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3512 Industrial Engine-Maintenance Intervals PDF
3512 Industrial Engine-Maintenance Intervals PDF
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3512 INDUSTRIAL
ENGINES
Maintenance Intervals
2007 Caterpillar
All Rights Reserved
63
Maintenance Section
Maintenance Interval Schedule
Air Starting Motor Lubricator Oil Level - Check .... 66 Overhaul (Top End) ............................................... 95
Cooling System Coolant Level - Check ................ 72 Overhaul Considerations ...................................... 96
Driven Equipment - Inspect/Replace/Lubricate ... 75
Engine Air Cleaner Service Indicator - Inspect ..... 79 Every 6000 Service Hours or 6 Years
Engine Air Precleaner - Clean .............................. 80
Alternator - Inspect ............................................... 66
Engine Oil Level - Check ...................................... 82
Cooling System Coolant (ELC) - Change ............. 70
Fuel System Primary Filter/Water Separator - Cooling System Water Temperature Regulator -
Drain ................................................................... 88
Replace ............................................................... 74
Fuel Tank Water and Sediment - Drain ................. 89
Magnetic Pickups - Clean/Inspect ........................ 93
Instrument Panel - Inspect .................................... 90 Starting Motor - Inspect ........................................ 99
Walk-Around Inspection ...................................... 100
Water Pump - Inspect ......................................... 101
Initial 250 Service Hours Every 18 000 Service Hours
Engine Valve Lash - Inspect/Adjust ...................... 86
Overhaul (Major) ................................................... 93
Fuel Injector - Inspect/Adjust ................................ 86
Overhaul Considerations ...................................... 96
Magnetic Pickups - Clean/Inspect ........................ 93
i00855723
Loose connections
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.
Adjust the Lubricator Check the drive belt tension according to the
information in the Service Manual, Systems
Note: Adjust the lubricator with a constant rate of air Operation/Testing and Adjusting.
flow. After the adjustment, the lubricator will release
oil in proportion to variations of the air flow. Replacement
1. Ensure that the fuel supply to the engine is OFF. For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
NOTICE one drive belt of a matched set will cause the new
Do not crank the engine continuously for more than drive belt to carry more load because the older drive
30 seconds. Allow the starting motor to cool for two belts are stretched. The additional load on the new
minutes before cranking the engine again. drive belt could cause the new drive belt to fail.
Batteries - Replace
SMCS Code: 1401-510
1. Remove the drive belt guard. 1. Turn the key start switch to the OFF position.
Remove the key and all electrical loads.
2. Loosen mounting bolt (2) and adjusting nuts (1).
2. Turn OFF the battery charger. Disconnect the
3. Turn adjusting nuts (1) in order to increase or charger.
decrease the drive belt tension.
3. The NEGATIVE - cable connects the NEGATIVE
4. Tighten adjusting nuts (1). Tighten mounting bolt - battery terminal to the ground plane. Disconnect
(2). Refer to the Operation and Maintenance the cable from the NEGATIVE - battery terminal.
Manual for the proper torques.
4. The POSITIVE + cable connects the POSITIVE
5. Reinstall the drive belt guard. + battery terminal to the starting motor.
Disconnect the cable from the POSITIVE +
If new drive belts are installed, check the drive belt battery terminal.
tension again after 30 minutes of engine operation at
the rated rpm. Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
recycling facility.
Fan Drive Belt Adjustment
5. Remove the used battery.
1. Loosen the mounting bolt for the pulley.
6. Install the new battery.
2. Loosen the adjusting nut for the pulley.
Note: Before connecting the cables, ensure that the
3. Move the pulley in order to adjust the belt tension. key start switch is OFF.
4. Tighten the adjusting nut. 7. Connect the cable from the starting motor to the
POSITIVE + battery terminal.
5. Tighten the mounting bolt.
8. Connect the cable from the ground plane to the
NEGATIVE - battery terminal.
68
Maintenance Section
Battery Electrolyte Level - Check
i01206348 i00849995
When the engine is not run for long periods of time or Clean the cooling system before the recommended
when the engine is run for short periods, the batteries maintenance interval if the following conditions exist:
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries The engine overheats frequently.
are properly charged, ammeter reading should be
very near zero. Foaming is observed.
Oil has entered the cooling system and the coolant
is contaminated.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
Fuel has entered the cooling system and the
coolant is contaminated.
shield and protective clothing when working on or
near batteries.
Drain the Cooling System
1. Remove the filler caps. Maintain the electrolyte 1. Stop the engine and allow the engine to cool.
level to the FULL mark on the battery. Ensure that the engine will not start when the
cooling system is drained.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean 2. Loosen the cooling system filler cap slowly in
water that is low in minerals. Do not use artificially order to relieve any pressure. Remove the cooling
softened water. system filler cap.
2. Check the condition of the electrolyte with the
1U-7298 Coolant/Battery Tester (C) or the
1U-7297 Coolant/Battery Tester (F).
For information regarding the disposal and the Cleaning a Cooling System that
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology
has Heavy Deposits or Plugging
Group:
Note: For the following procedure to be effective,
there must be an active flow through the cooling
Outside Illinois: 1-800-542-TOOL
system components.
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
1. After the cooling system has been drained, flush
the cooling system with clean water in order to
Clean the Cooling System remove any debris.
1. After the cooling system has been drained, flush 2. Close the cooling system drain valves (if
the cooling system with clean water in order to equipped). Clean drain plugs and install drain
remove any debris. plugs (1) and (2). See Illustration 25.
2. Close the cooling system drain valves (if 3. Fill the cooling system with a mixture of clean
equipped). Clean the drain plugs and install the water and Caterpillar Fast Acting Cooling System
drain plugs. Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
(1 to 2 US gal) of the cooling system capacity.
NOTICE Install the cooling system filler cap.
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo- 4. Start the engine. Operate the engine for a
nents. Use only cooling system cleaners that are ap- minimum of 90 minutes with a coolant temperature
proved for Caterpillar engines. of at least 82 C (180 F).
To avoid damage to the cooling system, make sure Fill the Cooling System
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone. NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
6. Allow the water to drain. Flush the cooling system
with clean water until the water that drains is
clean. Close the cooling system drain valves (if
equipped). Clean the drain plugs and install the
drain plugs.
70
Maintenance Section
Cooling System Coolant (ELC) - Change
4. Clean the cooling system filler cap. Inspect the Full Level I analysis
gaskets of the cooling system filler cap. If the
gaskets of the cooling system filler cap are Identification of the source of metal corrosion and
damaged, discard the old cooling system filler cap of contaminants
and install a new cooling system filler cap. If the
gaskets of the cooling system filler cap are not Identification of buildup of the impurities that cause
damaged, use a 9S-8140 Pressurizing Pump in corrosion
order to pressure test the cooling system filler cap.
The correct pressure is stamped on the face of Identification of buildup of the impurities that cause
the cooling system filler cap. If the cooling system scaling
filler cap does not maintain the correct pressure,
install a new cooling system filler cap. Determination of possible electrolysis within the
engines cooling system
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature. A report of the results of the analysis is provided.
Maintenance recommendations are based on the
results.
i00259474
4. Clean the cooling system filler cap. Inspect the Add Coolant
cooling system filler cap gaskets. Replace the
cooling system filler cap if the cooling system Note: For the proper coolant mixture to use, see
filler cap gaskets are damaged. Install the cooling this Operation and Maintenance Manual, Coolant
system filler cap. Recommendations topic (Maintenance Section).
Cooling System Coolant Level 2. Remove the cooling system filler cap slowly in
order to relieve any pressure. Pour the proper
- Check coolant mixture into the filler pipe.
g00103639
Illustration 28
Filler cap gaskets
73
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
3. Clean the cooling system filler cap. Inspect the SOS Coolant Analysis (Level I)
gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling Level I is a basic analysis of the coolant. The
system filler cap with a new cooling system filler following items are tested: SCA concentration, glycol
cap. Install the cooling system filler cap. concentration, pH, and conductivity.
4. Start the engine. Inspect the cooling system for The results are reported, and recommendations
leaks. are made according to the results. Consult your
Caterpillar dealer for information on the benefits of
managing your equipment with an SOS analysis.
i01065856
b. For cooling systems that use only a mixture Refer to the Service Manual for the replacement
of water and SCA, see this Operation and procedure of the water temperature regulator, or
Maintenance Manual, Water/Supplemental consult your Caterpillar dealer.
Coolant Additive (SCA) topic (Maintenance
Section). Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to
4. Clean the cooling system filler cap. Install the a level that is below the water temperature regulator
cooling system filler cap. housing.
i00912898 i00767300
NOTICE If the fluid leak is oil, inspect the crankshaft seals for
Failure to replace your water temperature regulator leaks. If a leak is observed, replace all of the seals.
on a regularly scheduled basis could cause severe
engine damage. Inspect the damper and repair or replace the damper
for any of the following reasons.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water The damper is dented, cracked, or leaking.
temperature regulator installed.
The paint on the damper is discolored from heat.
If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder head The engine has had a failure because of a broken
damage. Ensure that the new water temperature reg- crankshaft.
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open. An analysis of the oil has revealed that the front
bearing of the crankshaft is badly worn.
Do not use liquid gasket material on the gasket or
cylinder head surface. There is a large amount of gear train wear that is
not caused by a lack of oil.
75
Maintenance Section
Driven Equipment - Check
NOTICE
i00449093
Accumulated grease and oil on an engine is a fire haz-
Driven Equipment - Check ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
SMCS Code: 3279-535 the engine.
To minimize bearing problems and vibration of the Steam cleaning the engine will remove accumulated
engine crankshaft and the driven equipment, the oil and grease. A clean engine provides the following
alignment between the engine and driven equipment benefits:
must be maintained properly.
Easy detection of fluid leaks
Check the alignment according to the instructions
that are provided by the following manufacturers: Maximum heat transfer characteristics
Caterpillar Ease of maintenance
OEM of the coupling
i00174810
Inspect/Replace/Lubricate NOTICE
Never run the engine without an air cleaner element
SMCS Code: 3279-040
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
Observe the driven equipment during operation. Look
damaged pleats, gaskets or seals. Dirt entering the
for the following items:
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
Unusual noise and vibration borne debris from entering the air inlet.
Loose connections
NOTICE
Damaged parts Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Perform any maintenance that is recommended
by the OEM of the driven equipment. Refer to the
literature of the OEM of the driven equipment for the Servicing the Air Cleaner Elements
following service instructions.
If the air cleaner element becomes plugged, the air
Inspection can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
Lubricating grease and lubricating oil requirements wear. Your Caterpillar dealer has the proper air
cleaner elements for your application. Consult your
Specifications for adjustment Caterpillar dealer for the correct air cleaner element.
Replacement of components Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt
Requirements for ventilation and debris, as needed.
The air cleaner element may be cleaned up to Note: Refer to Cleaning the Primary Air Filter
six times if the element is properly cleaned and Elements.
inspected.
3. Cover the turbocharger air inlet with tape in order
The air cleaner element should be replaced at least to keep dirt out.
one time per year. This replacement should be
performed regardless of the number of cleanings. 4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
Replace the dirty paper air cleaner elements with
clean air cleaner elements. Before installation, the 5. Remove the tape for the turbocharger air inlet.
air cleaner elements should be thoroughly checked Install the secondary air cleaner element. Install a
for tears and/or holes in the filter material. Inspect primary air cleaner element that is new or cleaned.
the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner 6. Install the air cleaner cover.
elements for replacement purposes.
7. Reset the service indicator.
Dual Element Air Cleaners
Cleaning the Primary Air Cleaner
The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner Elements
element. The primary air cleaner element can be
used up to six times if the element is properly cleaned The primary air cleaner element can be used up
and inspected. The primary air cleaner element to six times if the element is properly cleaned and
should be replaced at least one time per year. This inspected. When the primary air cleaner element is
replacement should be performed regardless of the cleaned, check for rips or tears in the filter material.
number of cleanings. The primary air cleaner element should be replaced
at least one time per year. This replacement should
The secondary air cleaner element is not serviceable be performed regardless of the number of cleanings.
or washable. The secondary air cleaner element
should be removed and discarded for every three Use clean primary air cleaner elements while dirty
cleanings of the primary air cleaner element. When elements are being cleaned.
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more NOTICE
frequent replacement. 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.
Pressurized water
g00123209
Illustration 29
(1) Cover. (2) Primary air cleaner element. (3) Secondary air Pressurized air
cleaner element. (4) Turbocharger air inlet.
Vacuum cleaning
1. Remove the cover. Remove the primary air
cleaner element. Washing with nonsudsing detergent
2. The secondary air cleaner element should be
removed and discarded for every three cleanings
of the primary air cleaner element.
77
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Date cleaned
Number of cleanings
g00281693 Store the box in a dry location.
Illustration 31
For more detailed information on cleaning the primary
Inspect the clean, dry primary air cleaner element. air cleaner element, refer to Special Publication,
Use a 60 watt blue light in a dark room or in a similar SEBF8062, Procedure to Inspect and Clean Air
facility. Place the blue light in the primary air cleaner Filters.
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears
and/or holes. Inspect the primary air cleaner element i00736823
for light that may show through the filter material. If it
is necessary in order to confirm the result, compare Engine Air Cleaner
the primary air cleaner element to a new primary air
cleaner element that has the same part number.
Element (Single Element) -
Inspect/Replace
Do not use a primary air cleaner element that has
any tears and/or holes in the filter material. Do not SMCS Code: 1054-040; 1054-510
use an primary air cleaner element with damaged
pleats, gaskets or seals. Discard damaged primary NOTICE
air cleaner elements. Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
Storing Primary Air Cleaner Elements cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
If a primary air cleaner element that passes inspection engine causes premature wear and damage to engine
will not be used, the primary air cleaner element can components. Air cleaner elements help to prevent air-
be stored for future use. 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.
79
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Servicing the Air Cleaner Elements 4. Remove the tape for the air inlet. Install an air
cleaner element that is new or cleaned.
If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element. 5. Install the air cleaner cover.
Unfiltered air will drastically accelerate internal engine
wear. Your Caterpillar dealer has the proper air 6. If necessary, reset the air cleaner service indicator.
cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.
i00823657
g00287039
g00351792 Illustration 36
Illustration 35
Typical precleaner
Porous filter
(1) Wing nut
(2) Cover
A porous filter is part of a fitting that is used for (3) Body
mounting of the service indicator. Inspect the filter
for cleanliness. Clean the filter, if necessary. Use Remove wing nut (1) and cover (2). Check for an
compressed air or a clean, nonflammable solvent. accumulation of dirt and debris in body (3). Clean the
body, if necessary.
The service indicator may need to be replaced
frequently in environments that are severely dusty, if After cleaning the precleaner, install cover (2) and
necessary. Replace the service indicator annually wing nut (1).
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and Note: When the engine is operated in dusty
whenever major engine components are replaced. applications, more frequent cleaning is required.
Note: When a new service indicator is installed,
excessive force may crack the top of the service i01225429
indicator. Tighten the service indicator to a torque
of 2 Nm (18 lb in). Engine Crankcase Breather -
Clean
SMCS Code: 1317-070
g00597465
Illustration 38 i00855827
3. Remove O-ring seals (4) from the valve covers. Engine Mounts - Check
Inspect the O-ring seals for good condition. Obtain
new O-ring seals, if necessary. SMCS Code: 1152-535
Improper mounting
Loose bolts
Deterioration of the isolators
Ensure that the mounting bolts are tightened
to the proper torque. For standard torques, see
g00597466
Illustration 39 this Operation and Maintenance Manual, Torque
Specifications (Maintenance Section).
4. Remove two clamps (6). Remove both breathers
(5) from hose tee (7).
82
Maintenance Section
Engine Oil Level - Check
Ensure that the isolators are free of oil and a. If the engine is stopped, remove the oil level
contamination. Inspect the isolators for deterioration. gauge. Observe the oil level on ENGINE
Ensure that the bolts for the isolators are tightened to STOPPED WITH OIL COLD side (3).
the proper torque.
b. If the engine is operating, reduce the engine
Replace any isolator that shows deterioration. For speed to low idle. Remove the oil level gauge
more information, see the literature that is provided and observe the oil level on ENGINE AT LOW
by the OEM of the isolators. Also see the Application IDLE WITH WARM OIL side (4).
and Installation Guide for the engine. Consult your
Caterpillar dealer for assistance. The oil level should be between ADD mark
(5) and FULL mark (6).
i01071237
NOTICE
Engine Oil Level - Check Engine damage can occur if the crankcase is filled
above the FULL mark on the oil level gauge (dip-
SMCS Code: 1348-535-FLV stick).
The most accurate check of the oil level is An overfull crankcase can enable the crankshaft to
obtained when the engine is stopped. Perform this dip into the oil. This will reduce the power that is de-
maintenance on a surface that is as level as possible. veloped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oils ability to lubricate, reduction of oil
pressure, inadequate cooling of the pistons, oil blow-
ing out of the crankcase breathers, and excessive oil
consumption.
If the oil level is above the FULL mark on the oil level
gauge, drain some of the oil immediately.
g00424658
Illustration 40
(1) Oil filler
2. If necessary, remove oil filler cap (2) and add
(2) Oil level gauge oil. For the correct oil to use, see this Operation
and Maintenance Manual, Engine Oil topic
(Maintenance Section). Do not fill the crankcase
above the FULL mark on the oil level gauge.
Clean the oil filler cap. Install the oil filler cap.
i01070756
Obtain the Sample and the Analysis If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to For instructions, see Special Publication, PEHP6001,
contact the skin. How To Take A Good Oil Sample. Consult your
Caterpillar dealer for complete information and
Before you take the oil sample, complete the Label, assistance in establishing an SOS program for your
PEEP5031 for identification of the sample. In order engine.
to help obtain the most accurate analysis, provide
the following information: i00854772
A small residue of either type sample may remain in Note: Drain the oil into a suitable container. Dispose
the pump and may cause a false positive analysis for of the oil according to local regulations.
the sample being taken.
g00425765 g00103713
Illustration 42 Illustration 44
Oil drain Mounting base and gasket
a. Open oil drain (1). After the oil has drained, 2. Clean the sealing surface of the mounting base.
close the oil drain. Ensure that all of the old gasket is removed.
1. Remove the oil filter with a 1U-8760 Chain An excessive amount of debris in the element may
Wrench. indicate early wear or a pending failure.
Ferrous metals may indicate wear on the steel and 2. Clean the oil filler cap. Install the oil filler cap.
the cast iron parts of the engine. Nonferrous metals
may indicate wear on the aluminum parts, the brass NOTICE
parts, or the bronze parts of the engine. Parts that To prevent crankshaft or bearing damage, crank en-
may be affected include the following components: gine with fuel off to fill all filters before starting.
main bearings, rod bearings, turbocharger bearings,
and cylinder heads. Do Not crank engine for more than 30 seconds.
Due to normal wear and friction, it is not uncommon
to find small amounts of debris in the oil filter. If an 3. Close the fuel supply line and crank the engine
excessive amount of debris is found, consult your until the oil pressure gauge indicates 70 kPa
Caterpillar dealer in order to arrange for further oil (10 psi). Open the fuel supply line.
analysis.
Allow the starting motor to cool for two minutes
Fill the Crankcase before cranking again.
1. Remove the oil filler cap. Fill the crankcase A calibration check of the engine protective devices
through the oil filler tube only. will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective
For the amount of oil to use, see this Operation devices are functioning properly.
and Maintenance Manual, Refill Capacities topic
(Maintenance Section).
86
Maintenance Section
Engine Valve Lash - Inspect/Adjust
The tests must be performed correctly in order to pre- Perform the valve lash setting when the engine is
vent possible damage to the engine. cold. After the engine has been shut down and the
valve covers are removed, the engine is considered
cold. Before performing maintenance, prevent the
To prevent damage to the engine, only authorized entry of foreign matter into the top of the cylinder
service personnel or your Caterpillar dealer should head and the valve mechanism. Thoroughly clean
perform the tests. the area around the valve mechanism covers.
Visual Inspection For the valve lash setting, see this Operation and
Maintenance Manual, Engine Description topic
Visually check the condition of all gauges, sensors (Product Information Section).
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring i01225410
or components should be repaired or replaced
immediately. Fuel Injector - Inspect/Adjust
SMCS Code: 1290-025
i01071128
Engine Valve Lash - Note: Perform this procedure when the engine valve
lash is inspected.
Inspect/Adjust
SMCS Code: 1102-025 NOTICE
The camshafts must be correctly timed with the crank-
Note: For procedures on adjusting the valve shaft before an adjustment of the lash for the fuel in-
bridge and adjusting the engine valve lash, see the jector is made. The timing pins must be removed from
Service Manual, Systems Operation/Testing and the camshafts before the crankshaft is turned or dam-
Adjusting module. Consult your Caterpillar dealer age to the cylinder block will be the result.
for assistance.
Inspect the adjustment of the lash for the fuel injector
Valve Bridge according to the Systems Operation/Testing And
Adjusting, Fuel System topic. Adjust the lash for the
Check the valve bridge and adjust the valve bridge, fuel injector, if necessary.
if necessary. Perform the procedure for both valve
bridges for each cylinder. After the valve bridge is i00850285
checked for each cylinder, proceed with the valve
lash adjustment, if necessary. Fuel System - Prime
Engine Valve Lash SMCS Code: 1250-548; 1258-548
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
g00421659
Illustration 45
(1) Fuel priming pump plunger
1. Stop the engine. Ensure that the engine will not 8. Install the nut.
start during this procedure.
9. Open the fuel supply valve.
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.
88
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543 Note: It may be necessary to prime the fuel system
before the engine will start. See this Operation and
Maintenance Manual, Fuel System - Prime topic
(Maintenance Section).
NOTICE
NOTICE
The water separator is under suction during normal
Do not allow dirt to enter the fuel system. Thoroughly
engine operation. Ensure that the drain valve is tight-
clean the area around a fuel system component that
ened securely to help prevent air from entering the fuel
will be disconnected. Fit a suitable cover over discon-
system.
nected fuel system component.
i00787902
Fuel tanks should contain some provision for draining Inspect all hoses for leaks that are caused by the
water and draining sediment from the bottom of the following conditions:
fuel tanks.
Cracking
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close Softness
the drain valve.
Loose clamps
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain Replace hoses that are cracked or soft. Tighten any
the water and sediment from the fuel tank after the loose clamps.
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
90
Maintenance Section
Instrument Panel - Inspect
End fittings that are damaged or leaking 5. Disconnect the old hose.
Outer covering that is chafed or cut 6. Replace the old hose with a new hose.
Exposed wire that is used for reinforcement Note: For torques on hose clamps, see this Operation
and Maintenance Manual, Torque Specifications
Outer covering that is ballooning locally (Maintenance Section).
Flexible part of the hose that is kinked or crushed 7. Install the hose clamps with a torque wrench.
Armoring that is embedded in the outer covering Note: For the proper coolant to use, see this
Operation and Maintenance Manual, Coolant
A constant torque hose clamp can be used in place Recommendations (Maintenance Section).
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard 8. Refill the cooling system.
clamp.
9. Clean the cooling system filler cap. Inspect the
Due to extreme temperature changes, the hose will cooling system filler caps gaskets. Replace
heat set. Heat setting causes hose clamps to loosen. the cooling system filler cap if the gaskets are
This can result in leaks. A constant torque hose damaged. Install the cooling system filler cap.
clamp will help to prevent loose hose clamps.
10. Start the engine. Inspect the cooling system for
Each installation application can be different. The leaks.
differences depend on the following factors:
Table 33
Engine Performance
Engine Serial Number Authorization
Date
Engine hours
Engine rpm
Percent of load
Ambient temperature
Inlet manifold air temperature
Inlet manifold air pressure
Air restriction (left)
Air restriction (right)
Jacket water temperature
Engine oil temperature
Engine oil pressure
Fuel pressure
Fuel filter differential pressure
Exhaust manifold temperature (left)
Exhaust manifold temperature (right)
Cylinder temperature (1)
Cylinder temperature (2)
Cylinder temperature (3)
Cylinder temperature (4)
Cylinder temperature (5)
Cylinder temperature (6)
Cylinder temperature (7)
Cylinder temperature (8)
Cylinder temperature (9)
Cylinder temperature (10)
Cylinder temperature (11)
Cylinder temperature (12)
Auxiliary Equipment
Transmission oil pressure
Transmission oil temperature
Comments
93
Maintenance Section
Magnetic Pickups - Clean/Inspect
A major overhaul includes the work that is done for Piston pins
a top end overhaul. All other parts that are visible
during the major overhaul are completely inspected. Prelube pump
The seals and gaskets that are exposed are also
replaced. The internal passages of the engine are Scavenge oil pump
cleaned.
Turbochargers
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure Inspection of Components
that the components are operating within the
appropriate specifications. Inspect the following components according to
the instructions that are in Caterpillar reusability
If you elect to perform an overhaul without the publications. Refer to Guidelines for Reusable
services of a Caterpillar dealer, be aware of the Parts and Salvage Operations, SEBF8029, Index
following recommendations. of Publications on Reusability or Salvage of Used
Parts.
Camshaft
94
Maintenance Section
Overhaul (Major)
damage to the journals 3. Back flush the core internally with cleaner in order
to loosen foreign substances. This will also help
bearing material that has seized to the journals to remove oil.
Check the journal taper and the profile of the Note: Hydrosolv Liquid Cleaners are recommended.
crankshaft journals. Check these components by Table 34 lists the Hydrosolv Liquid Cleaners that are
interpreting the wear patterns on the following available from your Caterpillar dealer.
components:
Table 34
rod bearing Hydrosolv Liquid Cleaners(1)
i00868225
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow. Overhaul (Top End)
7. Inspect the components in order to ensure SMCS Code: 7595-020-TE
cleanliness. Pressure test the core. Many shops
that service radiators are equipped to perform
pressure tests. Repair the core, if necessary. Cylinder Head Assembly
Install the core.
Inspect the cylinder head assembly according to
the instructions that are in Caterpillar reusability
Obtain Coolant Analysis publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, Index
The concentration of supplemental coolant additive
of Publications on Reusability or Salvage of Used
(SCA) should be checked regularly with test kits. The
Parts.
concentration of SCA can also be checked with an
SOS coolant analysis (Level I). A more detailed
Your Caterpillar dealer can provide these services
coolant analysis is recommended periodically.
and components. Your Caterpillar dealer can ensure
that the components are operating within the
For example, considerable deposits are found in the
appropriate specifications.
water jacket areas on the external cooling system,
but the concentrations of coolant additives were
The use of out-of-spec parts will cause unscheduled
carefully maintained. The coolant water probably
downtime and/or costly repairs.
contained minerals which were deposited on the
engine over time.
Fuel Injectors
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the Replace the fuel injectors. Consult your Caterpillar
cooling system. A full water analysis can be obtained dealer about exchanging the fuel injectors. Your
by consulting your local water utility company or Caterpillar dealer can provide these services and
an agricultural agent. Private laboratories are also components.
available for water analysis.
The wear of fuel injectors is affected by the following
Caterpillar recommends an SOS coolant analysis considerations:
(Level II).
Quality of the fuel
SOS Coolant Analysis (Level II)
Quality of the filtration of the fuel
An SOS coolant analysis (Level II) is a
comprehensive coolant analysis which completely The wear of the fuel injectors can result in elevated
analyzes the coolant. An SOS coolant analysis levels of exhaust emissions and/or poor engine
(Level II) provides the following information: performance. The misfire of a single cylinder is not
typically attributed to normal wear. This condition can
Complete SOS coolant analysis (Level I). be repaired by replacing the defective fuel injector.
Properties of the coolant are visually inspected. The following list of circumstances indicate that the
fuel injectors should be inspected more frequently:
Metal corrosion and contaminants are identified.
Use of fuels that are not recommended in this
Operation and Maintenance Manual, Fuel
Specifications
96
Maintenance Section
Overhaul Considerations
Extreme ambient temperatures that reduce the An overhaul also includes the following maintenance:
ability of the fuel to provide lubrication
Inspection of all the parts that are visible during
Frequent plugging of the fuel filters the disassembly
Insufficient maintenance of the fuel tank or the Replacement of the seals and gaskets that are
fuel storage tank that can allow excessive water, removed
sediment, etc.
Cleaning of the internal passages of the engine
Insufficient maintenance of the fuel filters and the engine block
Clean the oil suction screen after the oil has been
drained.
When all of the costs are considered, The wear metal analysis of the lube oil
REPAIR-BEFORE-FAILURE is the least
expensive alternative for most components and An increase in the levels of noise and vibration
engines.
An increase of wear metals in the lube oil indicates
It is not practical to wait until the engine exhibits that the bearings and the surfaces that wear may
symptoms of excessive wear or failure. It is not less need to be serviced. An increase in the levels of
costly to wait. A planned overhaul before failure may noise and vibration indicates that rotating parts
be the best value for the following reasons: require service.
Costly unplanned downtime can be avoided. Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder
Many original parts can be reused according to the liners may be worn so that polishing of the bore
guidelines for reusable parts. occurs. Also, the increased use of lube oil will dilute
the wear metals.
The service life of the engine can be extended
without the risk of a major catastrophe due to Monitor the engine as the engine accumulates
engine failure. service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
Achieve the best cost/value relationship per hour
of extended service life. Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
Overhaul Intervals that is provided by the OEM of the driven equipment.
Some factors that are important for determining Using Fuel Consumption For Calculating the
the overhaul intervals include the following Overhaul Intervals
considerations:
The total fuel consumption is the most important
Performance of preventive maintenance factor for estimating the overhaul interval. Fuel
consumption compensates for the application and
Use of recommended lubricants for the engine load.
Use of recommended coolants If the total fuel consumption has not been recorded,
use the equation in Table 35 in order to estimate the
Use of recommended fuels hours until the overhaul. The equation may also be
used to estimate overhaul intervals for new engines.
Proper installation Table 35
Generally, engines that are operated at a reduced R is the rate of fuel consumption in liters per hour or
load and/or speed achieve more service life before gallons per hour.
an overhaul. However, this is for engines that are
properly operated and maintained. Use the actual records of fuel consumption, when
possible. If the actual records are not available, use
Other factors must also be considered for determining the following procedure in order to estimate the fuel
a major overhaul: consumption.
The total amount of fuel consumption 1. Estimate the average percent of the load for the
operation of the engine.
The service hours of the engine
An increase of oil consumption
An increase of crankcase blowby
98
Maintenance Section
Overhaul Considerations
2. Refer to the engines Caterpillar, Engine The use of out-of-spec parts could result in
Specifications (spec sheet). This will determine unscheduled downtime and/or costly repairs. The use
the fuel consumption for the percent of the load of out-of-spec parts can also contribute to increased
that was estimated in Step 1. Use this figure for fuel consumption and reduction of engine efficiency.
the equation in Table 35. New parts are not necessary if the old parts can be
reused, repaired, or salvaged. Otherwise, the old
Oil Consumption as an Overhaul Indicator parts can be replaced or exchanged.
Oil consumption, fuel consumption, and maintenance Your Caterpillar dealer can provide the parts that are
information can be used to estimate the total needed to rebuild the engine at the least possible
operating cost for your Caterpillar engine. Oil cost.
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable Overhaul Programs
for the maintenance intervals.
An economical way to obtain most of the parts
Oil consumption is in proportion to the percentage that are needed for overhauls is to use Caterpillar
of the rated engine load. As the percentage of the remanufactured parts. Caterpillar remanufactured
engine load is increased, the amount of oil that is parts are available at a fraction of the cost of new
consumed per hour also increases. parts. These parts have been rebuilt by Caterpillar
and certified for use. The following components are
The oil consumption rate (brake specific oil examples of the remanufactured parts:
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC) Cylinder heads
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil Oil Pumps
consumption rate for your engine.
Turbochargers
When an engines oil consumption has risen to
three times the original oil consumption rate due Water pumps
to normal wear, an engine overhaul should be
scheduled. There may be a corresponding increase Consult your Caterpillar dealer for details and for a
in blowby and a slight increase in fuel consumption. list of the remanufactured parts that are available.
1. Remove the exhaust outlet piping and remove For maximum engine service life, make a thorough
the air inlet piping from the turbocharger. Visually inspection of the engine compartment before starting
inspect the piping for the presence of oil. the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections and
2. Turn the compressor wheel and the turbine wheel trash buildup. Make repairs, as needed:
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for The guards must be in the proper place. Repair
contact with the turbocharger housing. There damaged guards or replace missing guards.
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the Wipe all caps and plugs before the engine is
turbocharger housing. If there is any indication of serviced in order to reduce the chance of system
contact between the rotating turbine wheel or the contamination.
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned. NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
3. Check the compressor wheel for cleanliness. fluid. If leaking is observed, find the source and correct
If only the blade side of the wheel is dirty, dirt the leak. If leaking is suspected, check the fluid levels
and/or moisture is passing through the air filtering more often than recommended until the leak is found
system. If oil is found only on the back side of the or fixed, or until the suspicion of a leak is proved to be
wheel, there is a possibility of a failed turbocharger unwarranted.
oil seal.
101
Maintenance Section
Water Pump - Inspect
Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.