3512B Engines: Maintenance Intervals
3512B Engines: Maintenance Intervals
3512B Engines: Maintenance Intervals
COM
3512B
ENGINES
Maintenance Intervals
2007 Caterpillar
All Rights Reserved
Note: Before each consecutive interval is performed, Every 1000 Service Hours
all maintenance from the previous interval must be
Engine - Clean ...................................................... 67
performed.
Engine Crankcase Breather - Clean ..................... 73
Engine Protection Devices - Calibrate .................. 78
When Required
Batteries - Replace ............................................... 56 Every 2000 Service Hours
Engine Air Cleaner Element (Dual Element) -
Crankshaft Vibration Damper - Inspect ................. 65
Clean/Replace .................................................... 67
Driven Equipment - Check .................................... 66
Engine Air Cleaner Element (Single Element) -
Clean/Replace .................................................... 70 Engine Mounts - Check ........................................ 74
Turbocharger - Inspect .......................................... 96
Fuel System - Prime ............................................. 79
Maintenance Recommendations .......................... 85
Radiator - Clean .................................................... 96 Every Year
Cooling System Coolant Sample (Level 2) -
Daily Obtain ................................................................. 63
Cooling System Coolant Level - Check ................ 62
Driven Equipment - Inspect/Replace/Lubricate ... 67 Every 3000 Service Hours or 3 Years
Engine Air Cleaner Differential Pressure - Check .. 67 Cooling System Coolant (DEAC) - Change .......... 58
Engine Air Precleaner - Clean .............................. 73 Cooling System Coolant Extender (ELC) - Add .... 61
Engine Oil Filter Differential Pressure - Check ..... 74
Engine Oil Level - Check ...................................... 74
Every 4000 Service Hours
Fuel System Fuel Filter Differential Pressure -
Check .................................................................. 80 Engine Valve Lash - Inspect/Adjust ...................... 79
Fuel System Primary Filter/Water Separator - Fuel Injector - Inspect/Adjust ................................ 79
Drain ................................................................... 81
Fuel Tank Water and Sediment - Drain ................. 82 Every 6000 Service Hours
Instrument Panel - Inspect .................................... 83
Walk-Around Inspection ........................................ 97 Air Shutoff Damper - Remove/Check ................... 55
Initial 250 Service Hours (or at first oil Every 6000 Service Hours or 6 Years
change)
Alternator - Inspect ............................................... 56
Engine Valve Lash - Inspect/Adjust ...................... 79 Cooling System Coolant (ELC) - Change ............. 60
Fuel Injector - Inspect/Adjust ................................ 79 Cooling System Water Temperature Regulator -
Magnetic Pickups - Clean/Inspect ........................ 85 Replace ............................................................... 65
Overhaul
Aftercooler Core - Inspect/Clean .......................... 52
Overhaul (Major) ................................................... 87
Overhaul (Top End) ............................................... 89
Overhaul Considerations ...................................... 92
i02253231
Aftercooler Core -
Personal injury can result from air pressure.
Inspect/Clean
Personal injury can result without following prop-
SMCS Code: 1063-040; 1064-571 er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
1. Remove the core. Refer to the Disassembly and
Assembly Manual for the procedure. Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
2. Turn the aftercooler core on one side in order
to remove debris. Remove the debris that is
accessible. 8. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
NOTICE
9. Prior to installation, inspect any O-rings or seals
Do not use a high concentration of caustic cleaner to
for damage. If necessary, replace the O-rings or
clean the core. A high concentration of caustic cleaner
seals.
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
10. Inspect the core for trapped debris and
cleaner.
cleanliness. If it is necessary, remove the debris
and repeat the cleaning procedure.
3. Back flush the core with cleaner.
11. Inspect the core for damage and perform a
Caterpillar recommends the use of Hydrosolv pressure test in order to detect leaks. Many shops
liquid cleaner. Table 21 lists Hydrosolv liquid that service radiators are equipped to perform
cleaners that are available from your Caterpillar pressure tests.
dealer.
12. Install the core. Refer to the Service Manual for
Table 21 the procedure.
Hydrosolv Liquid Cleaners(1)
For more information on cleaning the core, consult
Part your Caterpillar dealer.
Description Size
Number
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
i02332250
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner
Air Shutoff - Test
at temperatures up to 93C (200F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more SMCS Code: 1078-081
information.
Air shutoff valves must be tested and inspected in
4. Remove the drain plug. order to ensure proper operation. Before testing,
remove each limit switch and inspect each limit
5. Steam clean the core in order to remove any switch assembly for wear. The typical wear is erosion
residue. Flush the fins of the aftercooler core. of the plunger. This is due to vibration of the plunger
Remove any other trapped debris from the inside within the bore for the plunger. This usually causes
and from the outside of the core. the switch to jam or this causes the switch to become
otherwise inoperable.
Note: Do not use high pressure when the fins are
cleaned. High pressure can damage the fins. Note: The limit switches are normally open switches.
The switches are in the closed state when the
6. Wash the core with hot, soapy water. air shutoff valves are latched in the open, or Run
position. If the air shutoff valve is in the Closed
7. Flush the core thoroughly in order to remove position or the Stop position, the switch is in the open
residue and remaining debris. Flush the core with state, which will cause an emergency stop. This will
clean, fresh water until the water that is exiting the shut down the engine or this will prevent the engine
core is clear and free of debris. from starting. The engine will crank but the engine
will not start.
Observe the ammeter during engine operation in 7. Connect the cable from the starting motor to the
order to ensure proper battery performance and/or POSITIVE + battery terminal.
proper performance of the electrical system.
8. Connect the cable from the ground plane to the
Make repairs, if necessary. See the Service Manual NEGATIVE - battery terminal.
for service procedures. Consult your Caterpillar
dealer for assistance.
i02601752 i02509091
g01092641
Illustration 30
Typical alternator
(1) Mounting bolt
(2) Adjusting nuts
(3) Mounting bolt
2. Loosen mounting bolt (1), adjusting nuts (2) and Drain the Cooling System
mounting bolt (3).
1. Stop the engine and allow the engine to cool.
3. Turn adjusting nuts (2) in order to increase or Ensure that the engine will not start when the
decrease the drive belt tension. cooling system is drained.
4. Tighten adjusting nuts (2). Tighten mounting bolt 2. Loosen the cooling system filler cap slowly in
(3). Tighten mounting bolt (1). For the proper order to relieve any pressure. Remove the cooling
torque, see the Service Manual, Specifications system filler cap.
module.
Cooling System Coolant For information regarding the disposal and the
(DEAC) - Change recycling of used coolant, consult your Caterpillar
dealer or consult Dealer Service Tools Group:
SMCS Code: 1350-044
Outside Illinois: 1-800-542-TOOL
Clean the cooling system before the recommended Inside Illinois: 1-800-541-TOOL
maintenance interval if the following conditions exist: Canada: 1-800-523-TOOL
g00103639
Illustration 34
g00750429 Gaskets
Illustration 33
(1) Filler cap 3. Clean the cooling system filler cap. Inspect the
(2) Sight gauge
gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling
If the engine is equipped with a sight gauge, observe system filler cap with a new cooling system filler
the position of the coolant in the sight gauge. At cap. Install the cooling system filler cap.
normal operating temperature, the proper coolant
level is in the upper half of the sight gauge. If the 4. Start the engine. Inspect the cooling system for
coolant level is low, add the proper coolant mixture. leaks.
Note: Obtain a Coolant Sample (Level 1) if the Obtain coolant samples directly from the coolant
cooling system is filled with any other coolant sample port. You should not obtain the samples
instead of Cat ELC. This includes the following from any other location.
types of coolants:
Keep the lids on empty sampling bottles until you
Commercial long life coolants that meet the are ready to collect the sample.
Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1) Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
Cat DEAC (Diesel Engine Antifreeze/Coolant) contamination.
Table 23
Number of Concentration Maintenance
Cooling system coolant additive contains alkali. Drops of SCA Required
To help prevent personal injury, avoid contact with Less than 25 Less than the Add SCA.
the skin and eyes. Do not drink cooling system recommended Retest the
coolant additive. concentration of coolant.
SCA
Note: Caterpillar recommends an SOS coolant 25 to 30 The None
analysis (Level 1). recommended
concentration of
SCA
Test the Concentration of the SCA
More than 30 More than the Remove the
recommended coolant.
Coolant/Antifreeze and SCA concentration of Replace with
SCA water only
NOTICE Retest the
Do not exceed the recommended six percent supple- coolant.
mental coolant additive concentration.
4. Clean the cooling system filler cap. Install the Refer to two articles in the Disassembly and
cooling system filler cap. Assembly Manual, Water Temperature Regulators
- Remove and Water Temperature Regulators -
i02623972 Install for the replacement procedure of the water
temperature regulator, or consult your Caterpillar
Cooling System Water dealer.
Temperature Regulator - Note: If only the water temperature regulators are
Replace replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
SMCS Code: 1355-510 housing.
A damper that is hot may be the result of excessive Some dampers have ports for fluid samples. If the
friction. This could be due to misalignment. Use an damper has no external damage, collect a 2 to 5
infrared thermometer to monitor the temperature mL sample of the damper fluid. The fluid should be
of the damper during operation. If the temperature analyzed in order to check for a loss of viscosity. Use
reaches 93 C (200 F), consult your Caterpillar the results of the analysis to determine if the damper
dealer. should be rebuilt or replaced. Kits for fluid samples
are available from the address that follows. Return
Inspect the damper for evidence of dents, cracks, the kits to the same address for analysis.
and leaks of the fluid.
Hasse & Wrede GmbH
If a fluid leak is found, determine the type of fluid. Mohriner Allee 30-42
The fluid in the damper is silicone. Silicone has the D-12347 Berlin
following characteristics: transparent, viscous, and Germany
smooth. Phone: 49 30 / 70 181 195
Fax: 49 30 / 70 09 08-11
If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace all of the seals.
Dampers Without Sampling Ports
Inspect the damper and repair or replace the damper Some dampers do not have a port for a fluid sample.
for any of the following reasons.
These dampers must be rebuilt or the dampers must
be replaced when one of the following criteria has
The damper is dented, cracked, or leaking. been met:
The paint on the damper is discolored from heat. the damper has reached 20,000 hours of operation.
The engine has had a failure because of a broken the engine is undergoing a major overhaul.
crankshaft.
Caterpillar
OEM of the coupling
OEM of the driven equipment
g00819045
Illustration 35
Moisture can create paths of electrical conductiv- Engine Air Cleaner Element
ity.
(Dual Element) - Clean/Replace
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls DO SMCS Code: 1051; 1054-037
NOT OPERATE.
NOTICE
Never run the engine without an air cleaner element
NOTICE installed. Never run the engine with a damaged air
Accumulated grease and oil on an engine is a fire haz- cleaner element. Do not use air cleaner elements with
ard. Keep the engine clean. Remove debris and fluid damaged pleats, gaskets or seals. Dirt entering the
spills whenever a significant quantity accumulates on engine causes premature wear and damage to engine
the engine. components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
The air cleaner element may be cleaned up to 2. The secondary air cleaner element should be
six times if the element is properly cleaned and removed and discarded for every three cleanings
inspected. of the primary air cleaner element.
The air cleaner element should be replaced at least Note: Refer to Cleaning the Primary Air Cleaner
one time per year. This replacement should be Elements.
performed regardless of the number of cleanings.
3. Cover the turbocharger air inlet with tape in order
Replace the dirty paper air cleaner elements with to keep dirt out.
clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked 4. Clean the inside of the air cleaner cover and body
for tears and/or holes in the filter material. Inspect with a clean, dry cloth.
the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner 5. Remove the tape for the turbocharger air inlet.
elements for replacement purposes. Install the secondary air cleaner element. Install a
primary air cleaner element that is new or cleaned.
Dual Element Air Cleaners
6. Install the air cleaner cover.
The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner 7. Reset the air cleaner service indicator.
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 primary air cleaner element can be used up Aim the hose so that the air flows inside the element
to six times if the element is properly cleaned and along the length of the filter in order to help prevent
inspected. When the primary air cleaner element is damage to the paper pleats. Do not aim the stream
cleaned, check for rips or tears in the filter material. of air directly at the primary air cleaner element. Dirt
The primary air cleaner element should be replaced could be forced further into the pleats.
at least one time per year. This replacement should
be performed regardless of the number of cleanings. Note: Refer to Inspecting the Primary Air Cleaner
Elements.
Use clean primary air cleaner elements while dirty
elements are being cleaned. Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
NOTICE
primary air cleaner elements which require daily
Do not clean the air cleaner elements by bumping or
cleaning because of a dry, dusty environment.
tapping. This could damage the seals. Do not use el-
Cleaning with pressurized air is recommended prior
ements with damaged pleats, gaskets or seals. Dam-
to vacuum cleaning. Vacuum cleaning will not remove
aged elements will allow dirt to pass through. Engine
deposits of carbon and oil.
damage could result.
Note: Refer to Inspecting the Primary Air Cleaner
Visually inspect the primary air cleaner elements 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.
Pressurized air
Vacuum cleaning
Inspecting the Primary Air Cleaner Do not use paint, a waterproof cover, or plastic as a
Elements 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.
Date of cleaning
Number of cleanings
Store the box in a dry location.
g00281693
Illustration 38
i01553508
The air cleaner element should be replaced at least Cleaning the Air Cleaner Elements
one time per year. This replacement should be
performed regardless of the number of cleanings.
NOTICE
Caterpillar recommends certified air filter cleaning ser-
Replace the dirty paper air cleaner elements with
vices that are available at Caterpillar dealers. The
clean air cleaner elements. Before installation, the
Caterpillar cleaning process uses proven procedures
air cleaner elements should be thoroughly checked
to assure consistent quality and sufficient filter life.
for tears and/or holes in the filter material. Inspect
the gasket or the seal of the air cleaner element for
Observe the following guidelines if you attempt to
damage. Maintain a supply of suitable air cleaner
clean the filter element:
elements for replacement purposes.
Do not tap or strike the filter element in order to re-
move dust.
6. Reset the air cleaner service indicator. 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.
Pressurized air
Vacuum cleaning
g00281693
Illustration 42
Aim the hose so that the air flows inside the element Do not use an air cleaner element that has any tears
along the length of the filter in order to help prevent and/or holes in the filter material. Do not use an air
damage to the paper pleats. Do not aim the stream cleaner element with damaged pleats, gaskets or
of air directly at the air cleaner element. Dirt could be seals. Discard damaged air cleaner elements.
forced further into the pleats.
Storing Air Cleaner Elements
Note: Refer to Inspecting the Air Cleaner Elements.
If an air cleaner element that passes inspection will
Vacuum Cleaning not be used, the air cleaner element can be stored
for future use.
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.
g00281694
Illustration 43
Date of cleaning
Number of cleanings
Store the box in a dry location.
i01397717
g00736588
Illustration 44
Typical precleaner
(1) Wing nut
(2) Cover
(3) Body
g00597465
Illustration 46
Remove wing nut (1) and cover (2). Check for an
accumulation of dirt and debris in body (3). Clean the 3. Remove O-ring seals (4) from the valve covers.
body, if necessary. Inspect the O-ring seals for good condition. Obtain
new O-ring seals, if necessary.
After cleaning the precleaner, install cover (2) and
wing nut (1).
i01225429
Inspect the hose tee for cracks. If the tee is Ensure that the isolators are free of oil and
cracked, discard the old tee and obtain a new tee contamination. Inspect the isolators for deterioration.
for installation. Ensure that the bolts for the isolators are tightened to
the proper torque.
5. Turn the breathers upside-down in order to inspect
the condition of the breather elements. Replace any isolator that shows deterioration. For
more information, see the literature that is provided
Clean the breather elements with clean, by the OEM of the isolators. Also see the Application
nonflammable solvent. If the breather elements and Installation Guide for the engine. Consult your
remain contaminated after the cleaning, discard Caterpillar dealer for assistance.
the breathers and obtain new breathers. Do not
attempt to disassemble the breathers.
i01256787
6. Place clamps (6) over the parts of hose tee (7) Observe the oil filter differential pressure frequently
that will receive breathers (5). Install the breathers during engine operation.
into the tee. Tighten the clamps to the torque that
is listed in the Service Manual, Specifications. Oil Filter Differential Pressure (Restriction) This
indicates the difference in pressure between the
7. Coat O-ring seals (4) with clean engine oil. Place inlet side and the outlet side of the engine oil filters.
the O-ring seals on the valve covers. As the oil filter elements become plugged, oil filter
differential pressure will increase.
8. Place clamps (3) around the parts of the breathers
that will be attached to the valve covers. Install The nominal oil filter differential pressure during
both breathers as a unit. Tighten the clamps. normal engine operation is approximately 60 kPa
(9 psi).
9. Place clamp (1) on the part of the hose tee that
will receive tube (2). Install the tube into the hose Replace the oil filter elements when the oil filter
tee. Tighten the clamp to the torque that is listed differential pressure reaches 103 kPa (15 psi).
in the Service Manual, Specifications.
For instructions on replacement of the oil filter
elements, see this Operation and Maintenance
i01786814 Manual, Engine Oil and Filter - Change topic.
Engine Mounts - Check
i02418058
SMCS Code: 1152-535
Engine Oil Level - Check
Misalignment of the engine and the driven equipment
will cause extensive damage. Excessive vibration SMCS Code: 1348-535-FLV
can lead to misalignment. Excessive vibration of the
engine and the driven equipment can be caused by The most accurate check of the engine oil level is
the following conditions: obtained when the engine is stopped.
Improper mounting
Loose bolts
Deterioration of the isolators
Ensure that the mounting bolts are tightened
to the proper torque. For standard torques, see
Specifications, SENR3130, Torque Specifications.
NOTICE
Engine damage can occur if the crankcase is filled
above the FULL mark on the oil level gauge (dip-
stick).
i01935337
b. If the engine is operating, reduce the engine Obtain the Sample and the Analysis
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).
Hot oil and hot components can cause personal
The engine oil level should be between ADD injury. Do not allow hot oil or hot components to
mark (5) and FULL mark (6). contact the skin.
Before you take the oil sample, complete the Label, i02330991
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide Engine Oil and Filter - Change
the following information:
SMCS Code: 1318-510
Engine model
Service hours on the engine
Hot oil and hot components can cause personal
The number of hours that have accumulated since injury. Do not allow hot oil or hot components to
the last oil change contact the skin.
g00425765 g00103713
Illustration 50 Illustration 52
Oil drain Mounting base and gasket
a. Open the oil drain. 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.
Due to normal wear and friction, it is not uncommon 3. Close the fuel supply line and crank the engine
to find small amounts of debris in the oil filter. If an until the oil pressure gauge indicates 70 kPa
excessive amount of debris is found, consult your (10 psi). Open the fuel supply line.
Caterpillar dealer in order to arrange for further oil
analysis. Allow the starting motor to cool for two minutes
before cranking again.
Fill the Crankcase 4. Follow the Operation and Maintenance Manual,
Starting The Engine procedure (Operation
NOTICE Section).
Only use oils that are recommended by Caterpillar.
For the proper oil to use, refer to this Operation and Operate the engine at low idle for two minutes.
Maintenance Manual, Engine Oil topic (Maintenance
Section). This will ensure that the lubrication system has oil
and that the oil filters are filled with oil.
NOTICE Inspect the engine for oil leaks. Ensure that the
If the engine is equipped with an auxiliary oil filter oil level is at the FULL mark on the ENGINE
system, extra oil must be added when filling the AT LOW IDLE WITH WARM OIL side of the oil
crankcase. If equipped with an auxiliary oil filter level gauge.
system that is not supplied by Caterpillar, follow the
recommendations of the OEM. 5. Stop the engine and allow the oil to drain back into
the sump for a minimum of ten minutes.
NOTICE
Engine damage can occur if the crankcase is filled 6. Remove the oil level gauge and check the oil level.
above the FULL mark on the oil level gauge (dip-
stick). Maintain the oil level to the FULL mark on the
ENGINE STOPPED WITH OIL COLD side of the
An overfull crankcase can cause the crankshaft to dip oil level gauge.
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These i02272880
bubbles (foam) can cause the following problems: re-
duction of the oils ability to lubricate, reduction of oil Engine Protection Devices -
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption.
Calibrate
SMCS Code: 7400-524
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
Alarms and shutoffs must function properly. Alarms
posits in the combustion chamber lead to the following
provide timely warning to the operator. Shutoffs help
problems: guttering of the valves, packing of carbon
to prevent damage to the engine. It is impossible
under the piston rings, and wear of the cylinder liner.
to determine if the engine protective devices are
in good working order during normal operation.
If the oil level is above the FULL mark on the oil level
Malfunctions must be simulated in order to test the
gauge, drain some of the oil immediately.
engine protective devices.
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).
2. Clean the oil filler cap. Install the oil filler cap.
i02528928
NOTICE
Engine Valve Lash - The camshafts must be correctly timed with the crank-
Inspect/Adjust shaft before an adjustment of the lash for the fuel in-
jector is made. The timing pins must be removed from
SMCS Code: 1102-025 the camshafts before the crankshaft is turned or dam-
age to the cylinder block will be the result.
Note: For procedures on adjusting the valve lash and
adjusting the valve bridge, see Testing and Adjusting, Inspect the adjustment of the lash for the fuel injector
Valve Lash and Valve Bridge Adjustment. Consult according to the Systems Operation/Testing And
your Caterpillar dealer for assistance. Adjusting, Fuel System topic. Adjust the lash for the
fuel injector, if necessary.
Valve Bridge
i01395213
Check the valve bridge and adjust the valve bridge,
if necessary. Perform the procedure for both valve Fuel System - Prime
bridges for each cylinder. After the valve bridge is
checked for each cylinder, proceed with the valve SMCS Code: 1250-548; 1258-548
lash adjustment, if necessary.
1. Open the fuel supply valve. Ensure that the engine
Engine Valve Lash will not start during the priming procedure. Turn
the start switch to the OFF position.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
i01256795 1. Stop the engine. Ensure that the engine will not
start during this procedure.
Fuel System Fuel Filter
2. Shut off the fuel supply valve to the engine.
Differential Pressure - Check
SMCS Code: 1261-535 NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
Observe the fuel filter differential pressure frequently clean the area around a fuel system component that
during engine operation. will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Fuel Filter Differential Pressure (Restriction)
This indicates the difference in fuel pressure between
the inlet side and the outlet side of the fuel filter. NOTICE
As the fuel filter element becomes plugged, the Use a suitable container to catch any fuel that might
difference in pressure between the two sides of the spill. Clean up any spilled fuel immediately.
fuel filter increases.
3. Loosen nut (2). Hold filter case (1) and remove nut
(2). Prepare to catch the fuel that is inside of the
filter case with a suitable container. Remove the
filter case from the mounting bolt.
5. Clean the inside of the filter case. Allow the filter i01239636
case to dry.
Fuel System Secondary Filter -
6. Inspect the O-ring seals. Obtain new seal rings if
the old seal rings are damaged or deteriorated.
Replace
Ensure that the sealing surfaces for the seals are SMCS Code: 1261-510-SE
clean. Install the seals.
NOTICE
Do not fill the fuel filters with fuel before installing them.
Fuel leaked or spilled onto hot surfaces or elec-
The fuel would not be filtered and could be contami-
trical components can cause a fire. To help pre-
nated. Contaminated fuel will cause accelerated wear vent possible injury, turn the start switch off when
to fuel system parts.
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
7. Place the element in the filter case. Slide the filter
case over the mounting bolt.
NOTICE
8. Install the nut. Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
9. Open the fuel supply valve. will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
10. Prime the fuel system. See this Operation and
Maintenance Manual, Fuel System - Prime topic.
i00744357
For specific instructions for draining the primary 3. Apply clean diesel fuel to the new fuel filter gasket.
filter/water separator, see the service information that
is provided by the OEM of the primary filter/water
separator. NOTICE
Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be
NOTICE contaminated. Contaminated fuel will cause acceler-
The water separator is under suction during normal ated wear to fuel system parts.
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
system. 4. Install the new fuel filter.
Spin the new fuel filter onto the fuel filter base Check the fuel daily. Drain the water and sediment
until the gasket contacts the base. Tighten the from the fuel tank after operating the engine or drain
fuel filter by hand for an additional one full turn. the water and sediment from the fuel tank after the
Do not overtighten the fuel filter. Use the rotation fuel tank has been filled. Allow five to ten minutes
index marks that are on the fuel filter as a guide before performing this procedure.
for proper tightening.
Fill the fuel tank after operating the engine in
5. Prime the fuel system. order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
See this Operation and Maintenance Manual, fuel expands as the fuel gets warm. The tank may
Fuel System - Prime topic. overflow.
Replace hoses that are cracked or soft. Tighten any 2. Loosen the cooling system filler cap slowly in
loose clamps. order to relieve any pressure. Remove the cooling
system filler cap.
NOTICE
Do not bend or strike high pressure lines. Do not in- Note: Drain the coolant into a suitable, clean
stall bent or damaged lines, tubes or hoses. Repair container. The coolant can be reused.
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes 3. Drain the coolant from the cooling system to a
and hoses carefully. Tighten all connections to the rec- level that is below the hose that is being replaced.
ommended torque.
4. Remove the hose clamps.
End fittings that are damaged or leaking 6. Replace the old hose with a new hose.
Outer covering that is chafed or cut 7. Install the hose clamps with a torque wrench.
Exposed wire that is used for reinforcement Note: Refer to the Specifications, SENR3130,
Torque Specifications in order to locate the proper
Outer covering that is ballooning locally torques.
Flexible part of the hose that is kinked or crushed 8. Refill the cooling system.
Armoring that is embedded in the outer covering 9. Clean the cooling system filler cap. Inspect the
cooling system filler caps gaskets. Replace
A constant torque hose clamp can be used in place the cooling system filler cap if the gaskets are
of any standard hose clamp. Ensure that the constant damaged. Install the cooling system filler cap.
torque hose clamp is the same size as the standard
clamp. 10. Start the engine. Inspect the cooling system for
leaks.
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
i01257067
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps. Instrument Panel - Inspect
Each installation application can be different. The SMCS Code: 7451-040
differences depend on the following factors:
Replace the Hoses and the Clamps The data on engine performance can help to predict
problems with operation. Also, the data can provide
your Caterpillar dealer with information that is useful
for recommending optimum operation.
Pressurized System: Hot coolant can cause seri- Table 24 is offered for use as a log for engine
ous burns. To open the cooling system filler cap, performance. Make several copies of Table 24 for
stop the engine and wait until the cooling system continued use. Retain the recorded information for
components are cool. Loosen the cooling system reference.
pressure cap slowly in order to relieve the pres-
sure.
Table 24
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
g00614378
The total amount of fuel consumption
Illustration 56
The service hours of the engine
1. Remove the magnetic pickup from the flywheel
housing. Check the condition of the end of the An increase of oil consumption
magnetic pickup. Check for signs of wear and
contaminants. An increase of crankcase blowby
2. Clean the metal shavings and other debris from The wear metal analysis of the lube oil
the face of the magnet.
An increase in the levels of noise and vibration
3. Install the magnetic pickup until the magnet comes
in contact with the flywheel ring gear tooth. An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
4. Loosen the magnetic pickup by 180 degrees. need to be serviced. An increase in the levels of
Tighten the locknut to a torque of 25 5 Nm noise and vibration indicates that rotating parts
(18 4 lb ft). require service.
Refer to the Service Manual for more information on Note: It is possible for oil analysis to indicate a
the magnetic pickup. 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
i02651560
the wear metals.
Maintenance Monitor the engine as the engine accumulates
Recommendations service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
SMCS Code: 1000
Note: The driven equipment may also require service
Overhaul Intervals when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
Some factors that are important for determining
the overhaul intervals include the following Oil Consumption as an Overhaul
considerations: Indicator
Performance of preventive maintenance Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
Use of recommended lubricants operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
Use of recommended coolants required capacity of a makeup oil tank that is suitable
for the maintenance intervals.
Oil consumption is in proportion to the percentage Because of individual applications, it is not possible
of the rated engine load. As the percentage of the to identify all of the factors which can contribute to
engine load is increased, the amount of oil that is severe operation. Consult your Caterpillar dealer
consumed per hour also increases. about the maintenance that is needed for your
specific engine.
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per The following factors can contribute to severe
bhp). The brake specific oil consumption (BSOC) operation: environment, improper operating
depends on the engine load. Consult your Caterpillar procedures, and improper maintenance practices.
dealer for assistance in determining the typical oil
consumption rate for your engine. Environmental Factors
When an engines oil consumption has risen to Extreme Ambient Temperatures
three times the original oil consumption rate due
to normal wear, an engine overhaul should be Extended operation in environments that are
scheduled. There may be a corresponding increase extremely cold or hot can damage components. Valve
in blowby and a slight increase in fuel consumption. components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
Severe Operation cold temperatures. Extremely hot inlet air reduces
the performance capabilities of the engine.
Severe operation is the use of an engine that
exceeds current published standards for that engine. Note: See this Operation and Maintenance Manual,
Caterpillar maintains standards for the following Cold Weather Operation topic (Operation Section),
engine parameters: or see Supplement, SEBU5898, Cold Weather
Recommendations.
Horsepower
Cleanliness
Range of rpm
Unless the equipment is cleaned regularly, extended
Fuel consumption operation in a dirty environment and in a dusty
environment can damage components. Built up mud,
Fuel quality dirt, and dust can encase components. This can
make maintenance difficult. The buildup can contain
Altitude corrosive chemicals. Corrosive chemicals and salt
can damage some components.
Maintenance intervals
Improper Operating Procedures
Selection of oil
Extended operation at low idle
Selection of coolant
Minimum cool down periods after high load factor
Environmental qualities operation
Severe operation can accelerate component wear. Operating the engine at speeds that are greater
Engines that are operating under severe conditions than the rated speed
may need more frequent maintenance intervals for
the following reasons: Use of the engine for an application that is not
approved
Maximum reliability
Improper Maintenance Practices
Retention of full service life
Extension of maintenance intervals
Not using recommended fuel, lubricants, and
coolant
A major overhaul includes all of the work that is done Camshaft thrust washers
for the top end overhaul. A major overhaul includes
additional parts and labor. Additional parts and labor Connecting rods
are required in order to completely rebuild the engine.
Crankshaft vibration damper
For the major overhaul, all of the bearings,
seals, gaskets, and components that wear are Cylinder head assembly
disassembled. The parts are cleaned and inspected.
If necessary, the parts are replaced. The crankshaft Cylinder liners
is measured for wear. The crankshaft may require
regrinding. Alternatively, the crankshaft may be Engine mounts
replaced with a Caterpillar replacement part.
Scavenge oil pump
Engine wiring harness
For conventional heavy-duty coolant/antifreeze, Refer to this Operation and Maintenance Manual,
check the concentration of supplemental coolant Maintenance Recommendations in order to
additive (SCA) regularly. The concentration of SCA determine the maintenance interval for a top end
can be checked with an SOS coolant analysis (Level overhaul.
I). A more detailed coolant analysis is recommended
periodically. A top end overhaul involves the removal, the
inspection, and the rework of the cylinder head
For example, considerable deposits are found in the components. Some additional components are
water jacket areas on the external cooling system, replaced and serviced.
but the concentrations of coolant additives were
carefully maintained. The coolant water probably Your Caterpillar dealer can provide these services
contained minerals which were deposited on the and components. Your Caterpillar dealer can ensure
engine over time. that the components are operating within the
appropriate specifications.
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the Note: The driven equipment may also require service
cooling system. A full water analysis may be obtained when the engine is overhauled. Refer to the literature
from the following sources: that is provided by the OEM of the driven equipment.
Clean the oil suction screen after the oil has been Exhaust manifold seals
drained.
Exhaust manifold bellows
Note: Approximately 1 L (1 qt) of oil will remain in the
housing after the sump has been completely drained. Fuel pressure regulating valve
This oil will pour out of the housing when cover (1) is
removed. Prepare to catch the oil in a pan. Clean up Fuel priming pump
any spilled oil with absorbent towels or pillows. DO
NOT use absorbent particles to clean up the oil. Fuel transfer pump
Cylinder liners Note: Inspect only two of the components from each
cylinder bank. Inspecting only two components will
Scavenge oil pump provide an adequate example of the condition of the
other components.
Engine wiring harness
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Exhaust manifold seals
Overhaul Considerations
Exhaust manifold bellows
SMCS Code: 7595-043
Fuel pressure regulating valve
Fuel priming pump
Severe Operation
Severe operation is the use of an engine that
Fuel transfer pump exceeds current published standards for that engine.
Caterpillar maintains standards for the following
Inlet manifold gaskets engine parameters:
Inlet manifold seals
Horsepower
Oil pump
Range of rpm
Pistons
Fuel consumption
Piston pins
Fuel quality
Prelube pump
Altitude
Pushrods
Maintenance intervals
Rocker arms
Selection of oil
Selection of coolant Operating the engine beyond the guidelines for the
engine rating
Environmental qualities
Operating the engine at loads that are greater than
Installation the rated load
Refer to the standards for your engine or consult your Operating the engine at speeds that are greater
Caterpillar dealer in order to determine if your engine than the rated speed
is operating within the defined parameters.
Use of the engine for an application that is not
Severe operation can accelerate component wear. approved
Engines that are operating under severe conditions
may need more frequent maintenance intervals for Improper Maintenance Practices
the following reasons:
Extension of maintenance intervals
Maximum reliability
Not using recommended fuel, lubricants, and
Retention of full service life coolant/antifreeze
Because of individual applications, it is not possible
to identify all of the factors which can contribute to Overhaul Information
severe operation. Consult your Caterpillar dealer
about the maintenance that is needed for your An overhaul is replacing the major worn components
specific engine. of the engine. An overhaul interval is a maintenance
interval that is planned. The engine is rebuilt with
The following factors can contribute to severe certain rebuilt parts or new parts that replace the
operation: environment, improper operating worn parts.
procedures, and improper maintenance practices.
An overhaul also includes the following maintenance:
Environmental Factors
Inspection of all the parts that are visible during
the disassembly
Extreme Ambient Temperatures
Extended operation in environments that are Replacement of the seals and gaskets that are
removed
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 Cleaning of the internal passages of the engine
and the engine block
cold temperatures. Extremely hot inlet air reduces
the performance capabilities of the engine.
Most owners will save money by overhauling the
engine at the intervals that are recommended in this
Note: See this Operation and Maintenance Manual,
Operation and Maintenance Manual. Consider the
Cold Weather Operation topic (Operation Section),
graph in Illustration 57.
or see Supplement, SEBU5898, Cold Weather
Recommendations.
Cleanliness
Overhaul Intervals
Some factors that are important for determining
the overhaul intervals include the following
considerations:
Delaying an overhaul until a breakdown increases The total amount of fuel consumption
the chance of a catastrophic failure. This type of
failure requires more parts, labor, and cleanup. The service hours of the engine
Excessive wear means that fewer components An increase of oil consumption
will be reusable. More labor may be required for
salvage or repair of the components. An increase of crankcase blowby
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 engines. An increase in the levels of noise and vibration
It is not practical to wait until the engine exhibits An increase of wear metals in the lube oil indicates
symptoms of excessive wear or failure. It is not less that the bearings and the surfaces that wear may
costly to wait. A planned overhaul before failure may need to be serviced. An increase in the levels of
be the best value for the following reasons: noise and vibration indicates that rotating parts
require service.
Costly unplanned downtime can be avoided.
Note: It is possible for oil analysis to indicate a
Many original parts can be reused according to the decrease of wear metals in the lube oil. The cylinder
guidelines for reusable parts. liners may be worn so that polishing of the bore
occurs. Also, the increased use of lube oil will dilute
The service life of the engine can be extended the wear metals.
without the risk of a major catastrophe due to
engine failure.
Monitor the engine as the engine accumulates Oil Consumption as an Overhaul Indicator
service hours. Consult your Caterpillar dealer about
scheduling a major overhaul. Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
Note: The driven equipment may also require service operating cost for your Caterpillar engine. Oil
when the engine is overhauled. Refer to the literature consumption can also be used to estimate the
that is provided by the OEM of the driven equipment. required capacity of a makeup oil tank that is suitable
for the maintenance intervals.
Using Fuel Consumption For Calculating the
Overhaul Intervals Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the
Experience has shown that maintenance intervals engine load is increased, the amount of oil that is
are most accurately based on fuel consumption. Fuel consumed per hour also increases.
consumption corresponds more accurately to the
engine load. Table 25 lists average ranges of fuel The oil consumption rate (brake specific oil
consumption for a load factor of approximately 60 consumption) is measured in grams per kW/h (lb per
percent. bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
Table 25 dealer for assistance in determining the typical oil
Maintenance Intervals for Overhaul consumption rate for your engine.
Fuel Consumption for 3512B Engines (1)
When an engines oil consumption has risen to
Interval Fuel Consumption three times the original oil consumption rate due
Top End 787,500 L (208,030 US gal) to normal wear, an engine overhaul should be
Overhaul scheduled. There may be a corresponding increase
in blowby and a slight increase in fuel consumption.
Major 1575000 L (416,070 US gal)
Overhaul
Overhaul Inspection
(1) Fuel consumption is based on a load factor of approximately
60 percent. Refer to the Service Manual for the disassembly and
assembly procedures that are necessary in order
If the total fuel consumption has not been recorded, to perform the required maintenance on the items
use the equation in Table 26 in order to estimate the that are listed. Consult your Caterpillar dealer for
hours until the overhaul. The equation may also be assistance.
used to estimate overhaul intervals for new engines.
To determine the reusability publications that are
Table 26 needed to inspect the engine, refer to Guidelines for
Equation For Calculating Overhaul Intervals Reusable Parts and Salvage Operations, SEBF8029,
Index of Publications on Reusability or Salvage of
F/R = H Used Parts.
F is the estimated total amount of fuel consumption of
the engine. The Guidelines For Reusable Parts and Salvage
Operations is part of an established Caterpillar
R is the rate of fuel consumption in liters per hour or parts reusability program. These guidelines were
gallons per hour.
developed in order to assist Caterpillar dealers and
H is the number of estimated hours until the overhaul customers reduce costs by avoiding unnecessary
interval. expenditures for new parts. If the engine parts comply
with the established inspection specifications, the
Use the actual records of fuel consumption, when parts can be reused.
possible. If the actual records are not available, use
the following procedure in order to estimate the fuel The use of out-of-spec parts could result in
consumption. unscheduled downtime and/or costly repairs. The use
of out-of-spec parts can also contribute to increased
1. Estimate the average percent of the load for the fuel consumption and reduction of engine efficiency.
operation of the engine. New parts are not necessary if the old parts can be
reused, repaired, or salvaged. Otherwise, the old
2. Refer to the Caterpillar Engine Specifications, parts can be replaced or exchanged.
Spec Sheet in order to determine the fuel
Your Caterpillar dealer can provide the parts that are
consumption for the percent of the load that was
estimated in Step 1. Use this figure as variable F needed to rebuild the engine at the least possible
for the equation in Table 26. cost.
Cleaning and Inspecting The guards must be in the proper place. Repair
damaged guards or replace missing guards.
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually Wipe all caps and plugs before the engine is
inspect the piping for the presence of oil. serviced in order to reduce the chance of system
contamination.
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect NOTICE
the compressor wheel and the turbine wheel for For any type of leak (coolant, lube, or fuel) clean up the
contact with the turbocharger housing. There fluid. If leaking is observed, find the source and correct
should not be any visible signs of contact between the leak. If leaking is suspected, check the fluid levels
the turbine wheel or compressor wheel and the more often than recommended until the leak is found
turbocharger housing. If there is any indication or fixed, or until the suspicion of a leak is proved to be
of contact between the rotating turbine wheel unwarranted.
or the turbocharger wheel and the turbocharger
housing, the turbocharger should be reconditioned
or replaced. NOTICE
Accumulated grease and/or oil on an engine or deck is
3. Check the compressor wheel for cleanliness. a fire hazard. Remove this debris with steam cleaning
If only the blade side of the wheel is dirty, dirt or high pressure water.
and/or moisture is passing through the air filtering
system. If oil is found only on the back side of the
Note: Use care when you use steam cleaning. Use
wheel, there is a possibility of a failed turbocharger
care when you use high pressure water. Direct spray
oil seal.
to rotating electrics or electronic components can
cause nonfixable damage.
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 NOTICE
the inlet air (plugged air filters), which causes the Water and/or condensation can cause damage to
turbocharger to slobber. electrical components. Protect all electrical compo-
nents from exposure to water.
4. Inspect the bore of the turbine housing for
corrosion.
Ensure that the coolant lines are properly clamped.
Ensure that the fittings are tight. Check for leaks.
5. Clean the turbocharger housing with standard
Check the condition of all pipes.
shop solvents and a soft bristle brush.
6. Fasten the air inlet piping and the exhaust outlet Inspect the water pump for coolant leaks.
piping to the turbocharger housing.
Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
i02155206 of leakage to occur as the engine cools down and
the parts contract.
Walk-Around Inspection
Excessive coolant leakage may indicate the need
SMCS Code: 1000-040 to replace the water pump seal. For the removal of
water pump and the installation of water pump and/or
Inspect the Engine for Leaks and seals, refer to the Service Manual for the engine or
consult your Caterpillar dealer.
for Loose Connections
Inspect the lubrication system for leaks at the
A walk-around inspection should only take a few following locations: front crankshaft seal, rear
minutes. When the time is taken to perform these crankshaft seal, oil pan, oil filters, valve cover,
checks, costly repairs and accidents can be avoided. turbocharger, external oil lines, and connections.
For maximum engine service life, make a thorough Inspect the fuel system for leaks. Look for loose
inspection of the engine compartment before starting fuel line clamps or connections.
the engine. Look for items such as oil leaks, coolant
leaks, exhaust leaks, loose bolts, worn belts, loose Inspect the piping for the air inlet system and
connections and trash buildup. Make repairs, as the elbows for cracks and for loose clamps or
needed: connections.
i00524084