Motor Caterpillar 3512c
Motor Caterpillar 3512c
Motor Caterpillar 3512c
COM
2007 Caterpillar
All Rights Reserved
SEBU8024-03
August 2007
Operation and
Maintenance
Manual
3512C Oil Well Servicing Engine
R1A1-Up (Engine)
R3A1-Up (Engine)
i01658146
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Table of Contents
3
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 6
General Hazard Information ................................... 8
Burn Prevention .................................................... 10
Fire Prevention and Explosion Prevention ............ 10
Crushing Prevention and Cutting Prevention ........ 12
Mounting and Dismounting ................................... 13
Before Starting Engine .......................................... 13
Engine Starting ..................................................... 13
Engine Stopping ................................................... 14
Electrical System .................................................. 14
Engine Electronics ................................................ 14
Operation Section
Lifting and Storage ................................................ 23
Gauges and Indicators .......................................... 24
Features and Controls .......................................... 25
Engine Starting ..................................................... 36
Engine Operation .................................................. 41
Engine Stopping ................................................... 43
Cold Weather Operation ....................................... 45
Maintenance Section
Refill Capacities .................................................... 47
Maintenance Interval Schedule ............................ 49
Index Section
Index ................................................................... 101
4
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.
English is the primary language for all Caterpillar
publications. The English used facilitates translation
and consistency in electronic media delivery.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Caterpillar dealer for the latest
available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by fuel consumption, service hours and/or calendar
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that
follow.
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Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation and application. We recommend that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engines permanent record.
See the section in the Operation and Maintenance
Manual, Maintenance Records for information
regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized
Caterpillar dealer can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
programs. If you experience a major engine failure,
there are also numerous after failure overhaul options
available from your Caterpillar dealer. Consult with
your dealer for information regarding these options.
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5
Foreword
6
Safety Section
Safety Messages
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Safety Section
Crankcase Covers
i02307008
Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on
your engine. The exact location and a description of
the messages are reviewed in this section. Please
become familiar with all of the messages.
Ensure that all of the messages are legible. Clean
the messages or replace the messages if the
words cannot be read or if the illustrations are not
visible. Use a cloth, water, and soap for cleaning
the messages. Do not use solvents, gasoline, or
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. The messages that are loosened could
drop off of the engine.
Illustration 1
g00386802
g00123185
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7
Safety Section
Safety Messages
Fuel Injectors
Engine Lifting
Illustration 2
g00580494
Illustration 3
g00749734
g00103125
g00306083
Improper lift rigging can allow unit to tumble causing injury and damage.
Before lifting the engine, read this Operation
and Maintenance Manual, Engine Lifting topic
(Operation Section).
If improper equipment is used to lift the engine,
injury and damage can occur. Use cables that are
properly rated for the weight. Use a spreader bar and
attach the cables according to the information on the
warning label.
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
The ECM sends a high voltage signal to the fuel
injectors. To help prevent personal injury, disconnect
the fuel injector connector. Do not come in contact
with the harness connector for the fuel injector while
the engine is operating.
8
Safety Section
General Hazard Information
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i02566298
Illustration 5
g00702020
Illustration 4
g00104545
Filler caps
Grease fittings
Pressure taps
Breathers
Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
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9
Safety Section
General Hazard Information
Asbestos Information
Fluid Penetration
Illustration 7
g00702022
Illustration 6
g00687600
jobs.
10
Safety Section
Burn Prevention
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Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
Illustration 8
g00706404
i01480768
Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Illustration 9
g00704000
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Safety Section
Fire Prevention and Explosion Prevention
Illustration 10
g00704059
g00704135
12
Safety Section
Crushing Prevention and Cutting Prevention
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Ether
Ether is flammable and poisonous.
Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while you
are using an ether spray.
Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders
in direct sunlight or in temperatures above 49 C
(120 F). Keep ether cylinders away from open
flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Do not spray ether into an engine if the engine is
equipped with a thermal starting aid for cold weather
starting.
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13
Safety Section
Mounting and Dismounting
i01372247
Engine Starting
SMCS Code: 1000
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
Ether
Ether is poisonous and flammable.
Do not inhale ether, and do not allow ether to contact
the skin. Personal injury could result.
Do not smoke while ether cylinders are changed.
14
Safety Section
Engine Stopping
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Engine Stopping
SMCS Code: 1000
Electrical System
Grounding Practices
The electrical systems for the generator, the engine
and the control systems must be properly grounded.
Proper grounding is necessary for optimum
performance and reliability. Improper grounding will
result in uncontrolled electrical circuit paths and in
unreliable electrical circuit paths.
Uncontrolled electrical circuit paths can result
in damage to main bearings, to the surface of
crankshaft journals, and to aluminum components.
Uncontrolled electrical circuit paths can also cause
electrical activity that may degrade the performance
of the generator sets electronics.
The alternator and the starting motor must be
grounded to the negative battery terminal.
A ground plate with a direct path to the negative
battery terminal may be used as a common ground
for the components of one engine system.
For engines with an alternator that is grounded to
an engine component, a ground strap must connect
that component to the negative battery terminal.
Also, that component must be electrically isolated
from the engine.
The ground strap for the alternator must be of a size
that is adequate for carrying the full charging current
of the alternator.
i01964086
Engine Electronics
SMCS Code: 1000; 1900
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
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Engine overspeed
High aftercooler coolant temperature
High coolant temperature (jacket water)
High crankcase pressure
Low engine oil pressure
Except for an overspeed shutdown, the monitoring
system can be overridden. An override switch is
located in the Electronic Instrument Panel. Use of
the switch will allow the engine to provide full power
during an abnormal engine operating condition. The
override switch is provided only for use in emergency
situations.
For more information on the conditions that can
initiate warnings, deratings, and shutdowns, see this
Operation and Maintenance Manual, Monitoring
System topic (Operation Section).
15
Safety Section
Engine Electronics