (1) and remove nut(2). Prepare to catch the fuel that is inside of thefilter case with a suitable container. Remove thefilter case from the mounting bolt.

4. Remove the element and wash the element inclean, nonflammable solvent. Allow the element todry. Inspect the element. Install a new element if the old element is damaged or deteriorated.

5. Clean the inside of the filter case. Allow the filter case to dry.

6. Inspect the seal rings. Ensure that the surfaces for the seal rings are clean. Install new seal rings if the old seal rings are damaged or deteriorated.

NOTICEDo 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.

7. Place the element in the filter case. Slide the filter case over the mounting bolt.

8. Install the nut.

9. Open the fuel supply valve.



88Maintenance SectionFuel System Primary Filter/Water Separator - Drain

i00744357

Fuel System PrimaryFilter/Water Separator - Drain

SMCS Code: 1260-543; 1263-543

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

NOTICEUse a suitable container to catch any fuel that mightspill. Clean up any spilled fuel immediately.

Drain the primary filter/water separator on a dailybasis before starting the engine.

For specific instructions for draining the primaryfilter/water separator, see the service information thatis provided by the OEM of the primary filter/water separator.

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering thefuelsystem.

i00787902

Fuel System PrimaryFilter/Water Separator Element- Replace

SMCS Code: 1260-510-FQ; 1263-510-FQ

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.


Replace the element of the primary filter/water separator according to the instructions that areprovided by the OEM of the primary filter/water separator.

Note: It may be necessary to prime the fuel system

before the engine will start. See this Operation andMaintenance Manual, “Fuel System - Prime” topic(Maintenance Section).

i00854690

Fuel System Secondary Filter -Replace

SMCS Code: 1261-510-SE

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.


g00425598

Illustration 47Secondary fuel filters

1. Remove the used fuel filter with a 1U-8760 ChainWrench. 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.




Fuel Tank Water and Sediment - Drain

NOTICEDo not fill the f uel filters with fuel before installing thefuel filters. The fuel will not be filtered and could becontaminated. 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 untilthe gasket contacts the base. Tighten the fuel filter by hand by one f ull turn. Do not overtighten thefuel filter. Use the rotation index marks that are onthe fuel filter as a guide for proper tightening.

5. Prime the fuel system.

See this Oper ation and Maintenance Manual,“Fuel System - Prime” topic (Maintenance

Section).

i00073301

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S

Fuel Tank

Fuel quality is critical to the performance and tothe service life of the engine. Water in the fuel cancause excessive fuel system wear. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes through thefuel system and the fuel returns to the fuel tank. Thiscauses water to accumulate in fuel tanks. Drainingthe fuel tank regularly and obtaining fuel from reliablesources can help to eliminate water in the fuel.

Drain the Water and the Sediment

Fuel tanks should contain some provision for drainingwater and draining sediment from the bottom of thefuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

Check the fuel daily. Drain the water and sedimentfrom the fuel tank after operating the engine or drainthe water and sediment from the fuel tank after thefuel tank has been filled. Allow five to ten minutesbefore performing this procedure.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayoverflow.

Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel dir ectly 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 fuelstorage tank during the following conditions:

• Weekly

• Oil change

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank.

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaffles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from the

storage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

i00907072

Hoses and Clamps -Inspect/Replace

SMCS Code: 7554-040; 7554-510

Inspect all hoses for leaks that are caused by thefollowing conditions:

• Cracking

• Softness

• Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.



90Maintenance SectionInstrument Panel - Inspect

NOTICEDo 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 andhoses. Leaks can cause fires. Inspect all lines, tubes

and hoses carefully. Tighten all connections to the rec-ommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

A constant torque hose clamp can be used in placeof any standard hose clamp. Ensure that the constanttorque hose clamp is the same size as the standardclamp.

Due to extreme temperature changes, the hose willheat set. Heat setting causes hose clamps to loosen.This can result in leaks. A constant torque hoseclamp will help to prevent loose hose clamps.

Each installation application can be different. Thedifferences depend on the following factors:

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Stop the engine. Allow the engine to cool.


Note: Drain the coolant into a suitable, cleancontainer. The coolant can be reused.

3. Drain the coolant from the cooling system to alevel 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.

Note: For torques on hose clamps, see this Operationand Maintenance Manual, “Torque Specifications”(Maintenance Section).

7. Install the hose clamps with a torque wrench.

Note: For the proper coolant to use, see thisOperation and Maintenance Manual, “CoolantRecommendations” (Maintenance Section).

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler cap’s gaskets. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

10. Start the engine. Inspect the cooling system for

leaks.

i00849266

Instrument Panel - Inspect

SMCS Code: 7451-040

Inspect the instrument panel for good condition.Perform the self-test. All of the warning lamps shouldilluminate. If a warning lamp does not illuminate,replace the bulb immediately. If the alarm doesnot sound, investigate the problem and correct the

problem.

Check the condition of all of the gauges. If a gaugeis broken, repair the gauge or replace the gaugeimmediately.

Frequently monitor the following parameters duringnormal operation:

• Fuel filter differential pressure

• Inlet air restriction

• Oil filter differential pressure




Instrument Panel - Inspect

Record the data in a log. Compare the new data tothe data that was previously recorded. Comparingthe new data to the recorded data will establish thenormal gauge r eadings for the engine. A gaugereading that is abnormal may indicate a problem withoperation or a problem with the gauge.

Record the Performance of theEngine

Records of engine performance are an importantelement of a maintenance program. Recordinformation about the engine operation on a dailybasis. This will help to reveal the trends of the engineperformance.

The data on engine performance can help to predictproblems with operation. Also, the data can provideyour Caterpillar dealer with information that is useful

for recommending optimum operation.

Table 33 is offered for use as a log for engineperformance. Make several copies of Table 33 for continued use. Retain the recorded information for reference.



92Maintenance SectionInstrument Panel - Inspect

Table 33

Engine Performance

Engine Serial Number Authorization

Date

Engine hours

Engine rpm

Percent of load

Ambient temperature

Inlet manifold air temperature

Inlet manifold air pressure

Air restriction (left)

Air restriction (right)

Jacket water temperature

Engine oil temperatureEngine oil pressure

Fuel pressure

Fuel filter differential pressure

Exhaust manifold temperature (left)

Exhaust manifold temperature (right)

Cylinder temperature (1)












Auxiliary Equipment

Transmission oil pressure

Transmission oil temperature

Comments




Magnetic Pickups - Clean/Inspect

i00738324

Magnetic Pickups -Clean/Inspect

SMCS Code: 1907-040


Typical magnetic pickup

1. Remove the magnetic pickup from the flywheelhousing. Check the condition of the end of themagnetic pickup. Check for signs of wear andcontaminants.

2. Clean the metal shavings and other debris fromthe face of the magnet.

3. Install the magnetic pickup according to theinformation in the Service Manual, “Specifications”.

i00867892

Overhaul (Major)

SMCS Code: 7595-020-MJ

Major Overhaul Information

A major overhaul includes the work that is done for a top end overhaul. All other parts that are visibleduring the major overhaul are completely inspected.The seals and gaskets that are exposed are alsoreplaced. The internal passages of the engine arecleaned.

Your Caterpillar dealer can provide these servicesand components. Your Caterpillar dealer can ensurethat the components are operating within theappropriate specifications.

If you elect to perform an overhaul without theservices of a Caterpillar dealer, be aware of thefollowing recommendations.

Components for Replacement

Replace the following components during the major overhaul. In addition, replace the components thatare specified in this Operation and MaintenanceManual, “Overhaul (Top End)” topic.

• Connecting rod bearings

• Crankshaft seals

• Exhaust shields

• Gaskets and seals

• Main bearings

• Piston rings

• Valve rotators

Components f or Inspection, Rebuildingor Exchanging

Inspect the f ollowing components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”.

• Camshaft followers

• Connecting rods

• Cylinder liners

• Fuel transfer pump

• Oil pump

• Pistons

• Piston pins

• Prelube pump

• Scavenge oil pump

• Turbochargers

Inspection of Components

Inspect the following components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”.

• Camshaft



94Maintenance SectionOverhaul (Major)

• Camshaft bearings

• Crankshaft

• Crankshaft vibration damper

• Driven equipment (alignment)

• Gear train

• Gear train bushings

• Spacer plates

Inspect the camshaft for damage to the journals andthe lobes. Inspect the following components for signsof wear and/or for signs of fatigue:

• camshaft bear ings

• camshaft followers

Inspect the crankshaft for any of the followingconditions:

• deflection

• damage to the journals

• bearing material that has seized to the journals

Check the journal taper and the profile of thecrankshaft journals. Check these components byinterpreting the wear patterns on the following

components:

• rod bearing

• main bearings

Note: If the crankshaft or the camshaft are removedfor any reason, use the magnetic particle inspectionprocess to check for cracks.

Replace the crankshaft vibration damper if any of thefollowing conditions occur:

• Engine failure due to a broken crankshaft

• Excessive wear of the front bearing for thecrankshaft

• Excessive wear of the gear train that is not causedby a lack of lubrication

Inspect the gears of the gear train and inspect thegear train bushings for the following conditions:

• Worn gear teeth

• Unusual fit

• Unusual wear

In addition to the inspection of components, inspectthe alignment of the driven equipment. See the

Application and Installation Guide for the engine.

Cleaning of Components

Clean the oil cooler core and the aftercooler core.Then, pressur e test both of these cores.

1. Remove the core.

2. Remove any debris from the core. To removedebris from the oil cooler core, turn the oil cooler core onto one end. To remove debris fromthe aftercooler core, turn the aftercooler coreupside-down.

NOTICEDo not use a high concentration of caustic cleaner toclean the core. A high concentration of caustic cleaner can attack the internal metals of the core and causeleakage. Only use the recommended concentration of cleaner.

3. Back flush the core internally with cleaner in order to loosen foreign substances. This will also helpto remove oil.

Note: Hydrosolv Liquid Cleaners are recommended.Table 34 lists the Hydrosolv Liquid Cleaners that areavailable from your Caterpillar dealer.

Table 34

Hydrosolv Liquid Cleaners(1)

PartNumber

Description Size

1U-8812 4 L (1 US gal)

1U-5490 19 L (5 US gal)

8T-7570

Hydrosolv 4165

208 L (55 US gal)

1U-8804 4 L (1 US gal)

1U-5492 19 L (5 US gal)

8T-5571

Hydrosolv 100

208 L (55 US gal)

(1) Use these cleaners at a concentration of two to five percent andat a temperature up to 93 °C (200 °F). For more information,see Application Guide, NEHS0526, “Service Technical Group”.Consult your Caterpillar dealer for assistance.

4. Steam clean the core in order to remove anyresidue. Flush the fins of the oil cooler core andthe aftercooler core. Remove any other trappeddebris.

5. Wash the core with hot, soapy water. Rinse thecore thoroughly with clean water.




Overhaul (Top End)

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 lessthan 205 kPa (30 psi) for cleaning purposes.

6. Dry the core with compressed air. Direct the air inthe reverse direction of the normal flow.

7. Inspect the components in order to ensurecleanliness. Pressure test the core. Many shopsthat service radiators are equipped to performpressure tests. Repair the core, if necessary.Install the core.

Obtain Coolant Analysis

The concentration of supplemental coolant additive(SCA) should be checked regularly with test kits. Theconcentration of SCA can also be checked with anS·O·S coolant analysis (Level I). A more detailedcoolant analysis is recommended periodically.

For example, considerable deposits are found in thewater jacket areas on the external cooling system,but the concentrations of coolant additives werecarefully maintained. The coolant water probablycontained minerals which were deposited on theengine over time.

A coolant analysis can be conducted in order to verifythe condition of the water that is being used in thecooling system. A full water analysis can be obtainedby consulting your local water utility company or an agricultural agent. Private laboratories are alsoavailable for water analysis.

Caterpillar recommends an S·O·S coolant analysis(Level II).

S·O·S Coolant Analysis (Level II)

An S·O·S coolant analysis (Level II) is acomprehensive coolant analysis which completelyanalyzes the coolant. An S·O·S coolant analysis(Level II) provides the following information:

• Complete S·O·S coolant analysis (Level I).

• Properties of the coolant are visually inspected.

• Metal corrosion and contaminants are identified.

• Identification of built up impurities that can causeproblems BEFORE the problems make repairsnecessary.

A report of the results of the S·O·S coolant analysis(Level II) is provided. Maintenance recommendations

are based on the results.

For more information about S·O·S coolant analysis,consult your Caterpillar dealer.

i00868225

Overhaul (Top End)

SMCS Code: 7595-020-TE

Cylinder Head Assembly

Inspect the cylinder head assembly according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”.

Your Caterpillar dealer can provide these servicesand components. Your Caterpillar dealer can ensurethat the components are operating within theappropriate specifications.

The use of out-of-spec parts will cause unscheduleddowntime and/or costly repairs.

Fuel Injectors

Replace the fuel injectors. Consult your Caterpillar dealer about exchanging the fuel injectors. Your Caterpillar dealer can provide these services andcomponents.

The wear of fuel injectors is affected by the followingconsiderations:

• Quality of the fuel

• Quality of the filtration of the fuel

The wear of the fuel injectors can result in elevatedlevels of exhaust emissions and/or poor engineperformance. The misfire of a single cylinder is nottypically attributed to normal wear. This condition canbe repaired by replacing the defective fuel injector.

The following list of circumstances indicate that thefuel injectors should be inspected more frequently:

• Use of fuels that are not recommended in thisOperation and Maintenance Manual, “FuelSpecifications”



96Maintenance SectionOverhaul Considerations

• Extreme ambient temperatures that reduce theability 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

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact

skin.

Clean the oil suction screen after the oil has beendrained.

Note: Approximately 1 L (1 qt) of oil will remain in thehousing after the sump has been completely drained.This oil will pour out of the housing when the cover is removed. Prepare to catch the oil in a pan. Cleanup any spilled oil with rags. DO NOT use absorbentparticles to clean up the oil.

1. Remove the screen assembly according to the

instructions in the Service Manual, “Disassemblyand Assembly” module. Discard the used O-ringseals.

2. Wash the screen assembly in clean nonflammablesolvent. Allow the screen assembly to dry beforeinstallation.

3. Inspect the screen assembly for good condition.Obtain a new screen assembly, if necessary.Install the screen assembly. Install new O-ringseals.

i01045650

Overhaul Considerations

SMCS Code: 7595-043

Overhaul Information

An overhaul is replacing the major worn componentsof the engine. An overhaul interval is a maintenanceinterval that is planned. The engine is rebuilt withcertain rebuilt parts or new parts that replace theworn parts.

An overhaul also includes the following maintenance:

• Inspection of all the parts that are visible duringthe disassembly

• Replacement of the seals and gaskets that are

removed

• Cleaning of the internal passages of the engineand the engine block

Most owners will save money by overhauling theengine at the intervals that are recommended in thisOperation and Maintenance Manual. Consider thegraph in Illustration 49.


Costs of overhauls over time

(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 49, line (1) represents the maintenanceand repair costs for an owner that followed therecommendations for inspection, maintenance, andrepair. The peaks represent overhauls.

Line (2) represents the maintenance and repair costs for an owner that chose to operate beyondthe recommended intervals. The initial cost of the“repair-after-failure” philosophy is lower. Also, thefirst overhaul was delayed. However, the peaks aresignificantly higher than the peaks for the customer

that used the “repair-before-failure” philosophy .

The higher peaks result from two key factors:

• Delaying an overhaul until a breakdown increasesthe chance of a catastrophic failure. This type of failure requires more parts, labor, and cleanup.

• Excessive wear means that fewer componentswill be reusable. More labor may be required for salvage or repair of the components.




Overhaul Considerations

When all of the costs are considered,“REPAIR-BEFORE-FAILURE” is the leastexpensive alternative for most components andengines.

It is not practical to wait until the engine exhibits

symptoms of excessive wear or failure. It is not lesscostly to wait. A planned overhaul before failure maybe the best value for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according to theguidelines for reusable parts.

• The service life of the engine can be extendedwithout the risk of a major catastrophe due toengine failure.

• Achieve the best cost/value relationship per hour

of extended service life.

Overhaul Intervals

Some factor s that are important for determiningthe overhaul intervals include the followingconsiderations:

• Performance of preventive maintenance

• Use of recommended lubricants

• Use of recommended coolants

• Use of recommended fuels

• Proper installation

• Operating conditions

• Operation within acceptable limits

• Engine load

• Engine speed

Generally, engines that are operated at a reduced

load and/or speed achieve more service life beforean overhaul. However, this is for engines that areproperly operated and maintained.

Other factors must also be considered for determininga major overhaul:

• The total amount of fuel consumption

• The service hours of the engine

• An increase of oil consumption

• An increase of crankcase blowby

• The wear metal analysis of the lube oil

• An increase in the levels of noise and vibration

An increase of wear metals in the lube oil indicatesthat the bearings and the surfaces that wear may

need to be serviced. An increase in the levels of noise and vibration indicates that rotating partsrequire service.

Note: It is possible for oil analysis to indicate adecrease of wear metals in the lube oil. The cylinder liners may be worn so that polishing of the boreoccurs. Also, the increased use of lube oil will dilutethe wear metals.

Monitor the engine as the engine accumulatesservice hours. Consult your Caterpillar dealer aboutscheduling a major overhaul.

Note: The driven equipment may also require servicewhen the engine is overhauled. Refer to the literaturethat is provided by the OEM of the driven equipment.

Using Fuel Consumption For Calculating theOverhaul Intervals

The total fuel consumption is the most importantfactor for estimating the overhaul interval. Fuelconsumption compensates for the application andfor the engine load.

If the total fuel consumption has not been recorded,use the equation in Table 35 in order to estimate the

hours until the overhaul. The equation may also beused to estimate overhaul intervals for new engines.

Table 35

Equation For Calculating Overhaul Intervals

H = F/R

“H” is the number of estimated hours until the overhaulinterval.

“F” is the estimated total amount of fuel consumption of the engine.

“R” is the rate of fuel consumption in liters per hour or gallons per hour.

Use the actual records of fuel consumption, whenpossible. If the actual records are not available, usethe following procedure in order to estimate the fuelconsumption.

1. Estimate the average percent of the load for theoperation of the engine.



98Maintenance SectionOverhaul Considerations

2. Refer to the engine’s Caterpillar, “EngineSpecifications” (“spec” sheet). This will determinethe fuel consumption for the percent of the loadthat was estimated in Step 1. Use this figure for the equation in Table 35.

Oil Consumption as an Overhaul Indicator

Oil consumption, fuel consumption, and maintenanceinformation can be used to estimate the totaloperating cost for your Caterpillar engine. Oilconsumption can also be used to estimate therequired capacity of a makeup oil tank that is suitablefor the maintenance intervals.

Oil consumption is in proportion to the percentageof the rated engine load. As the percentage of theengine load is increased, the amount of oil that isconsumed per hour also increases.

The oil consumption rate (brake specific oilconsumption) 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 oilconsumption rate for your engine.

When an engine’s oil consumption has risen tothree times the original oil consumption rate dueto normal wear, an engine overhaul should bescheduled. There may be a corresponding increasein blowby and a slight increase in fuel consumption.

Overhaul Inspection

Refer to the Service Manual for the disassembly andassembly procedures that are necessary in order to perform the required maintenance on the itemsthat are listed. Consult your Caterpillar dealer for assistance.

To determine the reusability publications that areneeded to inspect the engine, refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029,“Index of Publications on Reusability or Salvage of Used Par ts”.

The Guidelines For Reusable Parts and SalvageOperations is part of an established Caterpillar parts reusability program. These guidelines weredeveloped in order to assist Caterpillar dealers andcustomers reduce costs by avoiding unnecessaryexpenditures for new parts. If the engine parts complywith the established inspection specifications, theparts can be reused.

The use of out-of-spec parts could result inunscheduled downtime and/or costly repairs. The useof out-of-spec parts can also contribute to increasedfuel consumption and reduction of engine efficiency.New parts are not necessary if the old parts can bereused, repaired, or salvaged. Otherwise, the old

parts can be r eplaced or exchanged.

Your Caterpillar dealer can provide the parts that areneeded to rebuild the engine at the least possiblecost.

Overhaul Programs

An economical way to obtain most of the partsthat are needed for overhauls is to use Caterpillar remanufactured parts. Caterpillar remanufacturedparts are available at a fraction of the cost of newparts. These parts have been rebuilt by Caterpillar and certified for use. The following components areexamples of the remanufactured parts:

• Cylinder heads

• Oil Pumps

• Turbochargers

• Water pumps

Consult your Caterpillar dealer for details and for alist of the remanufactured parts that are available.

Your Cater pillar dealer may be offering a variety of overhaul options.

A Flat Rate Overhaul guarantees the maximum pricethat you will pay for an overhaul. Flat rate prices onpreventive maintenance programs or major repair options are available from many servicing dealersfor all Caterpillar Engines. Consult your Caterpillar dealer in order to schedule a before failure overhaul.

Overhaul Recommendation

Caterpillar recommends a scheduled overhaul inorder 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 dealers. To obtainspecific information about the types of overhaulprograms and services, consult your Caterpillar dealer.




Starting Motor - Inspect

i01113939

Starting Motor - Inspect

SMCS Code: 1451-040; 1453-040

If the starting motor fails, the engine may not start inan 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 engineto start properly. The engine will not start if thestarting motor pinion does not engage the flywheelring gear. The teeth of the starting motor pinion andthe flywheel ring gear can be damaged because of irregular engagement.

Inspect the starting motor for proper operation. Listenfor grinding when the engine is started. Inspect the

teeth of the starting motor pinion and the flywheelring gear. Look for patterns of wear on the teeth. Lookfor teeth that are broken or chipped. If damaged teethare found, the starting motor pinion and the flywheelring gear must be replaced.

Electric Starting Motor

Note: Problems with the electric starting motor canbe caused by the following conditions: malfunction of the solenoid and malfunction of the electric startingsystem.

Inspect the electrical system for the followingconditions:


• Corrosion

• Wires that are worn or frayed

• Cleanliness

Make repairs, if necessary.

Air Starting Motor

Personal injury or death can result from improp-

erly checking for a leak.

Always use a board or cardboard when checkingfor 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 treatedimmediately 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 andconnections for leaks.

If the teeth of the starting motor pinion and/or theflywheel ring gear are damaged, the air circuit for the starting motor must be examined in order todetermine the cause of the problem.

Removal and Installation of theStarting Motor

Refer to the Service Manual, “Disassembly and Assembly” module for information on removing thestarting motor and installing the starting motor.

Consult your Caterpillar dealer for assistance.

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Turbocharger - Inspect

SMCS Code: 1052-040

Periodic inspection and cleaning is recommendedfor the turbocharger compressor housing (inlet side).

Any fumes from the crankcase are filtered throughthe air inlet system. Therefore, by-products from oiland from combustion can collect in the turbocharger

compressor housing. Over time, this buildup cancontribute to loss of engine power, increased blacksmoke and overall loss of engine efficiency.

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage to theturbocharger compressor wheel can cause additionaldamage to the pistons, the valves, and the cylinder head.



100Maintenance SectionWalk-Around Inspection

NOTICETurbocharger bearing failures can cause large quan-tities of oil to enter the air inlet and exhaust systems.Loss of engine lubricant can result in serious enginedamage.

Minor leakage of a turbocharger housing under ex-tended low idle operation should not cause problemsas long as a turbocharger bearing failure has not oc-curred.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is repaired or replaced.

An inspection of the turbocharger can minimize

unscheduled downtime. An inspection of theturbocharger can also reduce the chance for potentialdamage to other engine parts.

Note: Turbocharger components require precisionclearances. The turbocharger cartridge mustbe balanced due to high rpm. Severe Service

Applications can accelerate component wear.Severe Service Applications require more frequentinspections of the cartridge.

Removal and Installation

For options regarding the removal, installation, repair and replacement, consult your Caterpillar dealer.Refer to the Service Manual for this engine for theprocedure and specifications.

Cleaning and Inspecting

1. Remove the exhaust outlet piping and removethe air inlet piping from the turbocharger. Visuallyinspect the piping for the presence of oil.

2. Turn the compressor wheel and the turbine wheelby hand. The assembly should turn freely. Inspectthe compressor wheel and the turbine wheel for

contact with the turbocharger housing. Thereshould not be any visible signs of contact betweenthe turbine wheel or compressor wheel and theturbocharger housing. If there is any indication of contact between the rotating turbine wheel or thecompressor wheel and the turbocharger housing,the turbocharger must be reconditioned.

3. Check the compressor wheel for cleanliness.If only the blade side of the wheel is dirty, dirtand/or moisture is passing through the air filteringsystem. If oil is found only on the back side of thewheel, there is a possibility of a failed turbocharger oil seal.

The presence of oil may be the result of extendedengine operation at low idle. The presence of oilmay also be the result of a restriction of the linefor the inlet air (plugged air filters), which causesthe turbocharger to slobber.

4. Use a dial indicator to check the end clearanceon the shaft. If the measured end play is greater than the Service Manual specifications, theturbocharger should be repaired or replaced.

An end play measurement that is less than theminimum Service Manual specifications couldindicate carbon buildup on the turbine wheel. Theturbocharger should be disassembled for cleaningand for inspection if the measured end play is lessthan the minimum Service Manual specifications.

5. Inspect the bore of the turbine housing for corrosion.

6. Clean the turbocharger housing with standardshop solvents and a soft bristle brush.

7. Fasten the air inlet piping and the exhaust outletpiping to the turbocharger housing.

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Walk-Around Inspection

SMCS Code: 1000-040

Inspect the Engine for Leaks and

for Loose Connections

A walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thoroughinspection of the engine compartment before startingthe engine. Look for items such as oil leaks or coolantleaks, loose bolts, worn belts, loose connections andtrash buildup. Make repairs, as needed:

• The guards must be in the proper place. Repair

damaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.




Water Pump - Inspect

NOTICE Accumulated gr ease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaningor high pressure water.

• Ensure that cooling lines are properly clampedand tight. Check for leaks. Check the condition of all pipes.

• Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by coolantin the cooling system. It is normal for a small amountof leakage to occur as the engine cools down andthe parts contract.

Excessive coolant leakage may indicate the needto replace the water pump seal. For the removal of

water pump and the installation of water pump and/or seals, refer to the Service Manual for the engine or consult your Caterpillar dealer.

• Inspect the lubrication system for leaks at the frontcrankshaft seal, the rear crankshaft seal, the oilpan, the oil filters and the valve cover.

• Inspect the fuel system for leaks. Look for loosefuel line clamps.

• Inspect the piping for the air inlet system and theelbows for cracks and for loose clamps.

• Inspect the alternator belt and the accessory drivebelts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced asmatched sets. If only one belt is replaced, the belt willcarry more load than the belts that are not replaced.The older belts are stretched. The additional load onthe new belt could cause the belt to break.

• Drain the water and the sediment from fuel tankson a daily basis in order to ensure that only cleanfuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayedwires.

• Inspect the ground strap for a good connection andfor good condition.

• Inspect the engine-to-frame ground strap for agood connection and for good condition.

• Check the condition of the gauges. Replace anygauges which are cracked or can not be calibrated.

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Water Pump - Inspect

SMCS Code: 1361-040

A failed water pump might cause severe engineoverheating problems that could result in cracks inthe cylinder head, a piston seizure or other potentialdamage to the engine.

Visually inspect the water pump for leaks. If leakingof the water pump seals is observed, replace all of the water pump seals. Refer to the Service Manualfor the disassembly and assembly procedure.

Inspect the water pump for wear, cracks, pin holesand proper operation. Refer to the Service Manual or consult your Caterpillar dealer if repair is needed or replacement is needed.

3512 industrial engine-maintenance intervals

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