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3500 Industrial and Generator Set Engines-Maintenance

1. X Zs j Illustration 81 g00735191 1 Fuel priming pump plunger 2 Turn fuel priming pump plunger 1 counterclockwise in order to release the lock plate from the retainer 3 Operate the fuel priming pump until the air in the fuel system has been pumped through the fuel return line back to the fuel tank 4 Press the fuel priming pump plunger to the locking position Turn the fuel priming pump plunger clockwise in order to engage the lock plate in the retainer Note Enable the starting system only after all maintenance has been completed i01076701 Fuel System Fuel Filter Differential Pressure Check SMCS Code 1261 535 Observe the fuel filter differential pressure frequently during engine operation Fuel Filter Differential Pressure Restriction This gauge indicates the difference in fuel pressure between the inlet side and the outlet side of the fuel filter As the fuel filter element becomes plugged the difference in pressure between the two sides of the fuel filter increases SEBU6701 05 95 Maintenance Section Fuel System Secondary Filter Replace The nominal fuel filter differential pressure during normal engine operation is approximately 60 kP
2. Illustration 71 g00597466 4 Remove two clamps 6 Remove both breathers 5 from hose tee 7 86 Maintenance Section Engine Mounts Check SEBU6701 05 Inspect the hose tee for cracks If the tee is cracked discard the old tee and obtain a new tee for installation 5 Turn the breathers upside down in order to inspect the condition of the breather elements Clean the breather elements with clean nonflammable solvent If the breather elements remain contaminated after the cleaning discard the breathers and obtain new breathers Do not attempt to disassemble the breathers Allow the breather elements to dry before installation Note Coat the rubber parts with clean engine oil or petroleum jelly in order to make installation easier 6 Place clamps 6 over the parts of hose tee 7 that will receive breathers 5 Install the breathers into the tee Tighten the clamps to the torque that is listed in the Service Manual Specifications 7 Coat O ring seals 4 with clean engine oil Place the O ring seals on the valve covers 8 Place clamps 3 around the parts of the breathers that will be attached to the valve covers Install both breathers as a unit Tighten the clamps 9 Place clamp 1 on the part of the hose tee that will receive tube 2 Install the tube into the hose tee Tighten the clamp to the torque that is listed in the Service Manual Specifications 103214182
3. ceeeeeeeee 88 Every 1000 Service Hours Engine Clean cccececccceeeeseeceeeseseceeeneeeeeeeneeteees 78 Engine Crankcase Breather Clean 00 85 Engine Oil and Filter Change 88 Engine Protective Devices Check asese 93 Fuel System Secondary Filter Replace 95 Every 2000 Service Hours Actuator Control Linkage Lubricate 0 0 62 Air Starting Motor Lubricator Bowl Clean 63 Crankshaft Vibration Damper Inspect 77 Engine Mounts Check ceceeeeeeeeeeeeeeees 86 SEBU6701 05 61 Maintenance Section Maintenance Interval Schedule Every Year Cooling System Coolant Sample Level 2 ODN ie pices cet cate nica 75 Every 3000 Service Hours or 3 Years Cooling System Coolant DEAC Change 69 Every 4000 Service Hours Auxiliary Water Pump Inspect s is 65 Engine Valve Lash Inspect Adjust cee 93 Fuel Injector Inspect Adjust 2 0 0 0 94 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 73 Every 6000 Service Hours or 6 Years Alternator Inspect ceceeeeeeeeceeeeeeeeeeeeeteeeeees 65 Cooling System Water Temperature Regulator Replace 430226 E A 77 Magnetic Pickups Clean Inspect 2 5 102 Starting Motor Inspect i e 112 Turbocharger Inspect 0 eeeceeeeeeeeeeeeentteeeeeeeeee 112 Water Pump Inspect
4. 669 5 87S 5 C fe Sb a Illustration 84 g01411130 4 Control valve 5 Fill valve 1 Open FILL valve 5 for a minimum of five minutes in order to fill the fuel filters that will not be serviced The fuel filters that will not be serviced must be full of fuel Close the FILL valve 2 If the main filter will be serviced rotate control valve 4 to the AUX RUN position If the auxiliary filters will be serviced rotate control valve 4 to the MAIN RUN position NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 3 See Replacing the Fuel Filter Elements with the Engine Stopped Perform Step 3 through Step 9 from the Canister instructions 4 Open fill valve 5 for a minimum of five minutes in order to fill the new elements Close the fill valve After the new filter elements are full of fuel either the main filter or the auxiliary filter may be used 103645042 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of th
5. ccccceceeeeeeeeeeeeeeeeeees 115 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 71 Overhaul Overhaul Major arrira neinar a 102 Overhaul Top End o ar a 104 Overhaul Considerations s e 106 62 Maintenance Section Actuator Control Linkage Lubricate SEBU6701 05 100855723 Actuator Control Linkage Lubricate SMCS Code 1265 086 Illustration 45 g00426785 1 Grease Fitting Apply grease to the grease fittings 1 Use a hand grease gun and lubricate the grease fittings 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 and replacement see the Service Manual Consult your Caterpillar dealer for assistance 102353608 Air Shutoff Test SMCS Code 1078 081 Air shutoff valves must be tested and inspected in order to ensure proper operation Before testing remove each limit switch and inspect each limit switch assembly for wear The typical wear is erosion of the plunger This is due to vibration of the plunger within the bore for the plunger This usually causes the switch to jam or this causes the switch to become otherwise inoperable Note The limit switches are normally open switches The switches are in the closed state when the air shutoff valves are latche
6. 64 Cooling System Coolant Level Check 73 Engine Air Cleaner Service Indicator Inspect 84 Engine Air Precleaner Clean i e 85 Engine Oil Filter Differential Pressure Check 86 Engine Oil Level Check cccceeceeeeeeeeeteeeeerees 87 Fuel System Fuel Filter Differential Pressure COCK GAE EN PEPEE ened EET TS 94 Fuel Tank Water and Sediment Drain 97 Instrument Panel Inspect eeeeeereeees 102 Walk Around Inspection ceeceeeeeeeeteeeeeees 113 Initial 250 Service Hours or at first oil change Engine Valve Lash Inspect Adjust 0 0 0 eee 93 Fuel Injector Inspect Adjust 0 0 0 0 94 Magnetic Pickups Clean Inspect ceee 102 Every 250 Service Hours Battery Electrolyte Level Check n se 67 Belts Inspect Adjust Replace cceeseereeeee 68 Cooling System Coolant Sample Level 1 OD al a es eae sti eed a ee 74 Cooling System Supplemental Coolant Additive SCA Test Add 0 eeccecceeecceececeseeeeeeeseeeteteeeeeaees 75 Engine Oil Sample Obtain a a 87 Engine Oil and Filter Change n se 88 Fan Drive Bearing Lubricate 0eeeeeeeeeees 94 Hoses and Clamps Inspect Replace 100 Radiator Clean ccceeeceeeeccecceeeeeeeeteeteettenaeees 110 Every 500 Service Hours Air Shutoff Test ccceeececceeeeeeeseeeeeeeeeseeeeeeeaas 62 Engine Oil and Filter Change
7. associated components 1 Engine 2 Welding electrode 3 Keyswitch in the OFF position 4 Battery disconnect switch in the open position 5 Disconnected battery cables 6 Battery 7 Electrical Electronic component 8 Minimum distance between the component that is being welded and any electrical electronic component 9 The component that is being welded 10 Current path of the welder 11 Ground clamp for the welder 4 Connect the welding ground cable directly to the part that will be welded Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings hydraulic components electrical components and ground straps Note If electrical electronic components are used as a ground for the welder or electrical electronic components are located between the welder ground and the weld current flow from the welder could severely damage the component 5 Protect the wiring harness from welding debris and spatter 6 Use standard welding practices to weld the materials SEBU6701 05 59 Maintenance Section Maintenance Interval Schedule 103637532 Maintenance Interval Schedule Standby SMCS Code 1000 4450 7500 Note Ensure that the Safety Information warnings and instructions are read and understood before operation or maintenance procedures are performed Note For information on generator maintenance see the Operation and Mai
8. 76 Maintenance Section SEBU6701 05 Cooling System Supplemental Coolant Additive SCA Test Add NOTICE Excessive supplemental coolant additive concentra tion can form deposits on the higher temperature sur faces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temperature components Excessive supplemental coolant additive concentra tion could also result in blockage of the heat exchang er overheating and or accelerated wear of the water pump seal Do not exceed the recommended amount of supple mental coolant additive concentration NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog and to Special Publica tion GECJ0003 Cat Shop Supplies and Tools for tools and supplies suitable to collect and contain flu ids on Caterpillar products Dispose of all fluids according to applicable regula tions and mandates Note Caterpillar recommends an S O S coolant analysis Level 1 Cooling Systems that Use Conventional Coolant This maintenance procedure is required
9. Ensure that all of the old gasket is removed 3 Apply clean diesel fuel to the new fuel filter gasket NOTICE Do not fill the fuel filters with fuel before installing the fuel filters The fuel will not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts A Install the new fuel filter Spin the new fuel filter onto the fuel filter base until the gasket contacts the base Tighten the fuel filter by hand by one full turn Do not overtighten the fuel filter Use the rotation index marks that are on the fuel filter as a guide for proper tightening a Prime the fuel system See this Operation and Maintenance Manual Fuel System Prime topic Maintenance Section Replacing the Fuel Filter Elements During Engine Operation If the engine is equipped with duplex fuel filters the fuel filters can be changed while the engine is in operation If the filter is changed during rapid air movement an explosive vapor may be created The explosive vapor may result in personal injury or in death If rapid air movement exists stop the engine in order to change the filter Filter contains hot pressurized fluid when engine is running Follow instructions on control valve to avoid per sonal injury SEBU6701 05 97 Maintenance Section Fuel Tank Water and Sediment Drain Duplex Fuel Filters
10. Filler cap 2 Sight gauge If the engine is equipped with a sight gauge observe the position of the coolant in the sight gauge At normal operating temperature the proper coolant level is in the upper half of the sight gauge If the coolant level is low add the proper coolant mixture Engines That Are Not Equipped With a Sight Gauge Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure Check the coolant level when the engine is stopped and cool Check the coolant level only after the engine has been stopped and the cooling system filler cap is cool enough to touch with your bare hand Remove the cooling system filler cap slowly in order to relieve any pressure Maintain the coolant within 13 mm 0 5 inch below the bottom of the filler pipe Add Coolant Note For the proper coolant mixture to use see this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section 1 Stop the engine Allow the engine to cool 2 Remove the cooling system filler cap slowly in order to relieve any pressure Pour the proper coolant mixture into the filler pipe Illustration 56 g00103639 Gaskets 3 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If
11. Set Maintenance Recommendations SMCS Code 4450 041 A standby generator set may not need to be used very often However the generator set is usually needed for operation in an emergency situation Maintenance of the standby generator set is very important for the following reasons e The generator set must always be in excellent operating condition e The generator set must be ready to work under load at any time Establishing a Preventive Maintenance Program will provide these benefits e Maximum availability of the standby generator set e Longer service life for the generator set e Minimum of expensive repairs Your Caterpillar dealer can help you to establish an effective Preventive Maintenance Program for your generator set Consult your Caterpillar dealer for details Maintenance and Operation Procedures The high voltage that is produced by an operating generator set can cause severe injury or death Before performing any maintenance or repairs ensure that the generator will not start Place the engine control switch in the OFF posi tion Attach DO NOT OPERATE tags to all start ing controls Disconnect the batteries or disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator The recommended maintenance for the engine is listed in this Operation and Maintenance Manual Maintenance Interval Schedule Standby Generator Set E
12. Some worn components may be exchanged with your Caterpillar dealer for credit on replacement parts Consult your Caterpillar dealer about repair options for your engine If you elect to perform an overhaul without the services of a Caterpillar dealer be aware of the recommendations in Table 21 and Table 22 Table 21 Top End Overhaul 1 continued SEBU6701 05 105 Maintenance Section Overhaul Top End Table 21 contd Clean Oil suction screen Clean Aftercooler core Inspect Pressure test Table 22 Second Top End Overhaul 1 Clean Oil suction screen Clean Aftercooler core 2 Inspect Pressure test Exchange Fuel injectors Install new Inspect Engine wiring harness Install new Inspect Rocker arms Rebuild Inspect Cylinder head assemblies Rebuild Exchange Fuel priming pump Inspect Fuel pressure regulating Replace valve Pushrods Spacer plates Install new Air inlet manifold gaskets and seals Exhaust manifold seals and bellows 1 For instructions on removal and installation of components see the Service Manual Disassembly and Assembly module 2 For instructions on cleaning the core see this Operation and Maintenance Manual Aftercooler Core Clean Test topic Exchange Fuel injectors Install new Inspect Camshaft lifters Exchange I
13. 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 ELC Extended Life Coolant After filling the cooling system do not install the radiator filler cap 2 Open the water inlet for the separate circuit aftercooler if equipped Start the engine Operate the engine in order to purge the air from the cavities of the engine block Allow the ELC to warm and allow the coolant level to stabilize Stop the engine 3 Check the coolant level Maintain the coolant to the proper level on the sight gauge if equipped If a sight gauge is not equipped maintain the coolant within 13 mm 5 inch below the bottom of the filler pipe 4 Clean the radiator filler cap Inspect the gaskets of the radiator cap If the gaskets of the radiator filler cap are damaged discard the old radiator filler cap and install a new radiator filler cap If the gaskets of the radiator filler cap are not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the radiator filler cap The correct pressure is stamped on the face of the radiator filler cap If the radiator filler cap does not maintain the correct pressure install a new radiator filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature SEBU6701 05 73 Maintenance Section Cooling System Coolant Extender ELC Add 1024
14. EPDM rubber will swell in these solvents Do not allow the solvent to contact the gasket more than half an hour 1 Drain the heat exchanger 2 Disassemble the heat exchanger and remove the plates Keep the plates in order 3 Clean the plates with a cleaning solution and a soft brush Pressurized water may also be used Do not use steel wool or a wire brush which may scratch the plate Any iron scratches on the plates can lead to corrosion of the plates Rinse the plates with water 4 Assemble the heat exchanger Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 102121526 Inspect all hoses for leaks that are caused by the following conditions e Cracking SEBU6701 05 101 Maintenance Section Hoses and Clamps Replace e Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed e Armoring that is
15. Engine Mounts Check SMCS Code 1152 535 Illustration 72 g01340704 Typical configuration of mounting bolts for a Caterpillar genset 1 Mounting bolts for the engine 2 Mounting bolts for the generator 3 Levelling bolts for the isolators Misalignment of the engine and the driven equipment will cause extensive damage Excessive vibration can lead to misalignment Excessive vibration of the engine and the driven equipment can be caused by the following conditions e Improper mounting e Misalignment of driven equipment e Loose bolts e Deterioration of the isolators Ensure that the mounting bolts are tightened to the proper torque For standard torques see Specifications SENR3130 Torque Specifications Ensure that the isolators are free of oil and contamination Inspect the isolators for deterioration Ensure that the bolts for adjusting the isolator are correctly adjusted and secured with the locking nut Correctly adjusted isolators provide even support for the engine base Each isolator should impose nearly identical force on the base rail Each isolator should bear the same portion of the weight of the genset Replace any isolator that shows deterioration For more information see the literature that is provided by the OEM of the isolators Also see the Application and Installation Guide for the engine Consult your Caterpillar
16. Inspect the alternator for the following conditions e Proper connections e Clean ports for cooling airflow e Proper charging of the battery Observe the ammeter during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs if necessary See the Service Manual for service procedures Consult your Caterpillar dealer for assistance 101039675 Automatic Start Stop Inspect Generator Set SMCS Code 4462 The generator set must be ready to operate under a load at any time After performing maintenance on the generator set inspect the position of the control switches Ensure the following conditions e The starting system is enabled e The control switches are in the correct position for automatic starting e The switchgear and the automatic transfer switches that are associated with the generator are enabled For more information see the Operation and Maintenance Manual for the generator and the control panel Auxiliary Water Pump Inspect if equipped SMCS Code 1371 040 1371 Impellers and seals require periodic inspection Impellers have a service life that is limited The service life depends on the engine operating conditions Inspect the components more frequently when the pump is exposed to debris sand or other abrasive materials Inspect the components if the pump is operating at a differential pressure of more than 103 kPa 15
17. Maintenance Section Belts Replace 3 Move the pulley in order to adjust the belt tension 4 Tighten the adjusting nut to the proper torque 5 Tighten the mounting bolt to the proper torque For the proper torque specifications refer to the Service Manual Specifications module Replacement For applications that require multiple drive belts replace the drive belts in matched sets Replacing one drive belt of a matched set will cause the new drive belt to carry more load because the older drive belts are stretched The additional load on the new drive belt could cause the new drive belt to fail 101041135 Belts Replace SMCS Code 1357 510 Remove the used fan drive belt and the accessory drive belt Install new belts For applications that require multiple drive belts replace the belts in matched sets Used belts are stretched Replacing only one belt of a matched set will cause the new belt to carry an excessive load The additional load on the new belt could cause the new belt to break Check the belt tension according to the information in the Service Manual Specifications module To adjust the belt tension see this Operation and Maintenance Manual Alternator and Fan Belts Inspect Adjust Replace topic Maintenance Section After new belts are installed check the belt tension again after 30 minutes of engine operation at rated rpm 102417350 Cooling System Coolant DEAC Chang
18. also require service when the engine is overhauled Refer to the literature that is provided by the OEM of the driven equipment The following definitions explain the terminology for the services that are performed during an overhaul Exchange Your Caterpillar dealer will exchange your worn parts for parts that conform to original functional specifications Inspect Inspect the components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures New parts are not required if the existing parts can still be used reconditioned or repaired If the components are not in the reusability guidelines refer to the Service Manual Specifications module Install New The service life of the part is exhausted The part cannot be reconditioned The replacement part must be a new part Rebuild The component is reconditioned in order to comply with reusability guidelines Replace The service life of the part is exhausted The part may fail before the next maintenance interval The part must be replaced with a part that meets functional specifications The replacement part may be a new part a CAT remanufactured part a rebuilt part or a used part
19. clean the O ring seal Clean the inside of the fuel filter housing 7 Install new fuel filter elements 8 Inspect the O ring seal Ensure that the surfaces for the O ring seal are clean Install a new O ring seal if the old O ring seal is damaged or deteriorated 9 Install cover 2 Ensure that the springs are seated properly between the cover and the fuel filter elements 10 Open the fuel supply valve Reconnect the battery 11 Prime the fuel system Refer to this Operation and Maintenance Manual Fuel System Prime topic Maintenance Section Spin On Filter NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component ih P lt 2 pami k p ar HE z FRE 7 He ic J t dea LE a 0 Iia e TEAME Illustration 83 g00425598 Secondary fuel filters 1 Remove the used fuel filter with a 1U 8760 Chain Wrench Discard the used fuel filter 2 Clean the gasket sealing surface of the fuel filter base
20. dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The air cleaner element can be used up to six times if the element is properly cleaned and inspected When the air cleaner element is cleaned check for rips or tears in the filter material The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean air cleaner elements SEBU6701 05 83 Maintenance Section Engine Air Cleaner Element Single Element Clean Replace e Pressurized air e Vacuum cleaning Pressurized Air Pressurized
21. engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in SEBU6701 05 85 Maintenance Section Engine Air Precleaner Clean 101397717 Engine Air Precleaner Clean SMCS Code 1055 070 Illustration 68 g00736588 Typical precleaner 1 Wing nut 2 Cover 3 Body Remove wing nut 1 and cover 2 Check for an accumulation of dirt and debris in body 3 Clean the body if necessary After cleaning the precleaner install cover 2 and wing nut 1 Note When the engine is operated in dusty applications more frequent cleaning is required 101225429 Engine Crankcase Breather Clean SMCS Code 1317 070 If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage Illustration 69 g00597463 1 Loosen clamp 1 Slide the clamp down on tube 2 2 Loosen clamps 3 Remove both breathers as a unit Illustration 70 g00597465 3 Remove O ring seals 4 from the valve covers Inspect the O ring seals for good condition Obtain new O ring seals if necessary ae 6
22. equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEgj0047 How To Take A Good S 0 S Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine 102345348 Engine Oil and Filter Change SMCS Code 1318 510 Note Decrease the interval between oil changes by 20 percent and or increase the API service classification of the oil for engines that operate at high load factors of 80 percent or more for extended periods of time Refer to Caterpillar Publication PEDP8025 S O S Fluid Analysis Interpetation Guide in order to fully understand optimizing oil change intervals The oil change interval will be affected by the following items e Air fuel ratio e Ambient air conditions e Engine application e Fuel type e Oil type e Size of the oil sump The S O S oil analysis program analyzes used oil in order to determine if the oil change interval is suitable for your specific engine In the absence of S O S oil analysis change the engine oil and filters according to Table 17 SEBU6701 05 89 Maintenance Section Engine Oil and Filter Change Table 17 3500 Engine Oil Change Intervals Engine Sump Capacity Oil Change Inte
23. exchanger Refer to Table 19 for types of cleaners NOTICE Do not use hydrochloric acid to clean stainless steel plates Do not use hydrofluoric acid to clean titanium plates Water that contains more than 300 ppm of chlorine should not be used to prepare cleaning solutions Do not use Ketones such as Acetone and Methyle tyketone Do not use esters such as Ethylacetate and Butylac etate Do not use Halogenated hydrocarbons such as Chlorothene and Carbon Tetrachloride Do not use Aromatics such as Benzene and Toluene Table 19 Problem Source Cleaners Calcium carbonate Scaling Calcium sulphate Silicates Corrosion products Nitric acid Metal oxides Sulfamic acid Sediment Silt Citric acid Diatomic Phosphoric acid organisms Complexing agents Seaweed Sodium Gross fouling Chips of wood polyphosphates and fibers Mussels Bacteria Biological growth Nematodes Protozoa og Paraffinic or i ily ss Naphtha based Residue Asphalt h Fats solvent such as Kerosene 1 Cleaners should be mixed at a maximum concentration of 4 percent by weight The temperature of the cleaning solution should be less than 60 C 140 F 2 The addition of surfactants to the cleaning solution may ease cleaning 3 Do not mix the solvent with water for cleaning Dry the plates with a cloth or rinse the plates with water 4 Gaskets that are made from natural rubber butyl rubber and
24. for conventional coolants such as DEAC This maintenance is NOT required for cooling systems that are filled with Extended Life Coolant Test the Concentration of the SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Add the SCA If Necessary Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly 2 If necessary drain some coolant in order to allow space for the addition of the SCA 3 Add the proper amount of SCA For the proper amount of SCA refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic The proper concentration of SCA depends on the type of coolant that is used For the proper concentration of SCA refer to Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations 4 Clean the cooling system filler cap Install the cooling system filler cap Cooling Systems that Use Water and SCA Test the Concentration of the SCA Test the concentration of the SCA with a 298 5311 Coolant Nitrite Test Kit for SCA or perform an S O S Coolant Analysis The test k
25. 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 dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings The secondary air cleaner element is not serviceable or washable The secondary air cleaner element sho
26. is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing 68 Maintenance Section Belts Inspect Adjust Replace SEBU6701 05 All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water e A mixture of 0 1 L 0 11 qt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM 102
27. of wear metals in the lube oil The cylinder liners may be worn so that polishing of the bore occurs Also the increased use of lube oil will dilute the wear metals Monitor the engine as the engine accumulates service hours Consult your Caterpillar dealer about scheduling a major overhaul Note The driven equipment may also require service when the engine is overhauled Refer to the literature that is provided by the OEM of the driven equipment Using Fuel Consumption For Calculating the Overhaul Intervals Experience has shown that maintenance intervals are most accurately based on fuel consumption Fuel consumption corresponds more accurately to the engine load Tables 23 24 and 25 list average ranges of fuel consumption for a load factor of approximately 60 percent Table 23 Maintenance Intervals for Overhaul Fuel Consumption for 3508 and 3508B Engines Top End Overhaul 976 000 L 257 500 US gal Second Top End 1 952 000 L 515 000 US gal Overhaul Major 2 928 000 L 772 500 US gal overhaul Table 24 Maintenance Intervals for Overhaul Fuel Consumption for 3512 and 3512B Engines Top End Overhaul 1 460 000 L 385 000 US gal Second Top End 2 920 000 L 770 000 US gal Overhaul Major Overhaul 4 380 000 L 1 155 000 US gal SEBU6701 05 109 Maintenance Section Overhaul Considerations Table 25 Maintenance Intervals for Overhaul Fuel Cons
28. only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools Group Outside U S A 309 675 6277 Inside U S A 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL CSTG COSA Geneva Switzerland 41 22 849 40 56 Clean the Cooling System 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the coolant drain Clean the drain plugs and install the drain plugs NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Open the water inlet for the separate circuit aftercooler if equipped Fill the cooling system with clean water Install the radiator filler cap Operate the engine until the temperature reaches 49 C 120 F to 66 C 150 F 4 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler if equipped Ensure that the engine will not start when the cooling system is drained Loosen the radiator filler cap slowly in order to relieve any pressure Remove the radiator filler cap 5 Open the coolant drain Remove the drain plugs Allow the coolant to drain Flush the cooling system with clean water Close the coolant drain Install the drain plugs 6 Repeat Steps 3
29. operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure 98 Maintenance Section Heat Exchanger Inspect SEBU6701 05 Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank during the following conditions e Weekly e Oil change e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank A four micron c absolute filter for the breather vent on the fuel tank is also recommended Refer to Special Publication SENR9620 Improving Fuel System Durablity If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage t
30. pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the radiator filler cap 4 Open the water inlet for the separate circuit aftercooler if equipped Start the engine Operate the engine for a minimum of 90 minutes with a coolant temperature of at least 82 C 180 F 5 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler if equipped Loosen the radiator filler cap slowly in order to relieve any pressure Remove the radiator filler cap Open the coolant drain Remove the cooling system drain plugs Allow the water to drain SEBU6701 05 71 Maintenance Section Cooling System Coolant ELC Change NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 6 Flush the cooling system with clean water until the water that drains is clean Close the cooling system drain Clean the cooling system drain plugs and install the cooling system drain plugs Fill the Cooling System Note For information about the proper coolant to use see this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section For the capacity of the cooling system see
31. psi There are different types of pumps Some pumps will have a cover that is bolted to the main pump body Some pumps will have a clamp that holds the front part of the pump body to the main part of the pump body The cover or the front part of the pump body must be removed in order to inspect the pump Pumps with a Cover X 5 O Je Q 0 O P l 1 Illustration 48 1 Plug 2 Bolt 3 Cover 3 g01136356 1 Remove plug 1 and drain the water out of the pump 66 Maintenance Section Batteries Replace SEBU6701 05 2 Remove bolts 2 and cover 3 3 Inspect the priming impeller the wear plates for the priming impeller and the impeller for wear or damage Inspect the pump housing for wear damage or buildup 4 Inspect the pump shaft and the impeller for excessive axial movement 5 If wear or damage is found replace the components which are worn or damaged Use the proper repair kit for the pump Pumps with a Clamp Illustration 49 g01136382 1 Plug 2 Clamp 3 Clamp 4 Front part of the pump body 1 Remove plug 1 and drain the water out of the pump 2 Remove the water line and clamp 2 if necessary 3 Loosen clamp 3 and remove the front part of the pump body 4 4 Inspect the impeller the wear plates and the wear ring for wear or damage Inspect the pump housing for wear damage or buildup 5 Ins
32. 2 Close one air shutoff valve and attempt to start the engine If the engine cranks but the engine will not start the switches are functioning correctly Caterpillar Electronic Technician ET will also show an active emergency stop condition Proceed to step 3 If the engine starts with one of the air shutoffs closed check the switch on the valve that is closed The switch should not have continuity If the switch has continuity remove the switch and inspect the switch If the switch does not show continuity troubleshoot the switch wiring further Repair the necessary components or replace the necessary components Retest the system as required 3 With both air shutoff valves in the open position activate the emergency stop Both air shutoff valves should close If both valves close testing is complete If only one air shutoff closes purge air from the line at the cylinder that failed to close and repeat this step Note Testing is only complete when the engine successfully passes all of the steps Reset both air shutoff valves to the open position and clean up any spills that may have occurred Note The limit switch assemblies are items that wear and the limit switch assemblies may need to be replaced during normal maintenance intervals 102654935 Air Starting Motor Lubricator Bowl Clean SMCS Code 1451 070 If the engine is equipped with an air starting motor use the following procedure Personal injury can re
33. 2 Start the engine according to the instructions in this Operation and Maintenance Manual Engine Starting topic Operation Section NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted SEBU6701 05 115 Maintenance Section Water Pump Inspect 3 Perform an inspection of the installation after the engine is started Look for leaks Listen for unusual noises e Check the engine oil level when the engine is operating at low idle rom Observe the oil level on the LOW IDLE side of the oil level gauge dipstick Inspect the lubrication system for leaks at the oil pan the oil filter and the valve covers Inspect the cooling system for leaks at the hose connections Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Inspect the exhaust system for leaks If the enclosure has louvers inspect the louvers for proper operation Observe the gauges Ensure the correct readings for the engine rom Record the data for the gauges Record the data for the performance of the generator See the Operation and Maintenance Manual for the generator and the control panel 4 After exercising the generator set stop the engine
34. 3500 INDUSTRIAL and GENERATOR SET ENGINES Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU6701 05 00 2009 Caterpi 2009 cater CATERPILLAR SEBU6701 05 57 Maintenance Section Maintenance Recommendations Maintenance Recommendations 102909163 System Pressure Release SMCS Code 1250 1300 1350 5050 Coolant System Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure To relieve the pressure from the coolant system turn off the engine Allow the cooling system pressure cap to cool Remove the cooling system pressure cap slowly in order to relieve pressure Fuel System To relieve the pressure from the fuel system turn off the engine High Pressure Fuel Lines If Equipped Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head These fuel lines are different from fuel lines on other fuel systems This is because of the following differences e The high pressure fuel lines
35. 667833 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspection Inspect the alternator belt and the fan drive belts for wear and for cracking Replace the belts if the belts are not in good condition Check the belt tension according to the information in the Service Manual Specifications Slippage of loose belts can reduce the efficiency of the driven components Vibration of loose belts can cause unnecessary wear on the following components e Belts e Pulleys e Bearings If the belts are too tight unnecessary stress is placed on the components This reduces the service life of the components Adjusting the Alternator Belt Illustration 50 g01092641 Typical alternator 1 Mounting bolt 2 Adjusting nuts 3 Mounting bolt 1 Remove the drive belt guard 2 Loosen mounting bolt 1 adjusting nuts 2 and mounting bolt 3 3 Turn adjusting nuts 2 in order to increase or decrease the drive belt tension 4 Tighten adjusting nuts 2 Tighten mounting bolt 3 Tighten mounting bolt 1 For the proper torque see the Service Manual Specifications module 5 Reinstall the drive belt guard If new drive belts are installed check the drive belt tension again after 30 minutes of engine operation at the rated rom Adjusting the Fan Drive Belt 1 Loosen the mounting bolt for the pulley 2 Loosen the adjusting nut for the pulley SEBU6701 05 69
36. 82066 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Cat ELC Extended Life Coolant does not require the frequent additions of any supplemental cooling additives which are associated with the present conventional coolants The Cat ELC Extender only needs to be added once NOTICE Use only Cat Extended Life Coolant ELC Extender with Cat ELC Do NOT use conventional supplemental coolant addi tive SCA with Cat ELC Mixing Cat ELC with conven tional coolants and or conventional SCA reduces the Cat ELC service life Check the cooling system only when the engine is stopped and cool Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable container
37. Adjust the lubricator with a constant rate of air flow After the adjustment the lubricator will release oil in proportion to variations of the air flow 1 Ensure that the fuel supply to the engine is OFF NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 2 Operate the air starting motor Observe the drops of oil that are released in dome 1 Note Some lubricators have an adjustment screw rather than a knob 3 If necessary adjust the lubricator in order to release from one to three drops of oil per second To increase the rate turn knob 2 counterclockwise To decrease the rate turn the knob clockwise 100351324 Air Tank Moisture and Sediment Drain SMCS Code 1466 543 M amp S Moisture and sediment in the air starting system can cause the following conditions e Freezing e Corrosion of internal parts e Malfunction of the air starting system When opening the drain valve wear protective gloves a protective face shield protective cloth ing and protective shoes Pressurized air could cause debris to be blown and result in personal injury SEBU6701 05 65 Maintenance Section Alternator Inspect 1 Open the drain valve that is on the bottom of the air tank Allow the moisture and sediment to drain 2 Close the drain valve 102084374 Alternator Inspect SMCS Code 1405 040
38. ICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately L 2 Ter B Arel i Illustration 82 g01411122 1 Bolts 2 Cover 3 Plug 4 Drain valve 5 Drain 3 Connect a hose to drain 5 Place the other end of the hose into a suitable container in order to collect the fuel 4 Open drain valve 4 Remove plug 3 Allow the fuel to drain Clean the plug and install the plug Close the drain valve Remove the hose from the drain Note Some fuel will remain in the housing after the fuel has been drained This fuel will pour out of the housing when cover 2 is removed Prepare to catch the fuel in a suitable container Clean up any spilled fuel with absorbent towels or pillows DO NOT use absorbent particles to clean up the fuel Personal injury can result from parts and or cov ers under spring pressure Spring force will be released when covers are re moved Be prepared to hold spring loaded covers as the bolts are loosened 5 Be alert to the spring force Gradually loosen but do not remove bolts 1 Before removing bolts 1 pry cover 2 loose in order to relieve any spring pressure Remove cover 2 Remove the O ring seal on the inside of the cover Remove the fuel filter elements 96 Maintenance Section Fuel System Secondary Filter Replace SEBU6701 05 6 Clean cover 2 and
39. a 9 psi Replace the secondary fuel filter elements when the fuel filter differential pressure reaches 103 kPa 15 psi For instructions on replacement of the secondary fuel filter elements see this Operation and Maintenance Manual Fuel System Secondary Filter Replace topic 102828884 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Note If the engine is equipped with duplex fuel filters the fuel filter elements can be changed while the engine is in operation Refer to Replacing the Fuel Filter Elements During Engine Operation Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately Replace the secondary fuel filter elements whenever the following conditions occur e The fuel filter differential pressure gauge registers 103 kPa 15 psi e The fuel filters have been used for 1000 service hours Replacing the Fuel Filter Elements with the Engine Stopped Canister 1 Stop the engine Ensure that the engine will not start during this procedure 2 Shut off the fuel supply valve to the engine NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component NOT
40. a new zinc rod 4 Coat the external threads of the plug 3 with 5P 3413 Pipe Sealant Install the zinc rod See Specifications SENR3130 Torque Specifications for the torque for the plug Illustration 87 g00481100 b Tap the zinc rod lightly with a hammer If the zinc rod breaks install a new zinc rod 3 If the zinc rod will be reused scrape the layer of oxidation from the zinc rod before installation The layer of oxidation reduces the effectiveness of the zinc rod Replace the Zinc Rods 1 Use pliers to unscrew the old zinc rod from the plug If not enough material remains or the zinc rod has broken off drill the zinc from the plug 2 Clean the plug Illustration 88 g00748510 1 Shoulder 2 Threads 3 External threads of the plug Note Do not apply adhesive or sealant to the threads of the zinc rod 2
41. according to this Operation and Maintenance Manual Engine Stopping topic Operation Section 5 Perform the procedures that are described in this Operation and Maintenance Manual After Stopping Engine topic Operation Section 6 Ensure that the control switches are in the correct position for automatic starting of the generator set 102624237 Water Pump Inspect SMCS Code 1361 040 A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head a piston seizure or other potential damage to the engine Visually inspect the water pump for leaks If leaking of the water pump seals is observed replace all of the water pump seals Refer to two articles in the Disassembly and Assembly Manual Water Pump Disassemble and Water Pump Assemble for the disassembly and assembly procedure If it is necessary to remove the water pump refer to two articles in the Disassembly and Assembly Manual Water Pump Remove and Water Pump Install Inspect the water pump for wear cracks pin holes and proper operation Refer to the Parts Manual for the correct part numbers for your engine or consult your Caterpillar dealer if repair is needed or replacement is needed 103028045 Zinc Rods Inspect Replace SMCS Code 1388 040 1388 510 Corrosion in sea water circuits can result in the following issues premature deterioration of cooling system components l
42. acts the base Tighten the oil filter by hand for an additional 1 full turn 360 degrees Do not overtighten the oil filter Replacing the Engine Oil Filters During Engine Operation If the engine is equipped with duplex oil filters the engine oil filter elements can be changed while the engine is operation This is useful if the oil filter elements require more frequent replacement than the engine oil Filter contains hot pressurized fluid when engine is running Follow instructions on control valve to avoid per sonal injury If rapid air movement exists to blow fluid Stop the engine to avoid fire 92 Maintenance Section Engine Oil and Filter Change SEBU6701 05 1 Move the control valve to the AUX RUN position in order to change the main oil filter elements Move the selector valve to the MAIN RUN position in order to change the auxiliary oil filter elements 2 Allow the oil pressure gauge for the oil filter that is being changed to reach a ZERO pressure reading 3 Perform Step 1 through Step 8 of Replacing the Engine Oil Filters With the Engine Stopped 4 Open the FILL valve for a minimum of five minutes in order to fill the new oil filter elements 5 Close the FILL valve Rotate the control valve to the RUN position for the oil filter that was serviced Inspect the Used Oil Filter Elements Cut the used oil filter element open with a utility knife Remove t
43. ad to the following problems guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately 3 If necessary add engine oil For the correct engine oil to use refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section Do not fill the crankcase above the FULL mark on the engine oil level gauge Clean the filler cap 1 Install the filler cap 4 Record the amount of engine oil that is added For the next engine oil sample and analysis include the total amount of engine oil that has been added since the previous oil change This will help to provide the most accurate analysis 103542996 Engine Oil Sample Obtain SMCS Code 1348 554 SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels 88 Maintenance Section Engine Oil and Filter Change SEBU6701 05 Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oi
44. air can be used to clean air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 63 g00281692 Note When the air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Air Cleaner Elements Inspecting the Air Cleaner Elements Illustration 64 g00281693 Inspect the clean dry air cleaner element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the air cleaner element Rotate the air cleaner element Inspect the air cleaner element for tears and or holes Inspect the air cleaner element for light that may show through the filt
45. al vibration worn bearings or damage to the damper Use an infrared thermometer to monitor the temperature of the damper during operation Follow the instructions that are included with the infrared thermometer If the temperature reaches 100 C 212 F consult your Caterpillar dealer Inspect the damper for evidence of dents cracks and leaks of the fluid If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous and smooth If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace all of the seals Inspect the damper and repair or replace the damper for any of the following reasons e The damper is dented cracked or leaking e The paint on the damper is discolored from heat e The engine has had a failure because of a broken crankshaft The crankshaft bearings are showing excessive wear e There is a large amount of gear train wear that is not caused by a lack of oil Dampers With Sampling Ports Illustration 57 g00819045 Some dampers have ports for fluid samples If the damper has no external damage collect a sample of the damper fluid The fluid should be analyzed in order to check for a loss of viscosity Use the results of the analysis to determine if the damper should be rebuilt or replaced Kits for fluid samples are available from the address that follows Retu
46. and Adjusting manual 101106228 Fan Drive Bearing Lubricate SMCS Code 1359 086 BD Note Lubricate the bearing more frequently if the engine is operated in an environment that is dusty hot or humid 6 LT Illustration 80 g00583459 Grease fitting Fill the grease fitting for the fan drive bearing with Caterpillar Bearing Lubricant Alternatively use a multipurpose grease that has three to five percent of molybdenum and a grade of NLGI No 2 101225410 Fuel Injector Inspect Adjust SMCS Code 1290 025 Note Perform this procedure when the engine valve lash is inspected NOTICE The camshafts must be correctly timed with the crank shaft before an adjustment of the lash for the fuel in jector is made The timing pins must be removed from the camshafts before the crankshaft is turned or dam age to the cylinder block will be the result Inspect the adjustment of the lash for the fuel injector according to the Systems Operation Testing And Adjusting Fuel System topic Adjust the lash for the fuel injector if necessary 101395213 Fuel System Prime SMCS Code 1250 548 1258 548 1 Open the fuel supply valve Ensure that the engine will not start during the priming procedure Turn the start switch to the OFF position ATT 22 4 ao IS
47. andard Oil Sump change the oil after every 500 service hours If the engine has a Deep Oil Sump change the oil after every 1000 service hours Refer to this Operation and Maintenance Manual Engine Oil and Filter Change in order to determine the oil change interval that is suitable for your specific engine Note To determine the maintenance intervals for overhauls refer to this Operation and Maintenance Manual Overhaul Considerations Note Use service hours or calendar time which ever occurs first in order to determine the maintenance intervals Engines that operate in severe operating conditions may require more frequent maintenance Before each consecutive interval is performed all of the maintenance requirements from the previous interval must also be performed When Required Batteries Replace cceeseceeeeecceceeeeeeeeeeetees 66 Engine Air Cleaner Element Dual Element Clean Replace 0 0 0 cccccecceeeeeeeeceeeeeeeeeeeeeteeeeens 79 Engine Air Cleaner Element Single Element Clean Replace 2 cccccceceeeeeeeeeeeeeceeeeeeeeeeeteeeeees 81 Fuel System Prime ssssssssseecserrreerrrrrnsrrrrrserrerees 94 Heat Exchanger Inspect cccceeeeeeeeeeeeees 98 Sea Water Strainer Clean Inspect 0 0 111 Zinc Rods Inspect Replace n 115 Daily Air Starting Motor Lubricator Oil Level Check 64 Air Tank Moisture and Sediment Drain
48. ank helps to ensure the quality of the fuel When possible water separators should be used Heat Exchanger Inspect if equipped SMCS Code 1379 040 Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The heat exchanger and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove the filler cap slowly to relieve pressure only when the engine is stopped and the filler cap for the heat exchanger is cool enough to touch with your bare hand Cooling System Conditioner contains alkali Avoid contact with skin and eyes NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Shell and Tube Heat Exchanger The interval for the maintenance of the shell and tube heat exchanger depends on the operati
49. are constantly charged with high pressure e The internal pressures of the high pressure fuel lines are higher than other types of fuel system Before any service or repair is performed on the engine fuel lines perform the following tasks 1 Stop the engine 2 Wait for ten minutes Do not loosen the high pressure fuel lines in order to remove air pressure from the fuel system Engine Oil To relieve pressure from the lubricating system turn off the engine 103642798 Welding on Engines with Electronic Controls SMCS Code 1000 NOTICE Because the strength of the frame may decrease some manufacturers do not recommend welding onto a chassis frame or rail Consult the OEM of the equip ment or your Caterpillar dealer regarding welding on a chassis frame or rail Proper welding procedures are necessary in order to avoid damage to the engine s ECM sensors and associated components When possible remove the component from the unit and then weld the component If removal of the component is not possible the following procedure must be followed when you weld on a unit that is equipped with a Caterpillar Electronic Engine The following procedure is considered to be the safest procedure to weld on a component This procedure should provide a minimum risk of damage to electronic components NOTICE Do not ground the welder to electrical components such as the ECM or sensors Improper grounding can cause damage to th
50. arness Fuel pressure regulating valve Pistons Crowns and Skirts Pushrods Spacer plates Replace Camshaft bearings Connecting rod bearings Crankshaft seals Crankshaft thrust plates Fuel injectors Gear train bushings Main bearings Piston rings Seals and bellows for the exhaust manifold Seals and gaskets for the air Inlet manifold 1 For instructions on removal and installation of components see the Service Manual Disassembly and Assembly module 2 For instructions on cleaning the core see this Operation and Maintenance Manual Aftercooler Core Clean Test topic 102345052 Overhaul Top End SMCS Code 7595 020 TE Refer to this Operation and Maintenance Manual Overhaul Considerations in order to determine the maintenance interval for a top end overhaul A top end overhaul involves the removal the inspection and the rework of the cylinder head components A few additional components are replaced and serviced The top end overhaul second interval involves the same service that is performed for the first interval Because of the number of service hours some additional components are inspected and or serviced Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications Note The driven equipment may
51. atalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 2 Drain the oil according to the equipment on the mnie il g00328285 Ct Jj 1 Illustration 75 1 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 This will prevent dirt from entering into the oil pan Be careful not to strike the engine oil suction tubes or the piston cooling jets c If a suction device that attaches to the oil drain is used ensure that the suction device is clean Attach the suction device to the oil drain Open the oil drain After the oil has drained close the oil drain and remove the suction device d If the oil drain valve has a quick connect coupling attach the coupling Open the drain valve in order to drain the crankcase After the oil has drained close the drain valve Disconnect the coupling 3 Replace the engine oil filter elements before filling the crankcase with new oil 90 Maintenance Section Engine Oil and Filter Change SEBU6701 05 Replace the Oil Filter Elements Replace the eng
52. ate the problem and correct the problem Check the condition of all of the gauges If a gauge is broken repair the gauge or replace the gauge immediately Frequently monitor the gauges during normal operation Record the data in a log Compare the new data to the data that was previously recorded Comparing the new data to the recorded data will help to establish the trends of engine performance A gauge reading that is abnormal may indicate a problem with operation or a problem with the gauge 103230758 Jacket Water Heater Check SMCS Code 1383 535 Jacket water heaters help to improve startability in ambient temperatures that are below 21 C 70 F All installations that require automatic starting should have jacket water heaters Check the operation of the jacket water heater Check the operation of the circulation pump if equipped For an ambient temperature of 0 C 32 F the heater should maintain the jacket water coolant temperature at approximately 32 C 90 F Magnetic Pickups Clean Inspect If Equipped SMCS Code 1907 040 Illustration 85 g00614378 1 Remove the magnetic pickup from the flywheel housing Check the condition of the end of the magnetic pickup Check for signs of wear and contaminants 2 Clean the metal shavings and other debris from the face of the magnet 3 Install the magnetic pickup until the magnet comes in contact with the flywheel ring gear tooth 4 Lo
53. cleaner element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element for tears and or holes Inspect the primary air cleaner element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air cleaner element to a new primary air cleaner element that has the same part number Do not use a primary air cleaner element that has any tears and or holes in the filter material Do not use a primary air cleaner element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will not be used the primary air cleaner element can be stored for future use Illustration 61 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air cleaner elements in Volatile Corrosion Inhibited VCI paper Place the primary air cleaner element into a box for storage For identification mark the outside of the box and mark the primary air cleaner element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location 101553508 Engin
54. comply with the established inspection specifications the parts can be reused The use of out of spec parts could result in unscheduled downtime and or costly repairs The use of out of spec parts can also contribute to increased fuel consumption and reduction of engine efficiency New parts are not necessary if the old parts can be reused repaired or salvaged Otherwise the old parts can be replaced or exchanged Your Caterpillar dealer can provide the parts that are needed to rebuild the engine at the least possible cost 110 Maintenance Section Radiator Clean SEBU6701 05 Overhaul Programs An economical way to obtain most of the parts that are needed for overhauls is to use Caterpillar remanufactured parts Caterpillar remanufactured parts are available at a fraction of the cost of new parts These parts have been rebuilt by Caterpillar and certified for use The following components are examples of the remanufactured parts e Cylinder heads e Oil Pumps e Turbochargers e Water pumps Consult your Caterpillar dealer for details and for a list of the remanufactured parts that are available Your Caterpillar dealer may be offering a variety of overhaul options A Flat Rate Overhaul guarantees the maximum price that you will pay for an overhaul Flat rate prices on preventive maintenance programs or major repair options are available from many servicing dealers for all Caterpillar Engines Consult your Caterpilla
55. concentration of cleaner 4 Back flush the core with cleaner Caterpillar recommends the use of Hydrosolv liquid cleaner Table 18 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 18 Hydrosolv Liquid Cleaners Part ee z Number Description Size 1U 5490 Hydrosolv 4165 19 L 5 US gallon 174 6854 Hydrosolv 100 19 L 5 US gallon 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information 5 Steam clean the core in order to remove any residue Flush the tubes of the heat exchanger core Remove any other trapped debris 6 Wash the core with hot soapy water Rinse the core thoroughly with clean water Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 7 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 8 Inspect the core in order to ensure cleanliness Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 9 Install the heat exchanger Refer to the Service Manual for
56. contamination Never collect samples from expansion bottles Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see this Operation and Maintenance Manual Refill Capacities and Recommendations or consult your Caterpillar dealer 101987714 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6251 Caterpillar Commercial Diesel Engines Fluids Recommendations or consult your Caterpillar dealer 102839449 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and eyes Do not drink cooling system coolant additive
57. ct the cable from the ground plane to the NEGATIVE battery terminal SEBU6701 05 67 Maintenance Section Battery Charger Check 101039758 Battery Charger Check SMCS Code 1401 535 Checking Before Start Up Check the battery charger for proper operation If the batteries are properly charged the needle of the ammeter will register near 0 zero The battery charger must not produce excessive current during start up Alternatively the charger must be automatically disconnected for start up If the engine has an alternator the charger must be automatically disconnected during start up and during engine operation Charging the Battery Never disconnect any charging unit circuit or bat tery circuit cable from the battery when the charg ing unit is operated A spark can cause an explo sion from the flammable vapor mixture of hydro gen and oxygen that is released from the elec trolyte through the battery outlets Injury to per sonnel can be the result Perform the following procedure to charge the battery 1 Ensure that the charger is turned OFF 2 Adjust the voltage of the charger in order to match the voltage of the battery 3 Connect the POSITIVE lead of the charger to the POSITIVE battery terminal Connect the NEGATIVE lead of the charger to the NEGATIVE battery terminal 4 Turn ON the battery charger Overcharging of Batteries Overcharging reduce
58. d Inspection ccccceceeeeeeeeeeeeeteees 113 Walk Around Inspection cccccceeeeeeeeeeeeeeeeeees 114 Every Year Actuator Control Linkage Lubricate 0 0 62 Air Starting Motor Lubricator Bowl Clean 63 Alternator Inspect ceceeeeeeeeceeceeeeeeeeeeeteeeeees 65 Belts Inspect Adjust Replace ceee 68 Cooling System Coolant Sample Level 2 ODN ceetete catered et ais ated Blot at 75 Cooling System Supplemental Coolant Additive SCA Test Add 00 eeeceeceeeeecteeeeeeteneeeeeeeetteeeeeneas 75 Crankshaft Vibration Damper Inspect 77 Engine Clean aar eas E AA 78 Engine Air Cleaner Element Single Element Clean Replace 2 cccccccceeeeeeeeeeceeeeeeeeeeeeeeeeeees 81 Engine Crankcase Breather Clean aaeeei 85 Engine Mounts Check eeeeeeceeeeteeeeeeeeneeeeeeeees 86 Engine Oil Sample Obtain 20 0 0 eeeeeereeeees 87 Engine Oil and Filter Change 88 Engine Performance Test a 93 Engine Protective Devices Check asees 93 Engine Valve Lash Inspect Adjust eee 93 Fan Drive Bearing Lubricate eee 94 Fuel Injector Inspect Adjust 0 0 0 ceeeeeeeeeeeeees 94 Fuel System Secondary Filter Replace 95 Hoses and Clamps Inspect Replace 100 Magnetic Pickups Clean Inspect 0 102 Every 3 Years Batteries Replace ececeeece
59. d in the open or Run position If the air shutoff valve is in the Closed position or the Stop position the switch is in the open state which will cause an emergency stop This will shut down the engine or this will prevent the engine from starting The engine will crank but the engine will not start Electrically Operated Air Shutoff Valves 1 Power up the engine control panel with both air shutoff valves latched in the open position and both switches connected Both valves should remain open Check the wiring for the switch if both valves do not remain open 2 With the power to the engine control panel ON activate the emergency stop button Both of the air shutoff valves should close If both air shutoff valves do not close check the switch wiring and the solenoid wiring If both air shutoff valves close proceed to step 3 3 Turn the power engine control panel to the OFF position Ensure that the emergency stop button is in the run position Latch only the right side air shutoff valve to the open position and turn the power for the engine control panel to the ON position The right air shutoff valve should close If the right air shutoff valve closes proceed to step 4 If the right air shutoff valve does not close check the switch and wiring for the right air shutoff valve 4 Turn power for the engine control panel to the OFF position Ensure that the emergency stop button is in the run position Latch only the left side ai
60. dealer for assistance 102110431 Engine Oil Filter Differential Pressure Check SMCS Code 1308 535 Observe the oil filter differential pressure frequently during engine operation Oil Filter Differential Pressure Restriction This gauge indicates the difference in pressure between the inlet side and the outlet side of the engine oil filters As the oil filter elements become plugged oil filter differential pressure will increase The nominal oil filter differential pressure during normal engine operation is approximately 60 kPa 9 psi Replace the oil filter elements when the oil filter differential pressure reaches 103 kPa 15 psi For instructions on replacement of the oil filter elements see this Operation and Maintenance Manual Engine Oil and Filter Change topic SEBU6701 05 87 Maintenance Section Engine Oil Level Check 102418058 Engine Oil Level Check SMCS Code 1348 535 FLV The most accurate check of the engine oil level is obtained when the engine is stopped TI ae Illustration 73 g01208341 1 Filler cap 2 Engine oil level gauge dipstick 1 Remove filler cap 1 in order to ensure that the crankcase pressure is equal to the atmospheric pressure Excess pressure or a slight vacuum will affect engin
61. e SMCS Code 1350 044 Clean the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e The coolant is foaming e Oil or fuel has entered the cooling system and the coolant is contaminated Drain the Cooling System 1 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler if equipped Ensure that the engine will not start when the cooling system is drained 2 Loosen the radiator filler cap slowly in order to relieve any pressure Remove the radiator filler ee Illustration 51 g00750410 1 Coolant drain a eS e ea Illustration 52 g00750411 Locations of the cooling system drain plugs 1 Oil cooler 2 Jacket water pump 3 Engine block Note If the engine has a jacket water heater drain the coolant from the heater 3 Open the coolant drain Remove the cooling system drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillat
62. e Air Cleaner Element Single Element Clean Replace SMCS Code 1051 1054 037 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine 82 Maintenance Section SEBU6701 05 Engine Air Cleaner Element Single Element Clean Replace Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air cleaner element e Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element e The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected e The air cleaner element should be replaced at least one time per year This replace
63. e drive train the bearings hy draulic components electrical components and other components Do not ground the welder across the centerline of the package Improper grounding could cause damage to the bearings the crankshaft the rotor shaft and other components Clamp the ground cable from the welder to the com ponent that will be welded Place the clamp as close as possible to the weld This will help reduce the pos sibility of damage Note Perform the welding in areas that are free from explosive hazards 58 Maintenance Section Maintenance Recommendations SEBU6701 05 1 Stop the engine Turn the switched power to the OFF position 2 Disconnect the negative battery cable from the battery If a battery disconnect switch is provided open the switch 3 Disconnect the J1 P1 and J2 P2 connectors from the ECM Move the harness to a position that will not allow the harness to accidentally move back and make contact with any of the ECM pins ae SR 6 Illustration 44 g01075639 Use the example above The current flow from the welder to the ground clamp of the welder will not cause damage to any
64. e oil level that is measured 2 Ensure that engine oil level gauge 2 is seated ADD RS FULL Rat ENGINE STOPPED WITH OIL COLD D 00 m yf ENGINE AT LOW IDLE WITH WARN OTL Illustration 74 g00735162 3 ENGINE STOPPED WITH OIL COLD side 4 ENGINE AT LOW IDLE WITH WARM OIL side 5 ADD mark 6 FULL mark a If the engine is stopped remove the engine oil level gauge Observe the engine oil level on ENGINE STOPPED WITH OIL COLD side 3 b If the engine is operating reduce the engine speed to low idle Remove the engine oil level gauge and observe the engine oil level on ENGINE AT LOW IDLE WITH WARM OIL side 4 The engine oil level should be between ADD mark 5 and FULL mark 6 NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can cause the crankshaft to dip into the oil This will reduce the power that is devel oped and also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling oil blowing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber De posits in the combustion chamber le
65. e product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJO003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Note Failure to properly close the drain can allow air into the system which could have detrimental results to performance Check the fuel daily Drain the water and sediment from the fuel tank after
66. eaks and possible cooling system contamination The corrosion may be caused by the lack of zinc rods in the sea water system Zinc rods are installed in the sea water cooling system of the engine in order to help prevent the corrosive oxidation that is caused by sea water Electrical current is conducted through the contact of the zinc rods with the cooling system components The zinc rods oxidize rather than the cooling system components Rapid deterioration of zinc rods may indicate the presence of uncontrolled electrical currents from improperly installed electrical attachments or improperly grounded electrical attachments The engineer for the operation must determine the interval for inspecting the zinc rods The interval for inspecting the zinc rods will depend on the size of the zinc rods and the number of zinc rods that are installed Table 27 Locations of the Zinc Rods Location Quantity Elbow of the Auxiliary Water Pump 1 Elbow of the Aftercooler 1 Inspect the Zinc Rods 1 Remove the zinc rod 2 Inspect the zinc rod 116 SEBU6701 05 Maintenance Section Zinc Rods Inspect Replace Ensure that the zinc rod will remain effective until 3 Apply 9S 3263 Thread Lock Compound to the next scheduled inspection the shoulder 1 of a new zinc rod Apply the compound only to the shoulder of the zinc rod a If the zinc rod has deteriorated excessively Install the zinc rod onto the plug install
67. eam cleaning or high pressure water Note Use care when you use steam cleaning Use care when you use high pressure water Direct spray to rotating electrics or electronic components can cause nonfixable damage NOTICE Water and or condensation can cause damage to electrical components Protect all electrical compo nents from exposure to water e Ensure that the coolant lines are properly clamped Ensure that the fittings are tight Check for leaks Check the condition of all pipes e Inspect the water pump for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pump and the installation of water pump and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the following locations front crankshaft seal rear crankshaft seal oil pan oil filters valve cover turbocharger external oil lines and connections Inspect the fuel system for leaks Look for loose fuel line clamps or connections Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps or connections Ensure that the exhaust system is properly clamped Ensure that the connections are tight Check
68. eceeeeeeeeeeeeeeteees 66 Belts Replace cc ccfiavvcccectsdencgecetthd eet nedeeete eden 69 Cooling System Coolant DEAC Change 69 Cooling System Coolant Extender ELC Add 73 Cooling System Water Temperature Regulator Replace 2 2124 is cteceus tee atl ein ted tat 77 Hoses and Clamps Replace ceceeee 101 Turbocharger Inspect 0 2 ceeeeeeeeteeeeeeeteteeeeeeteee 112 Water Pump Inspect sssssessessseirennssesseeerrnnrrn ne 115 Every 6 Years Cooling System Coolant ELC Change 71 60 Maintenance Section Maintenance Interval Schedule SEBU6701 05 103637529 Maintenance Interval Schedule Standard SMCS Code 1000 4450 7500 Note Ensure that the Safety Information warnings and instructions are read and understood before operation or maintenance procedures are performed Note For information on generator maintenance see the Operation and Maintenance Manual for the generator All of the following will affect the oil change interval operating conditions fuel type oil type and size of the oil sump Scheduled oil sampling analyzes used oil in order to determine if the oil change interval is suitable for your specific engine In the absence of scheduled oil sampling change the engine oil and filters according to the following intervals If the engine has a Shallow Oil Sump change the oil after every 250 service hours If the engine has a St
69. embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings 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 system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine Allow the engine to cool 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suitable clean container The coolant can be reused 3 Drain the coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose 7 Install the hose clamps with a torque wrench Note Refer to t
70. enerators can operate without problems in humid environments However problems can occur when the generator is inactive Moisture can condense on the windings This can result in poor performance Also damage to the windings can occur Use space heaters in order to help keep the windings dry When the generator is not active ensure that the space heaters are operating When the generator is operating turn OFF the space heaters 101113939 Starting Motor Inspect SMCS Code 1451 040 1453 040 If the starting motor fails the engine may not start in an emergency situation A scheduled inspection of the starting motor is recommended The starting motor pinion and the flywheel ring gear must be in good condition in order for the engine to start properly The engine will not start if the starting motor pinion does not engage the flywheel ring gear The teeth of the starting motor pinion and the flywheel ring gear can be damaged because of irregular engagement Inspect the starting motor for proper operation Listen for grinding when the engine is started Inspect the teeth of the starting motor pinion and the flywheel ring gear Look for patterns of wear on the teeth Look for teeth that are broken or chipped If damaged teeth are found the starting motor pinion and the flywheel ring gear must be replaced Electric Starting Motor Note Problems with the electric starting motor can be caused by the following conditions malfunctio
71. er material If it is necessary in order to confirm the result compare the air cleaner element to a new air cleaner element that has the same part number Do not use an air cleaner element that has any tears and or holes in the filter material Do not use an air cleaner element with damaged pleats gaskets or seals Discard damaged air cleaner elements Storing Air Cleaner Elements If an air cleaner element that passes inspection will not be used the air cleaner element can be stored for future use Illustration 65 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the air cleaner elements in Volatile Corrosion Inhibited VCI paper 84 Maintenance Section Engine Air Cleaner Service Indicator Inspect SEBU6701 05 Place the air cleaner element into a box for storage For identification mark the outside of the box and mark the air cleaner element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location 101397712 Engine Air Cleaner Service Indicator Inspect SMCS Code 7452 040 A service indicator may be mounted on the air cleaner element or in a remote location ian Illustration 66 g00736586 1 Service indicator Some engines may be equipped w
72. for leaks Check the condition of all connections and components of the exhaust system e Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the engine to frame ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check the condition of the gauges Replace any gauges which are cracked Replace any gauges that can not be calibrated 101105559 Walk Around Inspection Exercise Inspection of Standby Generator Set Engines SMCS Code 1000 040 1 Perform the procedures that are described in this Operation and Maintenance Manual Before Starting Engine topic Operation Section
73. he Specifications SENR3130 Torque Specifications in order to locate the proper torques 8 Refill the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler cap s gaskets Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks 102164888 Hoses and Clamps Replace SMCS Code 1380 510 Note For instructions on draining the cooling system and filling the cooling system see this Operation and Maintenance Manual Cooling System Coolant DEAC Change topic or see the Operation and Maintenance Manual Cooling System Coolant ELC Change topic Maintenance Section 1 Drain the cooling system 102 Maintenance Section Instrument Panel Inspect SEBU6701 05 2 Remove the used hoses and clamps Discard the items 3 Install new hoses and clamps For the correct torque to use on the hose clamps see the Specifications SENR3130 Torque Specifications Hose Clamps topic 4 Fill the cooling system 5 Start the engine Inspect the hose connections for leaks 101048507 Instrument Panel Inspect SMCS Code 7451 040 Inspect the instrument panel for good condition Perform the self test All of the warning lamps should illuminate If a warning lamp does not illuminate replace the bulb immediately If the alarm does not sound investig
74. he metal wrap Cut the filter element free from the end caps Spread apart the pleats and inspect the element for metal debris An excessive amount of debris in the element may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the element Ferrous metals may indicate wear on the steel and the cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts the brass parts or the bronze parts of the engine Parts that may be affected include the following components main bearings rod bearings turbocharger bearings and cylinder heads Aluminum debris may indicate problems with the bearings of the front gears If aluminum debris is found inspect the crankshaft vibration damper and the bearings of the front idler gear Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter element If an excessive amount of debris is found in the oil filter element consult your Caterpillar dealer in order to arrange for further oil analysis Fill the Crankcase NOTICE Only use oils that are recommended by Caterpillar For the proper oil to use refer to this Operation and Maintenance Manual Engine Oil topic Maintenance Section NOTICE If the engine is equipped with an auxiliary oil filter system extra oil must be added when filling the crankcase If equipped with an au
75. ilter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected When the primary air cleaner element is cleaned check for rips or tears in the filter material The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean primary air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are u
76. in Clean the plug and install the plug Close the drain valve Remove the hose from the drain Note Some oil will remain in the housing after the oil has been drained This oil will pour out of the housing when cover 5 is removed Prepare to catch the oil in a suitable container Clean up any spilled oil with absorbent towels or pillows DO NOT use absorbent particles to clean up the oil Personal injury can result from parts and or cov ers under spring pressure Spring force will be released when covers are re moved Be prepared to hold spring loaded covers as the bolts are loosened 3 Be alert to the spring force Gradually loosen but do not remove bolts 4 Before removing the bolts pry the cover 5 loose or tap the cover with a rubber mallet in order to relieve any spring pressure Remove cover 5 g00350932 Illustration 77 Section view of the engine oil filter 5 Cover 6 O ring seal 7 Spring 8 Retainer 9 Oil filter element 4 Remove cover 5 and spring 7 Remove O ring seal 6 retainer 8 and oil filter elements 9 SEBU6701 05 91 Maintenance Section Engine Oil and Filter Change 5 Clean cover 5 spring 7 O ring seal 6 and retainer 8 Clean the inside of the oil filter housing NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in
77. ine oil filters when any of the following conditions occur e Every oil change e The engine oil filter differential pressure reaches 103 kPa 15 psi e The oil filter elements have been used for 1000 service hours Note Do not attempt to clean the used oil filters Used oil filters will retain waste particles The used oil filters would not filter the oil properly Service tools are available to aid in the service of oil filters Consult your Caterpillar dealer for the part names and the part numbers Follow the instructions that are supplied with the service tools If the service tools are not used perform the following appropriate procedure Replacing the Engine Oil Filters With the Engine Stopped Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Perform the following procedure after the oil has been drained Note Use this procedure if the engine oil filters do not have a control valve g00328146 Illustration 76 1 Drain 2 Drain valve Plug 4 Bolts 5 Cover Note Drain the oil into a suitable container Dispose of the oil according to local regulations 1 Connect a hose to drain 1 Place the other end of the hose into a suitable container in order to collect the oil 2 Open drain valve 2 Remove plug 3 Allow the oil to dra
78. ing system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface Refer to two articles in the Disassembly and Assembly Manual Water Temperature Regulators Remove and Water Temperature Regulators Install for the replacement procedure of the water temperature regulator or consult your Caterpillar dealer Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 102871204 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 The crankshaft vibration damper limits the torsional vibration of the crankshaft The visconic damper has a weight that is located inside a fluid filled case Damage to the crankshaft vibration damper or failure of the damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive torsional vibrations 78 Maintenance Section Engine Clean SEBU6701 05 A damper that is hot may be the result of excessive torsion
79. ing System Coolant ELC Change SMCS Code 1350 044 NL Use only clean water to flush the cooling system when ELC Extended Life Coolant is drained and replaced Drain the Cooling System 1 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler if equipped Ensure that the engine will not start when the cooling system is drained 2 Loosen the radiator filler cap slowly in order to relieve any pressure Remove the radiator filler CEJ Illustration 53 g00750410 1 Coolant drain 72 Maintenance Section Cooling System Coolant ELC Change SEBU6701 05 Ip SS Sa eye Illustration 54 g00750411 Locations of the cooling system drain plugs 1 Oil cooler 2 Jacket water pump 3 Engine block Note If the engine has a jacket water heater drain the coolant from the heater 3 Open the coolant drain Remove the cooling system drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the
80. ion Refer to the standards for your engine or consult your Caterpillar dealer in order to determine if your engine is operating within the defined parameters Severe operation can accelerate component wear Engines that are operating under severe conditions may need more frequent maintenance intervals for the following reasons e Maximum reliability e Retention of full service life Because of individual applications it is not possible to identify all of the factors which can contribute to severe operation Consult your Caterpillar dealer about the maintenance that is needed for your specific engine The following factors can contribute to severe operation environment improper operating procedures and improper maintenance practices Environmental Factors Extreme Ambient Temperatures Extended operation in environments that are extremely cold or hot can damage components Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures Extremely hot inlet air reduces the performance capabilities of the engine Note See this Operation and Maintenance Manual Cold Weather Operation topic Operation Section or see Supplement SEBU5898 Cold Weather Recommendations Cleanliness Unless the equipment is cleaned regularly extended operation in a dirty environment and in a dusty environment can damage components Built up mud dirt and dust can encase co
81. ion procedure is the only method acceptable by Caterpillar to reclaim the used coolant 70 Maintenance Section Cooling System Coolant DEAC Change SEBU6701 05 For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools Group Outside U S A 309 675 6277 Inside U S A 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL CSTG COSA Geneva Switzerland 41 22 849 40 56 Clean the Cooling System NOTICE Use of commercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the cooling system drain Clean the cooling system drain plugs and install the cooling system drain plugs NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the radiator filler cap 4 Open the water inlet for the separate circuit aftercooler if equipped Start the engine Operate the engine for a minimum of 30 minutes with a coolant temperature of a
82. it includes the following items a tool for the testing 30 ampoules for testing nitrite instructions and a case 294 7420 Test Kit contains the refill ampoules for the 298 5311 Coolant Nitrite Test Kit Use the instructions that are included with the test kit in order to properly conduct the testing Refer to this Operation and Maintenance Manual Maintenance Interval Schedule for the times at which the procedures should be conducted Test the concentration of the SCA more frequently if more frequent testing is indicated by the results of the S 0 S Coolant Analysis NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration SEBU6701 05 77 Maintenance Section Cooling System Water Temperature Regulator Replace Add the SCA If Necessary Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly 2 If necessary drain some coolant in order to allow space for the addition of the SCA 3 Add the proper amount of SCA For the proper amount of SCA refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic For the proper concentration of SCA refer to Special Publication SEBU6251 Caterpillar Co
83. ith a different service indicator Observe the service indicator Clean the air cleaner element or replace the air cleaner element when the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position e The air restriction reaches 6 kPa 25 inches of H20 Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three pushes Check the movement of the yellow core when the engine is accelerated to the engine rated rpm The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the fitting for the service indicator may be plugged Illustration 67 g00351792 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 Use compressed air or a clean nonflammable solvent The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the
84. ity guidelines Replace The service life of the part is exhausted The part may fail before the next maintenance interval The part must be replaced with a part that meets functional specifications The replacement part may be a new part a CAT remanufactured part a rebuilt part or a used part Some worn components may be exchanged with your Caterpillar dealer for credit on replacement parts Consult your Caterpillar dealer about repair options for your engine If you elect to perform an overhaul without the services of a Caterpillar dealer be aware of the recommendations in Table 20 Your Caterpillar dealer can provide these services and components Table 20 Major Overhaul Instructions Clean Oil suction screen Clean Aftercooler core 2 Inspect Test Inspect Camshafts Cylinder block Crankshaft vibration damper Driven equipment alignment Flywheel Front gear train gears Fuel system linkage Rear gear train gears Inspect Rocker arms Rebuild Inspect Connecting rods Rebuild 3 Replace Cylinder head assemblies Fuel priming pump Fuel transfer pump Oil cooler core Piston pins continued 104 Maintenance Section Overhaul Top End SEBU6701 05 Table 20 contd Major Overhaul Instructions Inspect Camshaft lifters Repl ener Camshaft thrust washers Crankshaft Cylinder liners Engine mounts Engine wiring h
85. l Inspect the gasket If the gasket is damaged replace the gasket 6 Install the bowl 7 Make sure that drain valve 3 is closed 8 For instructions on filling the lubricator see this Operation and Maintenance Manual Air Starting Motor Lubricator Oil Level Check topic 102654969 Air Starting Motor Lubricator Oil Level Check SMCS Code 1451 535 NOTICE Never allow the lubricator bowl to become empty The air starting motor will be damaged by a lack of lubrica tion Ensure that sufficient oil is in the lubricator bowl reste Illustration 47 g01333366 1 Observe the oil level in sight gauge 3 If the oil level is less than 1 2 add oil to the lubricator bowl A WARNING Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved 2 Ensure that the air supply to the lubricator is OFF Slowly loosen filler plug 4 in order to release pressure from the lubricator bowl 3 Remove filler plug 4 Pour oil into the lubricator bowl Use nondetergent SAE 10W oil for temperatures that are greater than 0 C 32 F Use air tool oil for temperatures that are below 0 C 32 F 4 Install filler plug 4 Adjust the Lubricator Note
86. l sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The fluid sampling bottle includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers If the engine is not
87. le for the maintenance intervals Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases consumption is measured in grams per kW h Ib per bhp The brake specific oil consumption BSOC depends on the engine load Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine When an engine s oil consumption has risen to three times the original oil consumption rate due to normal wear an engine overhaul should be scheduled There may be a corresponding increase in blowby and a slight increase in fuel consumption Overhaul Inspection Refer to the Service Manual for the disassembly and assembly procedures that are necessary in order to perform the required maintenance on the items that are listed Consult your Caterpillar dealer for assistance To determine the reusability publications that are needed to inspect the engine refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts The Guidelines For Reusable Parts and Salvage Operations is part of an established Caterpillar parts reusability program These guidelines were developed in order to assist Caterpillar dealers and customers reduce costs by avoiding unnecessary expenditures for new parts If the engine parts
88. ment should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Illustration 62 g00735127 1 Cover 2 Air cleaner element 3 Turbocharger air inlet 1 Remove the air cleaner cover Remove the air cleaner element Note Refer to Cleaning the Air Cleaner Elements 2 Cover the air inlet with tape in order to keep dirt out 3 Clean the inside of the air cleaner cover and body with a clean dry cloth 4 Remove the tape for the air inlet Install an air cleaner element that is new or cleaned 5 Install the air cleaner cover 6 Reset the air cleaner service indicator Cleaning the Air Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the
89. mine if the engine protective devices are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints Ensure that the engine protective devices are functioning properly NOTICE During testing abnormal operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately 102939209 Engine Valve Lash Inspect Adjust SMCS Code 1102 025 Note For procedures on adjusting the valve lash and adjusting the valve bridge see System Systems Operation Testing and Adjusting Valve Lash and Valve Bridge Adjustment Consult your Caterpillar dealer for assistance The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components En
90. mmercial Diesel Engine Fluids Recommendations 4 Clean the cooling system filler cap Install the cooling system filler cap 103645060 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime Refer to this Operation and Maintenance Manual Maintenance Interval Schedule for the proper maintenance interval A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cool
91. mponents This can make maintenance difficult The buildup can contain corrosive chemicals Corrosive chemicals and salt can damage some components Improper Operating Procedures Extended operation at low idle Minimum cool down periods after high load factor operation Operating the engine beyond the guidelines for the engine rating Operating the engine at loads that are greater than the rated load Operating the engine at speeds that are greater than the rated speed e Use of the engine for an application that is not approved Improper Maintenance Practices e Extension of maintenance intervals e Not using recommended fuel lubricants and antifreeze coolant Overhaul Information An overhaul is replacing the major worn components of the engine An overhaul interval is a maintenance interval that is planned The engine is rebuilt with certain rebuilt parts or new parts that replace the worn parts SEBU6701 05 107 Maintenance Section Overhaul Considerations An overhaul also includes the following maintenance e Inspection of all the parts that are visible during the disassembly e Replacement of the seals and gaskets that are removed Cleaning of the internal passages of the engine and the engine block Most owners will save money by overhauling the engine at the intervals that are recommended in this Operation and Maintenance Manual Consider the graph in Illustration 86 Illustratio
92. n 86 g00745964 Y Cost X Time 1 Cost of maintenance and repair that is planned 2 Cost of maintenance and repair that is not planned In Illustration 86 line 1 represents the maintenance and repair costs for an owner that followed the recommendations for inspection maintenance and repair The peaks represent overhauls Line 2 represents the maintenance and repair costs for an owner that chose to operate beyond the recommended intervals The initial cost of the repair after failure philosophy is lower Also the first overhaul was delayed However the peaks are significantly higher than the peaks for the customer that used the repair before failure philosophy The higher peaks result from two key factors e Delaying an overhaul until a breakdown increases the chance of a catastrophic failure This type of failure requires more parts labor and cleanup e Excessive wear means that fewer components will be reusable More labor may be required for salvage or repair of the components When all of the costs are considered repair before failure is the least expensive alternative for most components and engines It is not practical to wait until the engine exhibits symptoms of excessive wear or failure It is not less costly to wait A planned overhaul before failure may be the best value for the following reasons Costly unplanned downtime can be avoided Many original parts can be reused accordi
93. n for engine coolant 2 The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags e Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid
94. n of the solenoid and malfunction of the electric starting system Inspect the electrical system for the following conditions e Loose connections e Corrosion e Wires that are worn or frayed e Cleanliness Make repairs if necessary Air Starting Motor Personal injury or death can result from improp erly checking for a leak Always use a board or cardboard when checking for a leak Escaping air or fluid under pressure even a pin hole size leak can penetrate body tis sue causing serious injury and possible death If fluid is injected into your skin it must be treated immediately by a doctor familiar with this type of injury Inspect all of the components in the air circuit for the starting motor Inspect all of the air lines and connections for leaks If the teeth of the starting motor pinion and or the flywheel ring gear are damaged the air circuit for the starting motor must be examined in order to determine the cause of the problem Removal and Installation of the Starting Motor Refer to the Service Manual Disassembly and Assembly module for information on removing the starting motor and installing the starting motor Consult your Caterpillar dealer for assistance 101261768 Turbocharger Inspect SMCS Code 1052 040 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Fouling of the compressor can contribute to loss of engine power i
95. ncreased black smoke and overall loss of engine efficiency SEBU6701 05 113 Maintenance Section Walk Around Inspection If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel could allow parts from the compressor wheel to enter an engine cylinder This can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require clearances that are precise The turbocharger cartridge must be balanced due to high rpm Severe service applications can accelerate the wear of the components Severe service applications may require more frequent in
96. ng environment and the operating time The sea water that is circulated through the heat exchanger and the amount of operating time affects the following items e Cleanliness of the tubes for the heat exchanger e Effectiveness of the heat exchanger system SEBU6701 05 99 Maintenance Section Heat Exchanger Inspect Operating in water that contains the following will adversely affect the heat exchanger system silt sediment salt and algae In addition intermittent use will adversely affect the heat exchanger system The following items indicate that the heat exchanger may require cleaning e Increased coolant temperature e Engine overheating e Excessive pressure drop between the water inlet and the water outlet An operator that is familiar with the normal operating temperature of the coolant can determine when the coolant temperature is out of the normal range Inspection and maintenance of the heat exchanger are required if the engine is overheating Cleaning the Shell and Tube Heat Exchanger The following general guidelines are for cleaning a shell and tube heat exchanger 1 Drain the heat exchanger 2 Remove the heat exchanger 3 Turn the heat exchanger core upside down in order to remove debris NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended
97. ng to the guidelines for reusable parts The service life of the engine can be extended without the risk of a major catastrophe due to engine failure Achieve the best cost value relationship per hour of extended service life Overhaul Intervals Some factors that are important for determining the overhaul intervals include the following considerations Performance of preventive maintenance Use of recommended lubricants Use of recommended coolants Use of recommended fuels Proper installation Operating conditions e Operation within acceptable limits Engine load e Engine speed Generally engines that are operated at a reduced load and or speed achieve more service life before an overhaul However this is for engines that are properly operated and maintained Other factors must also be considered for determining a major overhaul e The total amount of fuel consumption e The service hours of the engine e An increase of oil consumption e An increase of crankcase blowby e The wear metal analysis of the lube oil e An increase in the levels of noise and vibration 108 Maintenance Section Overhaul Considerations SEBU6701 05 An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced An increase in the levels of noise and vibration indicates that rotating parts require service Note It is possible for oil analysis to indicate a decrease
98. ngines Maintenance Section For the recommended generator maintenance see the Operation and Maintenance Manual for the generator and the control panel Maintenance and Repair The maintenance that is recommended for Every Week can be performed by an authorized operator The maintenance that is recommended for the subsequent maintenance intervals must be performed by an authorized service technician or by your Caterpillar dealer Unless other instructions are provided perform maintenance and repairs under the following conditions e The engine is stopped The starting system is disabled e The generator does not pose an electrical shock hazard Operation To ensure proper operation the generator set must be exercised regularly For instructions on operating the generator set see the Operation and Maintenance Manual for the generator set control panel For these operation procedures follow the instructions that are provided in this Operation and Maintenance Manual Operation Section starting the engine engine operation and stopping the engine 112 Maintenance Section Starting Motor Inspect SEBU6701 05 Record Keeping Maintain a record in order to document these items gauge readings maintenance that is performed problems and repairs Space Heaters Moisture causes damage to generators and other electrical equipment Make every effort to keep the generator set as dry as possible G
99. nspect Connecting rod bearings Cylinder liners Piston crowns and skirts Piston pins Inspect Camshaft lifters Install new Engine wiring harness Inspect Cylinder head assemblies Rebuild 3 Exchange Engine oil pump Fuel priming pump Fuel transfer pump Prelube pump Scavenge oil pump Inspect Fuel pressure regulating Replace valve Pushrods Spacer plates Inspect Rocker arms Rebuild Install new Air inlet manifold gaskets and seals Exhaust manifold seals and bellows Rebuild Turbochargers Exchange 1 For instructions on removal and installation of components see the Service Manual Disassembly and Assembly module 2 For instructions on cleaning the core see this Operation and Maintenance Manual Aftercooler Core Clean Test topic 3 Inspect ONLY TWO of the components from each cylinder bank This inspection will provide adequate examples of the condition of the other corresponding components 106 Maintenance Section Overhaul Considerations SEBU6701 05 102345140 Overhaul Considerations SMCS Code 7595 043 Severe Operation Severe operation is the use of an engine that exceeds current published standards for that engine Caterpillar maintains standards for the following engine parameters e Horsepower e Range of rpm e Fuel consumption Fuel quality e Altitude e Maintenance intervals Selection of oil Selection of coolant e Environmental qualities e Installat
100. ntenance Manual for the generator Before each consecutive interval is performed all of the maintenance requirements from the previous interval must also be performed When Required Engine Air Cleaner Element Dual Element Clean Replace ccccccecceeeeeeceeeeeeeeeeeteeeeeettees 79 Fuel System PMS sireil anaana 94 Heat Exchanger Inspect sesers 98 Sea Water Strainer Clean Inspect 0 05 111 Standby Generator Set Maintenance Recommendations eccccceceeeeeeteeeseetees 111 Every Week Air Starting Motor Lubricator Oil Level Check 64 Air Tank Moisture and Sediment Drain 64 Automatic Start Stop Inspect 0 eee 65 Battery Charger Check 0 eeeececeeeeesseeeeeeeenneeees 67 Battery Electrolyte Level Check n se 67 Cooling System Coolant Level Check 73 Engine Air Cleaner Service Indicator Inspect 84 Engine Air Precleaner Clean 85 Engine Oil Filter Differential Pressure Check 86 Engine Oil Level Check eeeceeeeceeeteeeeeeenneeees 87 Fuel System Fuel Filter Differential Pressure GHECK ATE E E ite E TET 94 Fuel Tank Water and Sediment Drain 97 Instrument Panel Inspect ceeceeeeeeee 102 Jacket Water Heater Check eeee 102 Radiator Clean c ccccecceeeeeeeeeeeceeeeeeeeeeeeeeeeees 110 Starting Motor Inspect i e 112 Walk Aroun
101. onents Protect all electrical components from exposure to water NOTICE Accumulated grease and oil on an engine is a fire haz ard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumulates on the engine Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits e Easy detection of fluid leaks e Maximum heat transfer characteristics e Ease of maintenance Note For more information on cleaning and drying electric generators refer to Special Instruction SEHS9124 Cleaning and Drying of Electric Set Generators 101553486 Engine Air Cleaner Element Dual Element Clean Replace SMCS Code 1051 1054 037 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer
102. osen the magnetic pickup by 180 degrees Tighten the locknut to a torque of 45 7 Nem 33 5 Ib ft 102345114 Overhaul Major SMCS Code 7595 020 MJ Refer to this Operation and Maintenance Manual Overhaul Considerations in order to determine the maintenance interval for a major overhaul The need for a major overhaul is determined by several factors e An increase of oil consumption e An increase of crankcase blowby e The total amount of fuel consumption e The service hours of the engine e The wear metal analysis of the lube oil SEBU6701 05 103 Maintenance Section Overhaul Major e An increase in the levels of noise and vibration An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced An increase in the levels of noise and vibration indicates that rotating parts require service Note It is possible for oil analysis to indicate a decrease of wear metals in the lube oil The cylinder liners may be worn so that polishing of the bore occurs Also the increased use of lube oil will dilute the wear metals Monitor the engine as the engine accumulates service hours Consult your Caterpillar dealer about scheduling a major overhaul Note The driven equipment may also require service when the engine is overhauled Refer to the literature that is provided by the OEM of the driven equipment A major overhaul includes all of the work
103. pect the pump shaft and the impeller for excessive axial movement 6 If wear or damage is found replace the components which are worn or damaged Use the proper repair kit for the pump 101041029 Batteries Replace SMCS Code 1401 510 Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite This can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced 1 Turn the key start switch to the OFF position Remove the key and all electrical loads 2 Turn OFF the battery charger Disconnect the charger 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the ground plane Disconnect the cable from the NEGATIVE battery terminal 4 The POSITIVE cable connects the POSITIVE battery terminal to the starting motor Disconnect the cable from the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Return used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before connecting the cables ensure that the key start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Conne
104. r dealer in order to schedule a before failure overhaul Overhaul Recommendation Caterpillar recommends a scheduled overhaul in order to minimize downtime A scheduled overhaul will provide the lowest cost and the greatest value Schedule an overhaul with your Caterpillar dealer Overhaul programs vary between dealers To obtain specific information about the types of overhaul programs and services consult your Caterpillar dealer i02559063 Radiator Clean SMCS Code 1353 070 Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the radiator for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the radiator if necessary 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 The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the air nozzle is deadheaded Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure fo
105. r cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both sides of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water After cleaning start the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary For more detailed information on cleaning and inspection refer to Special Publication SEBD0518 Know Your Cooling System SEBU6701 05 111 Maintenance Section Sea Water Strainer Clean Inspect 102346696 Sea Water Strainer Clean Inspect if equipped SMCS Code 1371 040 1371 070 The sea water strainer must be clean in order to allow proper engine cooling Check the sea water strainer for plugging Inspect the sea water strainer more frequently in conditions with shallow water or dirty water Refer to the OEM recommendations for more information about inspecting and cleaning the sea water strainer 101038735 Standby Generator
106. r shutoff valve to the open position Turn the power for the engine control to the ON position The left air shutoff valve should close If the left air shutoff valve closes the test is complete If the left air shutoff valve does not close check the switch and the wiring for the left air shutoff valve Note Testing is only complete when the engine successfully passes step 1 through step 4 Hydraulically Actuated Air Shutoff Valves Note After checking the fluids in the engine ensure that both air shutoff valves are latched in the open position Start the engine and operate the engine at 1500 RPM This will allow the fluids to warm up before proceeding with the test for the air shutoff valves SEBU6701 05 63 Maintenance Section Air Starting Motor Lubricator Bowl Clean 1 Manually trip one of the air shutoff valves This should cause an emergency stop condition and the remaining air shutoff valve should close If the engine experienced an emergency stop condition but the remaining valve did not close purge the air from the line that goes to the hydraulic cylinder for the air shutoff valve If the engine did not have an emergency stop condition the switches are not correctly wired into the emergency stop circuit Note Both switches should be in a closed state and both switches should show continuity when the air shutoffs are latched in the open position After the issue with the wiring has been resolved repeat step 1
107. rn the kits to the same address for analysis Hasse amp Wrede GmbH Georg Knorr StraRe 4 12681 Berlin Germany Phone 49 30 9392 3135 Fax 49 30 9392 7 3135 Alternate phone 49 30 9392 3156 Alternate fax 49 30 9392 7 3156 The typical limit for the degradation of the damper fluid viscosity that is used by Hasse amp Wrede GmbH is 20 percent for the majority of applications The reports from Hasse amp Wrede should indicate that the fluid samples meet this viscosity limit Dampers Without Sampling Ports Some dampers do not have a port for a fluid sample These dampers must be rebuilt or the dampers must be replaced when one of the following criteria has been met e The damper has been operated for 20000 hours e The engine is undergoing a major overhaul Removal and Installation Refer to the Disassembly and Assembly Manual Vibration Damper Remove and Install article or consult your Caterpillar dealer for information about damper replacement 101664717 Engine Clean SMCS Code 1000 070 Personal injury or death can result from high volt age Moisture could create paths of electrical conduc tivity Make sure the unit is off line disconnected from utility and or other generators locked out and tagged Do Not Operate SEBU6701 05 79 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace NOTICE Water or condensation can cause damage to gen erator comp
108. rval Engines With a Shallow Sump 3508 104 L 27 US gal Every 250 Service 3512 152 L 40 US gal Meurs 3516 204 L 53 US gal Engines With a Standard Sump 3508 227 L 60 US gal Every 500 Service 3512 318 L 84 US gal Hours 3516 405 L 107 US gal Engines With a Deep Sump 3508 443 L 117 US gal Every 1000 3512 625 L 165 US gal FENE Hoe 3516 807 L 213 US gal Drain the Oil Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed when the cold oil is drained Drain the crankcase when the oil is warm This method allows proper draining of the waste particles that are suspended in the oil Failure to follow this recommended procedure will allow the waste particles to be recirculated through the engine lubrication system with the new oil 1 After the engine has been operated at normal operating temperature STOP the engine NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool C
109. s before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Cat ELC Extender 3 Add Cat ELC Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations article for more information 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 102158408 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Climbing equipment may be required to access this service point Refer to the Operation and Maintenance Manual Mounting and Dismount ing topic for safety information 74 Maintenance Section Cooling System Coolant Sample Level 1 Obtain SEBU6701 05 Engines That Are Equipped With a Sight Gauge fal ATT Illustration 55 g00750429 1
110. s the service life of batteries Use a battery charger that will not overcharge the battery DO NOT charge the battery if the meter of the battery charger is in the RED zone Overcharging is indicated by the following symptoms e The battery is very warm to the touch e A strong odor of acid is present e The battery emits smoke or a dense vapor gas Perform one of the following procedures if the battery shows symptoms of overcharging Reduce the rate of charging by a significant amount Complete the charging at the reduced rate Turn OFF the charger Table 15 describes the effects of overcharging on different types of batteries Table 15 Effects of Overcharging Batteries Type of Battery Effect Caterpillar General Service All of the battery cells have Batteries a low level of electrolyte Caterpillar Premium High Output Batteries When the plates of the battery are inspected through the filler holes the plates may appear to be warped This is caused by an excessive temperature The battery may not pass a load test Caterpillar Maintenance Free Batteries The battery may not accept a charging current The battery may not pass a load test Checking After Stopping Ensure that the battery charger is connected properly Observe the meter of the charger Record the amperage 102601752 Battery Electrolyte Level Check SMCS Code 1401 535 FLV When the engine
111. sed to clean primary air cleaner elements e Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 59 g00281692 Note When the primary air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Primary Air Cleaner Elements SEBU6701 05 81 Maintenance Section Engine Air Cleaner Element Single Element Clean Replace Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements Inspecting the Primary Air Cleaner Elements Illustration 60 g00281693 Inspect the clean dry primary air
112. severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 6 Ensure that the new oil filter elements are in good condition Install the new oil filter elements 7 Inspect the O ring seal Ensure that the surfaces for the O ring seal are clean Install a new O ring seal if the old O ring seal is damaged or deteriorated 8 Install retainer 8 spring 7 and cover 5 Ensure that the retainer and the spring are properly seated between the oil filter elements and the cover 9 Start the engine according to this Operation and Maintenance Manual Starting The Engine procedure Operation Section Check for oil leaks Replace the Spin On Oil Filters Illustration 78 g00396660 Spin on oil filters 1 Remove the spin on oil filter with a 1U 8760 Chain Wrench Illustration 79 g00103713 Mounting base and gasket 2 Clean the sealing surface of the mounting base Ensure that all of the old gasket is removed 3 Apply clean engine oil to the gasket of the new oil filter NOTICE Do 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 to engine components 4 Place the oil filter in position Tighten the oil filter until the gasket cont
113. spect the bore of the turbine housing for corrosion 5 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 6 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 102155206 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks coolant leaks exhaust leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination 114 Maintenance Section Walk Around Inspection SEBU6701 05 NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with st
114. spections of the turbocharger Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine or consult your Caterpillar dealer for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the turbocharger wheel and the turbocharger housing the turbocharger should be reconditioned or replaced 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber 4 In
115. sult from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved 1 Ensure that the air supply to the lubricator is OFF Illustration 46 g01333332 1 Filler plug 2 Bowl 3 Drain valve 2 Slowly loosen filler plug 1 in order to release the pressure from the lubricator NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 3 Place a suitable container under bowl 2 and open drain valve 3 in order to drain the oil from the bowl 4 Remove bowl 2 Clean the bowl with warm water 64 Maintenance Section Air Starting Motor Lubricator Oil Level Check SEBU6701 05 5 Dry the bowl Inspect the bowl for cracks If the bowl is cracked replace the damaged bowl with a new bow
116. sure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance Valve Bridge Check the valve bridge and adjust the valve bridge if necessary Perform the procedure for both valve bridges for each cylinder After the valve bridge is checked for each cylinder proceed with the valve lash adjustment if necessary Engine Valve Lash NOTICE Only qualified service personnel should perform this maintenance Refer to the Systems Operation Testing and Adjusting Manual Valve Lash and Valve Bridge Adjustment article or consult your Caterpillar dealer for the complete valve lash adjustment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life The valve bridge adjustment must be performed before making a valve lash adjustment If the valve lash is within the tolerance an adjustment of the valve lash is NOT necessary 94 Maintenance Section Fan Drive Bearing Lubricate SEBU6701 05 For the valve lash setting see the engine s Specifications manual For the procedure to set the valve lash see the engine s Systems Operation Testing
117. t least 82 C 180 F 5 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler if equipped Loosen the radiator filler cap slowly in order to relieve any pressure Remove the radiator filler cap Open the coolant drain Remove the cooling system drain plugs Allow the water to drain NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 6 Flush the cooling system with clean water until the water that drains is clean Close the coolant drain Clean the cooling system drain plugs and install the cooling system drain plugs Open the water inlet for the separate circuit aftercooler if equipped Cleaning a Cooling System that has Heavy Deposits or Plugging Note For the following procedure to be effective there must be an active flow through the cooling system components 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the coolant drain Clean the cooling system drain plugs and install the cooling system drain plugs 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1
118. that is done for the top end overhaul A major overhaul includes additional parts and labor Additional parts and labor are required in order to completely rebuild the engine For the major overhaul all of the bearings seals gaskets and components that wear are disassembled The parts are cleaned and inspected If necessary the parts are replaced The crankshaft is measured for wear The crankshaft may require regrinding Alternatively the crankshaft may be replaced with a Caterpillar replacement part Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications The following definitions explain the terminology for the services that are performed during an overhaul Inspect Inspect the components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures New parts are not required if the existing parts can still be used reconditioned or repaired If the components are not in the reusability guidelines refer to the Service Manual Specifications module Rebuild The component can be reconditioned in order to comply with reusabil
119. the gaskets are damaged replace the old cooling system filler cap with a new cooling system filler cap Install the cooling system filler cap 4 Start the engine Inspect the cooling system for leaks 102837191 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Note Obtaining a Coolant Sample Level 1 is optional if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC This includes the following types of coolants e Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat DEAC Diesel Engine Antifreeze Coolant e Commercial heavy duty coolant antifreeze SEBU6701 05 75 Maintenance Section Cooling System Coolant Sample Level 2 Obtain Table 16 Recommended Interval Type of Coolant Level 1 Level 2 Every 250 Cat DEAC Hours Yearly 0 Cat ELC Optional Yearly 1 This is the recommended interval for coolant samples for all conventional heavy duty coolant antifreeze This is also the recommended interval for coolant samples of commercial coolants that meet the Cat EC 1 specificatio
120. the engine until the oil pressure gauge indicates 70 kPa 10 psi Open the fuel supply line Allow the starting motor to cool for two minutes before cranking again 3 Follow this Operation and Maintenance Manual Starting The Engine procedure Operation Section Operate the engine at low idle for two minutes This will ensure that the lubrication system has oil and that the oil filters are filled with oil Inspect the engine for oil leaks Ensure that the oil level is at the FULL mark on the LOW IDLE side of the oil level gauge 4 Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes SEBU6701 05 93 Maintenance Section Engine Performance Test 5 Remove the oil level gauge and check the oil level Maintain the oil level to the FULL mark on the ENGINE STOPPED side of the oil level gauge 101042067 Engine Performance Test SMCS Code 1000 081 Operate the engine for a minimum of two hours at a minimum load of 60 percent e Monitor the operation of the generator set e Observe the gauges Ensure that the gauges are in the normal ranges e Record the data Maintain a record of the data for the engine performance 100626013 Engine Protective Devices Check SMCS Code 7400 535 Alarms and shutoffs must function properly Alarms provide timely warning to the operator Shutoffs help to prevent damage to the engine It is impossible to deter
121. the procedure For more information on cleaning the core consult your Caterpillar dealer Plate Type Heat Exchanger The interval for the maintenance of the plate type heat exchanger depends on the operating environment and the operating time The sea water that is circulated through the heat exchanger and the amount of operating time affects the following items e Cleanliness of the heat exchanger plates e Effectiveness of the heat exchanger system Operating in water that contains the following will adversely affect the heat exchanger system silt sediment salt and algae In addition intermittent use will adversely affect the heat exchanger system The following items indicate that the heat exchanger may require cleaning e Increased coolant temperature e Engine overheating e Excessive pressure drop between the water inlet and the water outlet 100 Maintenance Section Hoses and Clamps Inspect Replace SEBU6701 05 An operator that is familiar with the normal operating temperature of the coolant can determine when the coolant temperature is out of the normal range Inspection of the heat exchanger and maintenance of the heat exchanger are required if the engine is overheating Your Caterpillar dealer has the equipment and the personnel in order to measure the pressure drop across the heat exchanger Cleaning the Plate Type Heat Exchanger The following general guidelines are for cleaning a plate type heat
122. this Operation and Maintenance Manual Refill Capacities and Recommendations Maintenance Section NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze After filling the cooling system do not install the radiator filler cap 2 Open the water inlet for the separate circuit aftercooler if equipped Start the engine Operate the engine in order to purge the air from the cavities of the engine block Allow the coolant to warm and allow the coolant level to stabilize Stop the engine 3 Check the coolant level Maintain the coolant to the proper level on the sight gauge if equipped If a sight gauge is not equipped maintain the coolant within 13 mm 5 inch below the bottom of the filler pipe 4 Clean the radiator filler cap Inspect the gaskets of the radiator filler cap If the gaskets of the radiator filler cap are damaged discard the old radiator filler cap and install a new radiator filler cap If the gaskets of the radiator filler cap are not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the radiator filler cap The correct pressure is stamped on the face of the radiator filler cap If the radiator filler cap does not maintain the correct pressure install a new radiator filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 102417402 Cool
123. uld be removed and discarded for every three cleanings of the primary air cleaner element When the engine is operating in environments that are dusty or dirty air cleaner elements may require more frequent replacement Illustration 58 g00736431 1 Cover 2 Primary air cleaner element 3 Secondary air cleaner element 4 Turbocharger air inlet 80 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace SEBU6701 05 1 Remove the cover Remove the primary air cleaner element 2 The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element Note Refer to Cleaning the Primary Air Cleaner Elements 3 Cover the turbocharger air inlet with tape in order to keep dirt out 4 Clean the inside of the air cleaner cover and body with a clean dry cloth 5 Remove the tape for the turbocharger air inlet Install the secondary air cleaner element Install a primary air cleaner element that is new or cleaned 6 Install the air cleaner cover 7 Reset the air cleaner service indicator Cleaning the Primary Air Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the f
124. umption for 3516 and 3516B Engines Top End Overhaul 1 942 000 L 512 500 US gal Second Top End 3 884 000 L 1 025 000 US gal Overhaul Major Overhaul 5 826 000 L 1 537 500 US gal Table 26 The oil consumption rate brake specific oil Equation For Calculating Overhaul Intervals F R H 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 H is the number of estimated hours until the overhaul interval Use the actual records of fuel consumption when possible If the actual records are not available use the following procedure in order to estimate the fuel consumption 1 Estimate the average percent of the load for the operation of the engine 2 Refer to the fuel consumption data in the Technical Marketing Information TMI for your engine This will determine the fuel consumption for the percent of the load that was estimated in Step 1 Use this figure as variable F for the equation in Table 26 For more information about the Technical Marketing Information TMI for your engine consult your Caterpillar dealer Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitab
125. xiliary oil filter system that is not supplied by Caterpillar follow the recommendations of the OEM NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can cause the crankshaft to dip into the oil This will reduce the power that is devel oped and also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling oil blowing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber De posits in the combustion chamber lead to the following problems guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately 1 Remove the oil filler cap Fill the crankcase through the oil filler tube only For the amount of oil to use refer to this Operation and Maintenance Manual Refill Capacities Maintenance Section Clean the oil filler cap Install the oil filler cap NOTICE To prevent crankshaft or bearing damage crank en gine with fuel off to fill all filters before starting Do Not crank engine for more than 30 seconds 2 Close the fuel supply line and crank

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