Caterpillar 3500c Manual
Caterpillar 3500c Manual
Caterpillar 3500c Manual
October 2009
Operation and
Maintenance
Manual
3500C Petroleum Engines
LLA1-Up (Engine)
LLB1-Up (Engine)
LLC1-Up (Engine)
C8E1-Up (Engine)
LLE1-Up (Engine)
LLF1-Up (Engine)
C8K1-Up (Engine)
PES1-Up (Engine)
SAFETY.CAT.COM
i03684547
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU8101-07 3
Table of Contents
Operation Section
Lifting and Storage ................................................ 21
Maintenance Section
Refill Capacities .................................................... 53
Safety Section
i02294670
Safety Messages
SMCS Code: 1000; 7405
g01149169
Illustration 1
There may be several specific safety messages on Replace any safety message that is damaged or
your engine. The exact location and a description of missing. If a safety message is attached to a part
the safety messages are reviewed in this section. of the engine that is replaced, install a new safety
Please become familiar with all safety messages. message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
Ensure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water,
and soap to clean the safety messages. Do not Do not operate or work on this engine unless you
use solvents, gasoline, or other harsh chemicals. have read and understand the instructions and
Solvents, gasoline, or harsh chemicals could loosen warnings in the Operation and Maintenance Man-
the adhesive that secures the safety messages. The ual. Failure to follow the instructions or heed the
safety messages that are loosened could drop off warnings could result in injury or death. Contact
of the engine. any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.
SEBU8101-07 7
Safety Section
General Hazard Information
g00934493
i03704500
Crushing Hazard! Improper lifting could cause se-
rious injury or death. Follow the lifting instruc- General Hazard Information
tions in the Operation and Maintenance Manual for
safe lifting procedures. SMCS Code: 1000; 4450; 7405
g00104545
Illustration 2
Do not allow unauthorized personnel on the engine, • Use all cleaning solutions with care.
or around the engine when the engine is being
serviced. • Report all necessary repairs.
Engine exhaust contains products of combustion Unless other instructions are provided, perform
which may be harmful to your health. Always start the the maintenance under the following conditions:
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the • The engine is stopped. Ensure that the engine
engine exhaust to the outside. cannot be started.
Cautiously remove the following parts. To help • The protective locks or the controls are in the
prevent spraying or splashing of pressurized fluids, applied position.
hold a rag over the part that is being removed.
• Disconnect the batteries when maintenance
• Filler caps is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
• Grease fittings Tape the leads in order to help prevent sparks.
Use caution when cover plates are removed. • Start the engine with the operator controls. Never
Gradually loosen, but do not remove the last two short across the starting motor terminals or the
bolts or nuts that are located at opposite ends of batteries. This could bypass the engine neutral
the cover plate or the device. Before removing the start system and/or the electrical system could be
last two bolts or nuts, pry the cover loose in order to damaged.
relieve any spring pressure or other pressure.
Pressurized Air and Water
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.
g00687600 g00702022
Illustration 4 Illustration 5
Always use a board or cardboard when you check Caterpillar equipment and replacement parts that are
for a leak. Leaking fluid that is under pressure can shipped from Caterpillar are asbestos free. Caterpillar
penetrate body tissue. Fluid penetration can cause recommends the use of only genuine Caterpillar
serious injury and possible death. A pin hole leak can replacement parts. Use the following guidelines
cause severe injury. If fluid is injected into your skin, when you handle any replacement parts that contain
you must get treatment immediately. Seek treatment asbestos or when you handle asbestos debris.
from a doctor that is familiar with this type of injury.
Use caution. Avoid inhaling dust that might be
Containing Fluid Spillage generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
NOTICE asbestos fibers are brake pads, brake bands, lining
Care must be taken to ensure that fluids are contained material, clutch plates, and some gaskets. The
during performance of inspection, maintenance, test- asbestos that is used in these components is usually
ing, adjusting and repair of the product. Be prepared to bound in a resin or sealed in some way. Normal
collect the fluid with suitable containers before open- handling is not hazardous unless airborne dust that
ing any compartment or disassembling any compo- contains asbestos is generated.
nent containing fluids.
If dust that may contain asbestos is present, there
Refer to Special Publication, NENG2500, “Caterpillar are several guidelines that should be followed:
Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and • Never use compressed air for cleaning.
Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products. • Avoid brushing materials that contain asbestos.
Dispose of all fluids according to local regulations and • Avoid grinding materials that contain asbestos.
mandates.
• Use a wet method in order to clean up asbestos
materials.
• Wire that is exposed in reinforced hose Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
• Outer covering that is ballooning locally is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
• Flexible part of the hose that is kinked or crushed lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
• Armoring that is embedded in the outer covering items are disconnected.
Ensure that all of the clamps, the guards, and the Coolant
heat shields are installed correctly. This will help to
prevent these effects: vibration, rubbing against other When the engine is at operating temperature, the
parts, and excessive heat during operation. 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.
Cooling system conditioner contains alkali. Alkali can A flash fire may result if the covers for the engine
cause personal injury. Do not allow alkali to contact crankcase are removed within fifteen minutes after
the skin, the eyes, or the mouth. an emergency shutdown.
Electrolyte is an acid. Electrolyte can cause personal Remove all flammable materials such as fuel, oil, and
injury. Do not allow electrolyte to contact the skin or debris from the engine. Do not allow any flammable
the eyes. Always wear protective glasses for servicing materials to accumulate on the engine.
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended. All fluids that are captured in the fluid spill
containment basin should be cleaned up immediately.
Failure to clean up spilled fluids can cause a fire. Fire
i03649377
may cause personal injury and property damage.
Fire Prevention and Explosion Store fuels and lubricants in properly marked
Prevention containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
SMCS Code: 1000; 4450; 7405 containers. Do not smoke in areas that are used for
storing flammable materials.
Inspect all lines and hoses for wear or for Gases from a battery can explode. Keep any open
deterioration. The hoses must be properly routed. flames or sparks away from the top of a battery. Do
The lines and hoses must have adequate support not smoke in battery charging areas.
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires. Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
Oil filters and fuel filters must be properly installed. a hydrometer.
The filter housings must be tightened to the proper
torque. Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
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.
Illustration 8
g00704059 Ether
Ether is flammable and poisonous.
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not Use ether in well ventilated areas. Do not smoke
refuel an engine near open flames or sparks. Always while you are replacing an ether cylinder or while you
stop the engine before refueling. are using an ether spray.
• Outer coverings are chafed or cut. Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
• Wires are exposed. climb on the engine, and do not jump off the engine.
• Outer coverings are ballooning. Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
• Flexible part of the hoses are kinked. with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
• Outer covers have embedded armoring. controls as handholds.
• End fittings are displaced. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
Make sure that all clamps, guards, and heat shields platform. Secure the climbing equipment so that the
are installed correctly. During engine operation, this equipment will not move.
will help to prevent vibration, rubbing against other
parts, and excessive heat. Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
i01359666
If equipped, ensure that the lighting system for the Do not inhale ether, and do not allow ether to contact
engine is suitable for the conditions. Ensure that all the skin. Personal injury could result.
lights work properly, if equipped.
Do not smoke while ether cylinders are changed.
All protective guards and all protective covers must
be installed if the engine must be started in order Use ether in well ventilated areas.
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work Use ether with care in order to avoid fires.
around the parts carefully.
Keep ether cylinders out of the reach of unauthorized
Do not bypass the automatic shutoff circuits. Do not persons.
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The Store ether cylinders in authorized storage areas
circuits are also provided in order to help prevent only.
engine damage.
Do not store ether cylinders in direct sunlight or at
See the Service Manual for repairs and for temperatures above 49 °C (120 °F).
adjustments.
Discard the ether cylinders in a safe place. Do not
puncture the ether cylinders. Do not burn the ether
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cylinders.
Engine Starting
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SMCS Code: 1000
Engine Stopping
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move SMCS Code: 1000
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must Flash fire may result in personal injury, if
be installed if the engine must be started in order crankcase covers are removed within fifteen min-
to perform service procedures. To help prevent an utes after emergency shut down. Do not restart
accident that is caused by parts in rotation, work engine until cause for shutdown has been cor-
around the parts carefully. rected.
Start the engine from the operator's compartment or
from the engine start switch. To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
Always start the engine according to the procedure according to this Operation and Maintenance Manual,
that is described in this Operation and Maintenance “Engine Stopping” topic (Operation Section).
Manual, “Engine Starting” topic (Operation Section).
Knowing the correct procedure will help to prevent Use the Emergency Stop Button (if equipped)
major damage to the engine components. Knowing ONLY in an emergency situation. DO NOT use the
the procedure will also help to prevent personal injury. Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
To ensure that the jacket water heater (if equipped) until the problem that caused the emergency stop
and/or the lube oil heater (if equipped) is working has been corrected.
properly, check the water temperature gauge and the
oil temperature gauge during the heater operation. On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop the
Engine exhaust contains products of combustion engine if an overspeed condition occurs. This may be
that can be harmful to your health. Always start the accomplished by shutting off the fuel supply and/or
engine and operate the engine in a well ventilated the air supply to the engine.
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Ether
Ether is poisonous and flammable.
SEBU8101-07 15
Safety Section
Electrical System
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Electrical System
SMCS Code: 1000; 1400
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.
Product Information
Section
g01146156
Illustration 10
Left side view
(1) Air inlet (5) Oil filler (9) Starting motor output
(2) Exhaust (6) Oil level gauge (10) Coolant inlet
(3) Shunt line connection (7) Coolant drain
(4) Coolant Outlet (8) Air starting motor
SEBU8101-07 17
Product Information Section
Model Views and Specifications
g01146158
Illustration 11
Right side view
(11) Fuel filter (14) Lifting eye (17) Oil filter
(12) Fuel priming pump (15) Solenoid (18) Separate circuit coolant inlet
(13) Coolant outlet (16) Crankcase breather (19) Separate circuit coolant outlet
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Product Description
SMCS Code: 1000; 4450
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Specifications
SMCS Code: 1000
Table 1
3500C Engine Specifications
3508C 3512C 3516C
Item
Engine Engine Engine
Rated Speed
1200 1200 1200
(rpm)
Idle Speed (rpm) 600 to 1250
g00739600
Cylinders and Illustration 12
60 degree V-8
arrangement 3508C Engine
Bore 170 mm (6.7 inch) (A) Inlet valve
(B) Exhaust valve
215 mm (C) Flywheel
Stroke 190 mm (7.5 inch)
(8.4 inch)
Type 4 stroke cycle
Compression
14.7:1
ratio
Aspiration Turbocharged
Method of cooling
the turbocharged SCAC
air
Displacement per 4.8 L
4.3 L (263 in3)
cylinder (298 in3)
Total 34.5 L 51.8 L 76.8 L
displacement (2105 in3) (3158 in3) (4687 in 3)
Rotation (flywheel Counterclockwise rotation is g00749769
Illustration 13
end) standard. 3512C Engine
See this Operation and Maintenance (A) Inlet valve
Manual, “Refill Capacities and (B) Exhaust valve
Fuel (C) Flywheel
Recommendations” (Maintenance
Section).
Method of fuel
Electronic unit injectors
injection
Method of starting Air starting motor
Designed back
pressure in the 2.5 kPa (10 inches of H2O)
exhaust system
Maximum
allowable back 5.0 kPa (20 inches of H2O)
pressure
Maximum inlet air
6.2 kPa (25 inches of H2O)
Restriction
Air cleaners Single element Illustration 14
g00308357
3516C Engine
(A) Inlet valves
(B) Exhaust valves
(C) Flywheel
SEBU8101-07 19
Product Information Section
Product Identification Information
Product Identification
Information
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Engine Identification
Caterpillar engines are identified with serial numbers, Illustration 16
g00123229
with performance specification numbers, and with Typical Serial Number Plate
arrangement numbers. In some of the cases,
modification numbers are used. These numbers The following information is stamped on the Serial
are shown on the Serial Number Plate and the Number Plate: engine serial number, model, and
Information Plate that are mounted on the engine. arrangement number.
Caterpillar dealers need these numbers in order to
determine the components that were included with Information Plate
the engine. This permits accurate identification of
replacement part numbers.
g00739603
Illustration 17
(1) Location of the Information Plate
g00102789
Illustration 18
Typical Information Plate
20 SEBU8101-07
Product Information Section
Product Identification Information
Operation Section
Product Lifting
SMCS Code: 7000; 7002
g01218233
Illustration 20
Top view
(1) Elbow
(2) Lifting eye
i02425915
Product Storage
SMCS Code: 7002
Inspect the charging system if either of the following Service the fuel filter when the fuel filter differential
conditions are observed: pressure reaches 34 kPa (5 psi).
SEBU8101-07 25
Operation Section
Gauges and Indicators
Table 4
Engine Oil Pressure
Parameter Default Settings
Hysteresis Map
Activation delay 10 seconds
Security level Required password
Warning setpoint Map
Warning delay 4 seconds
Shutdown setpoint Map
Shutdown delay 9 seconds
g00749882
Illustration 24
Map of the engine oil pressure versus the engine rpm for engines that are rated up to 1300 rpm
(Y) Engine oil pressure in kPa (1) Hysteresis
(X) Engine rpm (2) Minimum engine oil pressure
28 SEBU8101-07
Operation Section
Features and Controls
g00749883
Illustration 25
Map of the engine oil pressure versus the engine rpm for engines that are rated at 1301 rpm and above
(Y) Engine oil pressure in kPa (1) Hysteresis
(X) Engine rpm (2) Minimum engine oil pressure
If the coolant temperature is above 107 °C (225 °F) Note: The low coolant temperature is monitored in
for 30 seconds, a derating will occur. A continuous order to detect a failure of the water temperature
25 percent derating is reached in 480 seconds. regulators. This feature is not intended to monitor
When the coolant temperature is less than 102 °C the operation of jacket water heaters.
(216 °F), the percent of the derating decreases. The
percent of the derating decreases until the capability Overspeed
of providing full power is restored. However, if the
coolant temperature rises above the setpoint again, The ECM will automatically perform the following
the derating will resume. functions if an engine overspeed occurs:
If the coolant temperature is above 107 °C (225 °F) • Warning
for five seconds, a shutdown will occur.
• Shutdown
Note: The default setting for the delay of the derating
is programmed to the maximum value of 30 seconds. Different setpoints are based on the engine
The delay for the shutdown is five seconds. These application and the engine rating. The default settings
settings result in a shutdown that occurs before a that are programmed at the factory are listed in Table
derating. These settings are programmed because 7.
most customers prefer a shutdown for high coolant
temperature. The settings can be programmed to Table 7
different values.
Overspeed
The setpoint can be programmed in the range of Parameter Default Setting
90 to 102 °C (194 to 215 °F).
Warning setpoint 1.18 times the rated rpm
• The coolant temperature must rise above 85 °C The ECM will automatically perform the following
(185 °F). functions if a high inlet air restriction occurs:
The strategy is applied to the right side air filter If the barometric pressure is below the setpoint, a
and/or the left side air filter. The default settings that warning and a derating will occur. The continuous
are programmed at the factory are listed in Table 8. schedule of the derating is three percent per
1 kPa (.15 psi) of pressure below the setpoint. The
Table 8 maximum derating is 35 percent.
Inlet Air Restriction
Parameter Default Setting
Exhaust Temperature
Warning setpoint 7 kPa (1 psi) The ECM will automatically perform the following
functions if a high exhaust temperature occurs:
Warning delay 5 seconds
Derate setpoint 7 kPa (1 psi) • Warning
Derate delay 5 seconds
• Derating
Security level No required password
The strategy is applied to the right side exhaust
Derating per 1 kPa (.15 psi) 2%
manifold and/or the left side exhaust manifold. The
Maximum restriction 25 kPa (3.6 psi) default settings that are programmed at the factory
are listed in Table 10.
If the inlet air restriction is above 7 kPa (1 psi) for Table 10
five seconds, both a warning and a derating will
occur. The continuous schedule of the derating is two Exhaust Temperature
percent per 1 kPa (0.15 psi). The maximum derating Parameter Default Setting
is 50 percent at 25 kPa (3.6 psi).
Warning setpoint 2T specification
The derating remains at the maximum level until the Warning delay 5 seconds
situation is corrected. To reset the derating to zero
percent, remove power from the ECM. The ECM will Derate setpoint 2T specification
reset when power is returned. Derate delay 5 seconds
Delay per step 15 seconds
Altitude
Hysteresis 10 °C (18 °F)
The ECM automatically compensates for engine
Security level Required password
operation at higher elevations. The ECM derates
the fuel delivery according to the barometric Derating per step 2% per step
pressure. The barometric pressure is sensed by
the atmospheric pressure sensor. The atmospheric
If the exhaust temperature is above the setpoint for
pressure has an effect on the performance of the
the warning for five seconds, a warning will occur.
engine. Derating the fuel delivery maintains the
temperatures of the exhaust gas within acceptable
If the exhaust temperature is above the setpoint for
limits.
the derating for five seconds, the derating will occur.
The derating of the engine starts at a specific
The derating reduces the power by two percent.
barometric pressure. The barometric pressure is
This is followed by a 15 second delay. If the exhaust
equal to the atmospheric pressure of an elevation.
temperature is not reduced below the setpoint after
The atmospheric pressure is specific for the engine
the 15 second delay, the engine is derated another
and for the engine rating. The default settings that
two percent.
are programmed at the factory are listed in Table 9.
Table 11 Table 13
Oil Filter Differential Pressure Crankcase Pressure
Parameter Default Setting Parameter Default Setting
Warning setpoint 105 kPa (15 psi) Warning setpoint 2 kPa (.3 psi)
Warning delay 5 seconds Warning delay 3 seconds
Hysteresis 10 kPa (1.5 psi) Derate setpoint 6 kPa (.9 psi)
Security level No required password Derate delay 10 seconds
Maximum time of derating 480 seconds
If the oil filter differential pressure is above 105 kPa
Hysteresis 0.25 kPa (.036 psi)
(15 psi) for five seconds, a warning will occur. To
deactivate the warning, the oil filter differential Security level Required password
pressure must be below 95 kPa (13.5 psi).
Maximum derating 15%
Fuel Filter Differential Pressure Shutdown setpoint 3.5 kPa (.51 psi)
Shutdown delay 3 seconds
The ECM automatically warns the operator of high
fuel filter differential pressure. The default settings
that are programmed at the factory are listed in Table If the crankcase pressure is above 2 kPa (.3 psi) for
12. three seconds, a warning will occur. To deactivate
the warning, the crankcase pressure must be below
Table 12 1.75 kPa (.254 psi).
Fuel Filter Differential Pressure
If the crankcase pressure is above 6 kPa (.9 psi) for
Parameter Default Setting 10 seconds, a derating will occur. The continuous
schedule of the derating will reach 15 percent in 480
Warning setpoint 70 kPa (10 psi)
seconds.
Warning delay 5 seconds
When the crankcase pressure is less than 5.75 kPa
Hysteresis 10 kPa (1.5 psi)
(.39 psi), the percent of the derating is decreased
Security level No required password until full power is restored. However, if the crankcase
pressure rises above the setpoint again, the derating
resumes.
If the fuel filter differential pressure is above 70 kPa
(10 psi) for five seconds, a warning will occur. To
If the crankcase pressure is above 3.5 kPa (.51 psi)
deactivate the warning, the fuel filter differential
for three seconds, a shutdown will occur.
pressure must be below 60 kPa (8.7 psi).
Note: The default settings result in a shutdown
Crankcase Pressure that occurs before a derating. These settings were
selected for the reason that high crankcase pressure
The ECM will automatically perform the following can occur rapidly. The settings can be reprogrammed.
functions if high crankcase pressure occurs:
Aftercooler Coolant Temperature
• Warning
Note: The following information concerns engines
• Derating with separate circuit aftercooling. For engines
with jacket water aftercooling, monitoring of the
• Shut down aftercooler coolant temperature is disabled. However,
The default settings that are programmed at the the jacket water coolant temperature is monitored
for all engines.
factory are listed in Table 13.
The ECM will automatically perform the following
functions when high aftercooler coolant temperature
occurs:
• Warning
• Derating
32 SEBU8101-07
Operation Section
Features and Controls
The default settings that are programmed at the Alarms and Shutoffs
factory are listed in Table 14.
SMCS Code: 7400
Table 14
This section contains some general information about
Aftercooler Coolant Temperature
the function of typical engine protective devices.
Parameter Default Setting
Alarms and shutoffs are electronically controlled.
Warning setpoint 102 °C (215 °F)
The operation of all alarms and shutoffs utilize
Warning delay 5 seconds components which are actuated by a sensing unit.
The alarms and shutoffs are set at critical operating
Derate setpoint 107 °C (225 °F)
temperatures, pressures, or speeds in order to
Derate delay 5 seconds protect the engine from damage.
Maximum time of derating 480 seconds
The alarms function in order to warn the operator
Hysteresis 3 °C (5.4 °F) when an abnormal operating condition occurs. The
shutoffs function in order to shut down the engine
Security level No required password
when a more critical abnormal operating condition
Maximum derating 25% occurs. The shutoffs help to prevent damage to the
equipment.
Shutdown setpoint 107 °C (225 °F)
Shutdown delay 5 seconds If an engine protective device shuts off the engine,
always determine the cause of the shutoff. Make
the necessary repairs before attempting to start the
If the aftercooler coolant temperature is above 102 °C
engine.
(215 °F) for five seconds, a warning will occur.
To deactivate the warning, the aftercooler coolant
Become familiar with the following information:
temperature must be below 99 °C (210 °F).
If the aftercooler coolant temperature is above 107 °C • Types of the alarm and shutoff controls
(225 °F) for five seconds, a derating will occur. The
continuous schedule of the derating will reach 25 • Locations of the alarm and shutoff controls
percent in 480 seconds.
• Conditions which cause each control to function
When the aftercooler coolant temperature is less
than 104 °C (220 °F), the percent of the derating is • Resetting procedure that is required before starting
the engine
decreased until full power is restored. However, if
the aftercooler coolant temperature rises above the
For information about the specific alarms and shutoffs
setpoint again, the derating resumes.
for the engine, see this Operation and Maintenance
Manual, “Monitoring System” topic (Operation
If the aftercooler coolant temperature is above 107 °C
Section).
(225 °F) for five seconds, a shutdown will occur.
SEBU8101-07 33
Operation Section
Features and Controls
i02556180
Control Panel
SMCS Code: 7451
Type 1
g01139933
Illustration 26
(1) Main display module (4) “CLEAR MODE” switch (7) “ALARM SILENCER” switch
(2) Gauge cluster modules (5) “LH/RH SELECT” switch (8) Engine control switch
(3) “SCROLL” switch (6) Emergency stop button
The electronic instrument panel is the center for Display “SCROLL” switch (3)
engine control and for information about engine
operation. Each component of the instrument panel The main display module is capable of seven different
is described below. modes of operation. The “SCROLL” switch is used to
display the various parameters that are within each
Main display module (1) mode.
This module is the main component of the system. Display “CLEAR/MODE” switch (4)
The module receives information from the switches,
sensors and other electronic controls on the engine The “CLEAR/MODE” switch is used to move
via the CAT Data Link. The main module processes between the available modes of operation. Also,
the information. The module then displays the the “CLEAR/MODE” switch is used to clear the
information. The module also sends the information information that is currently displayed on the Main
to the gauge cluster modules. Display Module .
Type 2
g01217074
Illustration 27
(1) Marine Power Display (MPD) (4) Emergency stop switch (7) Starter select switch (if equipped)
(2) Pyrometer (if equipped) (5) Overspeed Indicator (8) Emergency stop lamp
(3) Engine control switch (ECS) (6) Alarm (horn)
Marine Power Display (MPD) (1) Note: The Oil Temperature and the Inlet Manifold
Temperature will be displayed if the engine is
The Caterpillar Marine Power Display is an equipped with the appropriate sensors.
attachment that is available from your Caterpillar
dealer. The Caterpillar Marine Power Display will
supply the current engine data. The Caterpillar Marine
Power Display will supply the current data for the
transmission. The screens can be customized. The
screens can display a variety of engine parameters.
The parameters are described in the following text.
Operating Information
Engine Control Switch (ECS) (3) Start Select Switch (If equipped) (7)
Refer to Operation and Maintenance Manual, This switch does not start the engine. Use the start
“Starting the Engine” for detailed information about select switch in order to select the starter that will
starting the engine with the engine control switch. start the engine. When the switch is in the PRIMARY
Refer to Operation and Maintenance Manual, “Engine position, the primary starter will be used to start the
Stopping” for detailed information about stopping the engine. When the switch is in the SECONDARY
engine with the engine control switch. position, the secondary starter will be used to start
the engine.
SMCS Code: 1000; 1900; 1901; 1902 Personality Module Part Software dependent
Number
Configuration parameters concern various engine Personality module release Software dependent
features. Some parameters can affect the date
performance of the engine. Most of the parameters
may be programmed with a Caterpillar Electronic Rated fuel position Yes
Technician (ET). Some of the parameters require a Total fuel Yes
password in order to be programmed.
Total hours Yes
Note: For information on programming the Total tattletale No
parameters, use Cat ET and see the Service Manual, (1) Jacket water aftercooling or separate circuit aftercooling
“Troubleshooting” module.
Some parameters may not be available on all The following parameters are programmed at the
applications. If a parameter is not available the Cat factory to zero:
ET will indicate that the parameter is unavailable
when the parameter is selected. • “Crank Duration”
The air shutoff uses a moving plate to block inlet air The following conditions must be met in order to
to the aftercooler. The engine stops because of the activate the Cold Cylinder Cutout:
restricted air supply to the combustion chamber. The
air shutoff only actuates for the following conditions: • The Cold Cylinder Cutout parameter is
programmed to “ENABLE”.
• The Emergency Stop button is pressed.
• The fuel rack is less than 13 mm (0.5 inch).
• An overspeed shutdown occurs.
• The jacket water coolant temperature is less than
Both of the air shutoffs must be reset before the 63 °C (145 °F).
engine can be restarted.
The Cold Cylinder Cutout strategy is activated under
either of the following conditions:
g00751561
• The jacket water coolant temperature is more than
Illustration 29 70 °C (158 °F).
Reset knob for the air shutoff
• A Cat ET is used for the cold cylinder cutout test.
To reset the air shutoff, turn the reset knob to the
“OPEN” position. • The ether injection system is used.
Ensure that both of the air shutoffs are reset. • The coolant temperature sensor has failed.
Cold Cylinder Cutout • The engine is operating at a certain rpm when the
Cold Cylinder Cutout is activated. If the engine rpm
then varies by more than 50 rpm, the feature is
Note: This feature can be enabled or disabled with deactivated for three seconds. A new engine speed
a Cat ET. is established when the feature is reactivated.
The Cold Cylinder Cutout feature provides the
following benefits: • The engine is at low idle rpm for ten seconds. If
the engine speed is then reduced by more than
50 rpm, the Cold Cylinder Cutout is deactivated
• Reduction of white smoke during cold starting for 30 seconds.
• Reduction of the duration of advanced timing (cold • If the fuel rack is greater than 13 mm (0.5 inch), the
mode) Cold Cylinder Cutout is deactivated for one second.
• Reduction of ether injection
Droop
The ECM automatically turns off one electronic unit
injector at a time during the following occurrences: This feature enables an engine to share a load with
other engines. If an engine is operating at high idle
• Cold start-up rpm and a load is applied, the engine rpm is reduced.
The engine rpm is reduced as the load increases.
• Extended time at low idle This reduction in rpm is the droop. The droop can be
programmed from zero to ten percent. If the percent
The ECM monitors the change of the fuel rack in of droop is equal for two identical engines in parallel
order to determine if a cylinder is firing. If the cylinder operation, the engines share the load equally.
is firing, the ECM activates the electronic unit injector.
If the cylinder is not firing, the electronic unit injector
remains deactivated. This reduces white smoke.
40 SEBU8101-07
Operation Section
Engine Diagnostics
• Engine rpm
• Percent of engine load
• Left side exhaust temperatures
• Right side exhaust temperatures
g00749824
Illustration 30
Temperature of the jacket water and duration of ether injection Incrementing the Hours of the ECM
(Y) Temperature in °C
(X) Time in seconds A new ECM that is installed on an engine can be
programmed to display the correct total number of
A momentary contact switch is installed on the control operating hours for that engine. A Cat ET and a
panel or the instrument panel. The momentary factory level security password are required.
contact switch enables the operator to inject ether
manually under the following conditions: Adjusting the Total Fuel Consumption for
the ECM
• The momentary contact switch for the ether
injection is activated. A new ECM that is installed on an engine can
be programmed to display the correct total fuel
• The engine rpm is more than 75 rpm. consumption for that engine. A Cat ET and a factory
level security password are required.
• The jacket water coolant temperature is less than
30 °C (86 °F).
SEBU8101-07 41
Operation Section
Engine Diagnostics
Before Starting Engine • Inspect the cooling system hoses for cracks and
for loose clamps.
SMCS Code: 1000; 1400; 1450
• Inspect the water pumps for evidence of leaks.
• Inspect the fan drive belts for cracks and for
Engine exhaust contains products of combustion deterioration.
which may be harmful to your health. Always start
and operate the engine in a well ventilated area • Check the coolant level. Add coolant, if necessary.
and, if in an enclosed area, vent the exhaust to the For information on the proper coolant to use, see
outside. this Operation and Maintenance Manual, “Refill
Capacities and Recommendations”.
Air Inlet System • Inspect the fuel lines for loose fittings and leaks.
Ensure that the fuel lines are properly clamped.
• Ensure that the air inlet piping and the air filters • Ensure that the fuel is supplied to the engine.
are in place.
If the engine has not been started for several weeks,
• Ensure that all clamps and connections are secure. fuel may have drained from the fuel system. Air
may have entered the filter housing. Also, when
• Observe the air cleaner service indicator. Service fuel filters have been changed, some air space will
the air cleaner when the yellow diaphragm enters be left in the housing. In these instances, prime the
the red zone, or when the red piston locks in the fuel system. See this Operation and Maintenance
visible position. Manual (Maintenance Section), “Fuel System-Prime”
for information on priming the fuel system.
SEBU8101-07 43
Operation Section
Engine Starting
Heaters
Note: Oil pan immersion heaters are not
recommended for heating the lube oil. To ensure the
compatibility of the components, only use equipment
g00736087
that is recommended by Caterpillar.
Illustration 31
Oil level gauge Startability will be improved at temperatures below
(1) “ADD” mark 12 °C (55 °F) with a starting aid. A jacket water
(2) “FULL” mark heater may be needed and/or the crankcase oil may
need to be warmed.
• Check the engine crankcase oil level. Maintain the
oil level between the “ADD” and “FULL ” marks Note: The fluid that is heated must be continuously
on the “ENGINE STOPPED” side of the oil level circulated. This will help to prevent localized
gauge. For information on the proper oil to use, see overheating of the fluid.
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations”. A jacket water heater is available as an option for
starting in temperatures as low as 0 °C (32 °F).
• Check for leaks at the following components: The jacket water heater can maintain the water
crankshaft seals, crankcase, oil filters, oil gallery temperature at approximately 32 °C (90 °F). The
plugs, sensors, and valve covers. heated water will help to keep the oil in the engine
block warm enough to flow when the engine is
• Inspect the tubes, tee pieces, and clamps on the started.
crankcase breathers.
When No. 2 diesel fuel is used, a fuel heater will
• Inspect the Closed Crankcase Ventilation (CCV) maintain the temperature of the fuel above the cloud
filter, if equipped. If the restriction indicator is point. Fuel line insulation will help to maintain the fuel
visible, service the CCV. temperature.
3. Crank the engine. Use of the starting aid depends Engine exhaust contains products of combustion
on these conditions: which may be harmful to your health. Always start
and operate the engine in a well ventilated area
a. The engine control module controls the and, if in an enclosed area, vent the exhaust to the
duration of automatic ether injection in these outside.
circumstances:
i00817006
NOTICE
For electric starting motors, do not crank the engine
Starting with Jump Start
continuously for more than 30 seconds. Allow the Cables
starting motor to cool for two minutes before cranking
the engine again. SMCS Code: 1000; 1401; 1402; 1900
i00857435
Warm-up
1. Operate the engine at low idle for two to three
minutes. Allow the jacket water temperature to
begin to rise before increasing the engine rpm.
Check the gauges and the driven equipment Shut off the engine rather than idle for long periods of
frequently while the engine is operating under a load. time.
The engine can be operated for extended periods
of time at full load. • Observe the service indicator frequently. Keep the
air cleaner elements clean.
• Settings for the fuel system and the limits for the
operating altitude are stamped on the Engine
Information Plate. If an engine is moved to a
higher altitude, the settings must be changed by a
Caterpillar dealer. Changing the settings will help
prevent damage to the turbocharger. Changing the
settings will help to provide the maximum efficiency
for the engine. Engines can be operated safely at
higher altitudes, but the engines will deliver less
horsepower. The fuel settings should be changed
by a Caterpillar dealer in order to obtain the rated
horsepower.
SEBU8101-07 49
Operation Section
Engine Stopping
NOTICE
Do not start the engine until the problem necessitating
the emergency stop has been located and corrected.
Air Shutoffs
g00751603
Illustration 32
i02301544 i02885872
Excessive temperatures in the turbocharger center- • If necessary, perform minor adjustments. Repair
housing will cause oil coking problems. any leaks and tighten loose bolts.
Allow the engine to gradually cool before stopping the • Note the service hour meter reading. Perform the
engine maintenance that is scheduled in this Operation
and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section).
There may be several ways to stop the engine.
Ensure that the stopping procedure is understood.
NOTICE
Use the following general guidelines for stopping the
Follow the guidelines for antifreeze/coolant mixtures
engine.
that are recommended in this Operation and Mainte-
nance Manual, “Refill Capacities and Recommenda-
1. Disengage the driven equipment. Unload the
tions” topic. Failure to do so can cause engine dam-
compressor or pump.
age.
a. Disengage the clutch (if equipped).
• Allow the engine to cool. Check the coolant level.
b. Place the transmission and/or other
attachments for the power take-off in • Loosen the cooling system filler cap slowly in
NEUTRAL. order to relieve any pressure. Remove the cooling
system filler cap.
2. Reduce the engine rpm to low idle. Operate the
engine at low idle rpm for a cooldown period • If freezing temperatures are expected, check the
before stopping the engine. coolant for protection against freezing. The cooling
system must be protected against freezing to the
a. If the engine has been operated at a low load, lowest expected outside temperature. Add the
operate the engine at low idle for approximately proper coolant/water mixture, if necessary.
30 seconds before stopping the engine.
• Perform all required periodic maintenance on all
b. If the engine has been operated at a high load, driven equipment. Refer to the instructions that are
operate the engine at low idle for three to five provided by the OEM of the driven equipment.
minutes before stopping the engine.
Cold Weather Operation When No. 2 diesel fuel is used the following
components provide a means of minimizing problems
in cold weather:
i02237624
• Starting aids
Fuel and the Effect from Cold
Weather • Engine oil pan heaters
The following fuels are the grades that are available • Fuel heaters
for Caterpillar engines:
• Fuel line insulation
• No. 1
For more information on cold weather operation,
• No. 2 see Special Publication, SEBU5898, “Cold Weather
Recommendations”.
• Blend of No. 1 and No. 2
i00932529
No. 2 diesel fuel is the most commonly used fuel.
Either No. 1 diesel fuel or a blend of No. 1 and No. 2 Fuel Related Components in
is best suited for cold weather operation.
Cold Weather
Quantities of No. 1 diesel fuel are limited. No. 1 diesel
fuels are usually available during the months of the SMCS Code: 1000; 1250; 1280
winter in the colder climates. During cold weather
operation, if No. 1 diesel fuel is not available, use No. Fuel Tanks
2 diesel fuel, if necessary.
Condensation can form in partially filled fuel tanks.
There are three major differences between No. 1 and Top off the fuel tanks after operating the engine.
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties: Fuel tanks should have a provision for draining water
and sediment from the bottom of the tanks. Some
• Lower cloud point fuel tanks use supply pipes that allow water and
sediment to settle below the end of the fuel supply
• Lower pour point pipe. Drain the water and sediment in order to help
prevent freezing.
• Lower rating of kJ (BTU) per unit volume of fuel
When No. 1 diesel fuel is used, a decrease in power
Fuel Filters
and in fuel efficiency may be noticed. Other operating
A primary fuel filter and/or a water separator is
effects should not be experienced.
recommended between the fuel tank and the
secondary fuel filter.
The cloud point is the temperature when a cloud of
wax crystals begins to form in the fuel. These crystals
The micron rating and the location of a primary fuel
can cause the fuel filters to plug. The pour point is
filter is important in cold weather operation. The
the temperature when diesel fuel will thicken. The
primary fuel filter and the fuel supply line are the most
diesel fuel becomes more resistant to flow through
common components that are affected by cold fuel.
fuel pumps and through fuel lines.
The micron rating of the primary fuel filter should only
Be aware of these values when diesel fuel is
be low enough to protect the fuel transfer pump. A
purchased. Anticipate the average ambient
primary filter with a low micron rating can be plugged
temperature of the area. Engines that are fueled in
by wax crystals in cold weather.
one climate may not operate well if the engines are
moved to another climate. Problems can result due
Note: Refer to the Parts Manual for the engine in
to changes in temperature.
order to determine the part numbers of the fuel filters.
Before troubleshooting for low power or for poor
performance in the winter, check the type of fuel that
is being used.
52 SEBU8101-07
Operation Section
Cold Weather Operation
Fuel Heaters
Fuel heaters help prevent plugging of the fuel filters
due to waxing in cold weather. Install fuel heaters
so that the fuel is heated before the fuel enters the
primary fuel filters.
SMCS Code: 1348; 1395; 7560 SAE 5W-40 −30 °C (−22 °F) 50 °C (122 °F)
SAE 10W-30 −18 °C (0 °F) 40 °C (104 °F)
Lubrication System SAE 10W-40 −18 °C (0 °F) 50 °C (122 °F)
SAE 15W-40 −9.5 °C (15 °F) 50 °C (122 °F)
Lubricant Recommendations
Due to significant variations in the quality and in Refer to Special Publication, SEBU6251, “Caterpillar
the performance of commercially available oils, Commercial Diesel Engine Fluids Recommendations”
Caterpillar recommends the following oils: for additional information that relates to lubricants.
i03642798
NOTICE
To relieve the pressure from the coolant system, turn
Because the strength of the frame may decrease,
off the engine. Allow the cooling system pressure cap
some manufacturers do not recommend welding onto
to cool. Remove the cooling system pressure cap
a chassis frame or rail. Consult the OEM of the equip-
slowly in order to relieve pressure.
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
Fuel System
Proper welding procedures are necessary in order
To relieve the pressure from the fuel system, turn off to avoid damage to the engine's ECM, sensors,
the engine. and associated components. When possible,
remove the component from the unit and then
High Pressure Fuel Lines (If Equipped) weld the component. If removal of the component
is not possible, the following procedure must be
followed when you weld on a unit that is equipped
with a Caterpillar Electronic Engine. The following
procedure is considered to be the safest procedure to
Contact with high pressure fuel may cause fluid
weld on a component. This procedure should provide
penetration and burn hazards. High pressure fu-
a minimum risk of damage to electronic components.
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death. NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
The high pressure fuel lines are the fuel lines that cause damage to the drive train, the bearings, hy-
are between the high pressure fuel pump and the draulic components, electrical components, and other
high pressure fuel manifold and the fuel lines that are components.
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel Do not ground the welder across the centerline of the
systems. package. Improper grounding could cause damage to
the bearings, the crankshaft, the rotor shaft, and other
This is because of the following differences: components.
• The high pressure fuel lines are constantly charged Clamp the ground cable from the welder to the com-
with high pressure. ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
• The internal pressures of the high pressure fuel sibility of damage.
lines are higher than other types of fuel system.
Before any service or repair is performed on the Note: Perform the welding in areas that are free from
engine fuel lines, perform the following tasks: explosive hazards.
56 SEBU8101-07
Maintenance Section
Maintenance Recommendations
1. Stop the engine. Turn the switched power to the Note: If electrical/electronic components are used
OFF position. as a ground for the welder, or electrical/electronic
components are located between the welder ground
2. Disconnect the negative battery cable from the and the weld, current flow from the welder could
battery. If a battery disconnect switch is provided, severely damage the component.
open the switch.
5. Protect the wiring harness from welding debris
3. Disconnect the J1/P1 and J2/P2 connectors from and spatter.
the ECM. Move the harness to a position that will
not allow the harness to accidentally move back 6. Use standard welding practices to weld the
and make contact with any of the ECM pins. materials.
g01075639
Illustration 33
Use the example above. The current flow from the welder to
the ground clamp of the welder will not cause damage to any
associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being welded
and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
In the absence of scheduled oil sampling, replace Every 500 Service Hours
the engine oil and filters according to the following
Engine Oil and Filter - Change ............................. 80
intervals:
If the engine has a shallow oil sump, change the oil Every 1000 Service Hours
after every 250 service hours. Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 66
If the engine has a standard oil sump, change the oil Engine - Clean ...................................................... 70
after every 500 service hours. Engine Crankcase Breather - Clean ..................... 76
Engine Protective Devices - Check ...................... 84
If the engine has a deep oil sump, change the oil Fuel System Primary Filter - Clean/Inspect/
after every 1000 service hours. Replace ............................................................... 86
Fuel System Secondary Filter - Replace .............. 87
Refer to this Operation and Maintenance Manual,
“Engine Oil and Filter - Change” in order to determine Every 2000 Service Hours
the oil change interval that is suitable for your specific
engine. Crankshaft Vibration Damper - Inspect ................. 68
Driven Equipment - Check .................................... 69
To determine the maintenance intervals for the Engine Mounts - Check ........................................ 77
overhauls, refer to this Operation and Maintenance Turbocharger - Inspect ........................................ 103
Manual, “Maintenance Recommendations” .
Every 3000 Service Hours or 3 Years
When Required
Cooling System Coolant (DEAC) - Change .......... 60
Batteries - Replace ............................................... 59 Cooling System Coolant Extender (ELC) - Add .... 63
58 SEBU8101-07
Maintenance Section
Maintenance Interval Schedule
Overhaul
Overhaul (Major) ................................................... 94
Overhaul (Top End) ............................................... 97
Overhaul Considerations .................................... 100
SEBU8101-07 59
Maintenance Section
Alternator - Inspect
• Clean ports for cooling airflow 8. Connect the cable from the ground plane to the
NEGATIVE “-” battery terminal.
• Proper charging of the battery
Observe the ammeter during engine operation in i02667833
order to ensure proper battery performance and/or
proper performance of the electrical system. Belts - Inspect/Adjust/Replace
Make repairs, if necessary. See the Service Manual SMCS Code: 1357-025; 1357-040; 1357-510
for service procedures. Consult your Caterpillar
dealer for assistance. Inspection
Inspect the alternator belt and the fan drive belts for
i01041029
wear and for cracking. Replace the belts if the belts
Batteries - Replace are not in good condition.
SMCS Code: 1401-510 Check the belt tension according to the information in
the Service Manual, “Specifications”.
Adjusting the Alternator Belt For the proper torque specifications, refer to the
Service Manual, “Specifications” module.
Replacement
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.
i02327874
2. Loosen mounting bolt (1), adjusting nuts (2) and • Fuel has entered the cooling system and the
mounting bolt (3). coolant is contaminated.
3. Turn adjusting nuts (2) in order to increase or Drain the Cooling System
decrease the drive belt tension.
1. Stop the engine and allow the engine to cool.
4. Tighten adjusting nuts (2). Tighten mounting bolt Ensure that the engine will not start when the
(3). Tighten mounting bolt (1). For the proper cooling system is drained.
torque, see the Service Manual, “Specifications”
module. 2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
5. Reinstall the drive belt guard. system filler cap.
If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation at
the rated rpm.
Clean the Cooling System 1. After the cooling system has been drained, flush
the cooling system with clean water in order to
1. After the cooling system has been drained, flush remove any debris.
the cooling system with clean water in order to
remove any debris. 2. Close the cooling system drain valves (if
equipped). Clean drain plugs and install the drain
2. Close the cooling system drain valves (if plugs . See Illustration 35.
equipped). Clean the drain plugs and install the
drain plugs. 3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
NOTICE (1 to 2 US gal) of the cooling system capacity.
Use of commercially available cooling system clean- Install the cooling system filler cap.
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap- 4. Start the engine. Operate the engine for a
proved for Caterpillar engines. minimum of 90 minutes with a coolant temperature
of at least 82 °C (180 °F).
62 SEBU8101-07
Maintenance Section
Cooling System Coolant (ELC) - Change
5. Stop the engine and allow the engine to cool. 4. Clean the cooling system filler cap. Inspect
Loosen the cooling system filler cap slowly in the gaskets of the cooling system filler cap. If
order to relieve any pressure. Remove the cooling the gaskets of the cooling system filler cap are
system filler cap. Open the cooling system drain damaged, discard the old cooling system filler cap
valves (if equipped) or remove the drain plugs. and install a new cooling system filler cap. If the
See Illustration 35. Allow the water to drain. gaskets of the cooling system filler cap are not
damaged, use a 9S-8140 Pressurizing Pump in
NOTICE order to pressure test the cooling system filler cap.
Improper or incomplete rinsing of the cooling system The correct pressure is stamped on the face of
can result in damage to copper and other metal com- the cooling system filler cap. If the cooling system
ponents. filler cap does not maintain the correct pressure,
install a new cooling system filler cap.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa- 5. Start the engine. Inspect the cooling system for
ter. Continue to flush the system until all signs of the leaks and for proper operating temperature.
cleaning agent are gone.
i02327899
6. Flush the cooling system with clean water until
the water that drains is clean. Close the cooling
Cooling System Coolant (ELC)
system drain valves (if equipped). Clean the drain - Change
plugs and install the drain plugs.
SMCS Code: 1350-044-NL
Fill the Cooling System Use only clean water to flush the cooling system
when Extended Life Coolant (ELC) is drained and
NOTICE replaced.
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Drain the Cooling System
Note: For information about the proper coolant to use, 1. Stop the engine and allow the engine to cool.
see this Operation and Maintenance Manual, “Refill Ensure that the engine will not start when the
Capacities and Recommendations” (Maintenance cooling system is drained.
Section). For the capacity of the cooling system,
see this Operation and Maintenance Manual, “Refill 2. Loosen the cooling system filler cap slowly in
Capacities and Recommendations” (Maintenance order to relieve any pressure. Remove the cooling
Section). system filler cap.
3. Open the cooling system drain valves (if Fill the Cooling System
equipped). If the cooling system is not equipped
with drain valves, remove drain plugs (1), (2), and
NOTICE
(3). Allow the coolant to drain.
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used 1. Fill the cooling system with Extended Life Coolant
coolant for reuse in engine cooling systems. The full (ELC). See the Operation and Maintenance
distillation procedure is the only method acceptable by Manual, “Refill Capacities and Recommendations”
Caterpillar to reclaim the used coolant. for the correct cooling system capacity. Do not
install the cooling system filler cap.
For information regarding the disposal and the 2. Start the engine. Operate the engine in order to
recycling of used coolant, consult your Caterpillar purge the air from the cavities of the engine block.
dealer or consult Caterpillar Dealer Service Tools Allow the ELC to warm and allow the coolant level
Group: to stabilize. Stop the engine.
Outside Illinois: 1-800-542-TOOL 3. Check the coolant level. Maintain the coolant to
Inside Illinois: 1-800-541-TOOL the proper level on the sight gauge (if equipped).
Canada: 1-800-523-TOOL If a sight gauge is not equipped, maintain the
coolant within 13 mm (0.5 inch) below the bottom
Clean the Cooling System of the filler pipe.
1. After the cooling system has been drained, flush 4. Clean the cooling system filler cap. Inspect
the cooling system with clean water in order to the gaskets of the cooling system filler cap. If
remove any debris. the gaskets of the cooling system filler cap are
damaged, discard the old cooling system filler cap
2. Close the cooling system drain valves (if and install a new cooling system filler cap. If the
equipped). Clean the drain plugs and install the gaskets of the cooling system filler cap are not
drain plugs. damaged, use a 9S-8140 Pressurizing Pump in
order to pressure test the cooling system filler cap.
The correct pressure is stamped on the face of
NOTICE the cooling system filler cap. If the cooling system
Fill the cooling system no faster than 19 L (5 US gal) filler cap does not maintain the correct pressure,
per minute to avoid air locks. install a new cooling system filler cap.
3. Fill the cooling system with clean water. Install the 5. Start the engine. Inspect the cooling system for
cooling system filler cap. Operate the engine until leaks and for proper operating temperature.
the temperature reaches 49 °C (120 °F) to 66 °C
(150 °F). i02482066
4. Stop the engine and allow the engine to cool. Cooling System Coolant
Ensure that the engine will not start when the
cooling system is drained. Loosen the cooling Extender (ELC) - Add
system filler cap slowly in order to relieve any
pressure. Remove the cooling system filler cap. SMCS Code: 1352-544-NL
5. Open the cooling system drain valves (if Cat ELC (Extended Life Coolant) does not require
equipped). If the cooling system is not equipped the frequent additions of any supplemental cooling
with drain valves, remove the drain plugs. See additives which are associated with the present
Illustration 36. Allow the coolant to drain. Flush conventional coolants. The Cat ELC Extender only
the cooling system with clean water. Close the needs to be added once.
cooling system drain valves (if equipped). Install
the drain plugs.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00750429
Refer to Special Publication, NENG2500, “Caterpillar Illustration 37
Dealer Service Tool Catalog” for tools and supplies (1) Filler cap
suitable to collect and contain fluids on Caterpillar (2) Sight gauge
products.
If the engine is equipped with a sight gauge, observe
Dispose of all fluids according to local regulations and the position of the coolant in the sight gauge. At
mandates. normal operating temperature, the proper coolant
level is in the upper half of the sight gauge. If the
coolant level is low, add the proper coolant mixture.
1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling
system filler cap.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
Illustration 38
g00103639 dealers and customers.
Gaskets
Note: Level 1 results may indicate a need for
3. Clean the cooling system filler cap. Inspect the Level 2 Analysis.
gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.
Obtain the sample of the coolant as close as possible Submit the sample for Level 2 analysis.
to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you For additional information about coolant
must establish a consistent trend of data. In order analysis, see Special Publication, SEBU6251,
to establish a pertinent history of data, perform “Caterpillar Commercial Diesel Engines Fluids
consistent samplings that are evenly spaced. Recommendations” or consult your Caterpillar dealer.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
i02839449
• Obtain coolant samples directly from the coolant Cooling system coolant additive contains alkali.
sample port. You should not obtain the samples To help prevent personal injury, avoid contact with
from any other location. the skin and eyes. Do not drink cooling system
coolant additive.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample.
NOTICE
• Place the sample in the mailing tube immediately Excessive supplemental coolant additive concentra-
after obtaining the sample in order to avoid tion can form deposits on the higher temperature sur-
contamination. faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer
• Never collect samples from expansion bottles. could cause cracking of the cylinder head and other
high temperature components.
• Never collect samples from the drain for a system.
Excessive supplemental coolant additive concentra-
Submit the sample for Level 1 analysis. tion could also result in blockage of the heat exchang-
er, overheating, and/or accelerated wear of the water
For additional information about coolant analysis, pump seal.
see this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” or consult your Do not exceed the recommended amount of supple-
Caterpillar dealer. mental coolant additive concentration.
i01987714 NOTICE
Care must be taken to ensure that fluids are contained
Cooling System Coolant during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
Sample (Level 2) - Obtain collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
nent containing fluids.
Refer to Operation and Maintenance Manual, Note: Caterpillar recommends an S·O·S coolant
“Cooling System Coolant Sample (Level 1) - Obtain” analysis (Level 1).
for the guidelines for proper sampling of the coolant.
SEBU8101-07 67
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
2. If necessary, drain some coolant in order to allow Pressurized System: Hot coolant can cause seri-
space for the addition of the SCA. ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
3. Add the proper amount of SCA. For the components are cool. Loosen the cooling system
proper amount of SCA, refer to this Operation pressure cap slowly in order to relieve the pres-
and Maintenance Manual, “Refill Capacities sure.
and Recommendations” topic. The proper
concentration of SCA depends on the type of 1. Remove the cooling system filler cap slowly.
coolant that is used. For the proper concentration
of SCA, refer to Special Publication, SEBU6251, 2. If necessary, drain some coolant in order to allow
“Caterpillar Commercial Diesel Engine Fluids space for the addition of the SCA.
Recommendations”.
3. Add the proper amount of SCA. For the proper
4. Clean the cooling system filler cap. Install the amount of SCA, refer to this Operation and
cooling system filler cap. Maintenance Manual, “Refill Capacities and
Recommendations” topic. For the proper
concentration of SCA, refer to Special Publication,
SEBU6251, “Caterpillar Commercial Diesel
Engine Fluids Recommendations”.
Replace
i02871204
SMCS Code: 1355-510
Crankshaft Vibration Damper
Replace the water temperature regulator before - Inspect
the water temperature regulator fails. This is a
recommended preventive maintenance practice. SMCS Code: 1205-040
Replacing the water temperature regulator reduces
the chances for unscheduled downtime. Refer to this The crankshaft vibration damper limits the torsional
Operation and Maintenance Manual, “Maintenance vibration of the crankshaft. The visconic damper has
Interval Schedule” for the proper maintenance a weight that is located inside a fluid filled case.
interval.
Damage to the crankshaft vibration damper or failure
A water temperature regulator that fails in a of the damper can increase torsional vibrations. This
partially opened position can cause overheating or can result in damage to the crankshaft and to other
overcooling of the engine. engine components. A deteriorating damper can
cause excessive torsional vibrations.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive A damper that is hot may be the result of excessive
overheating could result in cracking of the cylinder torsional vibration, worn bearings, or damage to the
head or piston seizure problems. damper. Use an infrared thermometer to monitor the
temperature of the damper during operation. Follow
A water temperature regulator that fails in the open the instructions that are included with the infrared
position will cause the engine operating temperature thermometer. If the temperature reaches 100°C
to be too low during partial load operation. Low (212 °F), consult your Caterpillar dealer.
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the Inspect the damper for evidence of dents, cracks,
cylinders. This excessive carbon buildup could result and leaks of the fluid.
in an accelerated wear of the piston rings and wear
of the cylinder liner. If a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has the
NOTICE following characteristics: transparent, viscous, and
Failure to replace your water temperature regulator smooth.
on a regularly scheduled basis could cause severe
engine damage. If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace all of the seals.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water Inspect the damper and repair or replace the damper
temperature regulator installed. for any of the following reasons.
If the water temperature regulator is installed incor- • The damper is dented, cracked, or leaking.
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg- • The paint on the damper is discolored from heat.
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open. • The engine has had a failure because of a broken
crankshaft.
Do not use liquid gasket material on the gasket or
cylinder head surface. • The crankshaft bearings are showing excessive
wear.
Refer to two articles in the Disassembly and • There is a large amount of gear train wear that is
Assembly Manual, “Water Temperature Regulators not caused by a lack of oil.
- Remove and Water Temperature Regulators -
Install” for the replacement procedure of the water
temperature regulator, or consult your Caterpillar
dealer.
SEBU8101-07 69
Maintenance Section
Driven Equipment - Check
i00449093
• Caterpillar
g00819045
Illustration 39
• OEM of the coupling
Some dampers have ports for fluid samples. If the
damper has no external damage, collect a sample • OEM of the driven equipment
of the damper fluid. The fluid should be analyzed in
order to check for a loss of viscosity. Use the results i00935098
of the analysis to determine if the damper should be
rebuilt or replaced. Kits for fluid samples are available Driven Equipment -
from the address that follows. Return the kits to the
same address for analysis. Inspect/Replace/Lubricate
Hasse & Wrede GmbH SMCS Code: 3279-040
Georg-Knorr-Straße 4
12681 Berlin Observe the driven equipment during operation. Look
Germany for the following items:
Phone: +49 30 9392-3135
Fax: +49 30 9392-7-3135 • Unusual noise and vibration
Alternate phone: +49 30 9392-3156
Alternate fax: +49 30 9392-7-3156 • Loose connections
The typical limit for the degradation of the damper • Damaged parts
fluid viscosity that is used by Hasse & Wrede GmbH
is 20 percent for the majority of applications. The Perform any maintenance that is recommended
reports from Hasse & Wrede should indicate that the by the OEM of the driven equipment. Refer to the
fluid samples meet this viscosity limit. literature of the OEM of the driven equipment for the
following service instructions.
Dampers Without Sampling Ports • Inspection
Some dampers do not have a port for a fluid sample. • Lubricating grease and lubricating oil requirements
These dampers must be rebuilt or the dampers must
be replaced when one of the following criteria has • Specifications for adjustment
been met:
• Replacement of components
• The damper has been operated for 20000 hours.
• Requirements for ventilation
• The engine is undergoing a major overhaul.
70 SEBU8101-07
Maintenance Section
Engine - Clean
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 NOTICE
benefits: Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
• Easy detection of fluid leaks
• Maximum heat transfer characteristics Servicing the Air Cleaner Elements
If the air cleaner element becomes plugged, the air
• Ease of maintenance can split the material of the air cleaner element.
Note: Caution must be used in order to prevent Unfiltered air will drastically accelerate internal engine
electrical components from being damaged by wear. Your Caterpillar dealer has the proper air
excessive water when you clean the engine. Avoid cleaner elements for your application. Consult your
electrical components such as the alternator, the Caterpillar dealer for the correct air cleaner element.
starter, and the ECM.
• Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt
i01256781 and debris, as needed.
Engine Air Cleaner Differential • Operating conditions (dust, dirt and debris) may
Pressure - Check require more frequent service of the air cleaner
element.
SMCS Code: 1051; 7452-040
• The air cleaner element may be cleaned up to
Observe the air cleaner differential pressure six times if the element is properly cleaned and
frequently during engine operation. inspected.
The air cleaner differential pressure is measured from • The air cleaner element should be replaced at least
the turbocharger air inlet. As the air filter element one time per year. This replacement should be
becomes plugged, the difference in pressure between performed regardless of the number of cleanings.
the two sides of the air cleaner element will increase.
Replace the dirty paper air cleaner elements with 5. Remove the tape for the turbocharger air inlet.
clean air cleaner elements. Before installation, the Install the secondary air cleaner element. Install a
air cleaner elements should be thoroughly checked primary air cleaner element that is new or cleaned.
for tears and/or holes in the filter material. Inspect
the gasket or the seal of the air cleaner element for 6. Install the air cleaner cover.
damage. Maintain a supply of suitable air cleaner
elements for replacement purposes. 7. Reset the air cleaner service indicator.
3. Cover the turbocharger air inlet with tape in order Visually inspect the primary air cleaner elements
to keep dirt out. before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
4. Clean the inside of the air cleaner cover and body Discard any damaged air cleaner elements.
with a clean, dry cloth.
72 SEBU8101-07
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
There are two common methods that are used to Inspecting the Primary Air Cleaner
clean primary air cleaner elements: Elements
• Pressurized air
• Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
g00281693
Illustration 42
Aim the hose so that the air flows inside the element Storing Primary Air Cleaner Elements
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream If a primary air cleaner element that passes inspection
of air directly at the primary air cleaner element. Dirt will not be used, the primary air cleaner element can
could be forced further into the pleats. be stored for future use.
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not remove
deposits of carbon and oil.
Do not use paint, a waterproof cover, or plastic as a • The air cleaner element should be replaced at least
protective covering for storage. An airflow restriction one time per year. This replacement should be
may result. To protect against dirt and damage, wrap performed regardless of the number of cleanings.
the primary air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper. Replace the dirty paper air cleaner elements with
clean air cleaner elements. Before installation, the
Place the primary air cleaner element into a box air cleaner elements should be thoroughly checked
for storage. For identification, mark the outside of for tears and/or holes in the filter material. Inspect
the box and mark the primary air cleaner element. the gasket or the seal of the air cleaner element for
Include the following information: damage. Maintain a supply of suitable air cleaner
elements for replacement purposes.
• Date of cleaning
• Number of cleanings
Store the box in a dry location.
i01553508
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. Reset the air cleaner service indicator.
cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.
Do not use air filters with damaged pleats, gaskets, or Note: When the air cleaner elements are cleaned,
seals. Dirt entering the engine will cause damage to always begin with the clean side (inside) in order to
engine components. force dirt particles toward the dirty side (outside).
The air cleaner element can be used up to six times if Aim the hose so that the air flows inside the element
the element is properly cleaned and inspected. When along the length of the filter in order to help prevent
the air cleaner element is cleaned, check for rips or damage to the paper pleats. Do not aim the stream
tears in the filter material. The air cleaner element of air directly at the air cleaner element. Dirt could be
should be replaced at least one time per year. This forced further into the pleats.
replacement should be performed regardless of the
number of cleanings. Note: Refer to “Inspecting the Air Cleaner Elements”.
Use clean air cleaner elements while dirty elements Vacuum Cleaning
are being cleaned.
Vacuum cleaning is a good method for cleaning
NOTICE air cleaner elements which require daily cleaning
Do not clean the air cleaner elements by bumping or because of a dry, dusty environment. Cleaning with
tapping. This could damage the seals. Do not use el- pressurized air is recommended prior to vacuum
ements with damaged pleats, gaskets or seals. Dam- cleaning. Vacuum cleaning will not remove deposits
aged elements will allow dirt to pass through. Engine of carbon and oil.
damage could result.
Note: Refer to “Inspecting the Air Cleaner Elements”.
• Pressurized air
• Vacuum cleaning
SEBU8101-07 75
Maintenance Section
Engine Air Precleaner - Clean
Inspecting the Air Cleaner Elements Place the air cleaner element into a box for storage.
For identification, mark the outside of the box and
mark the air cleaner element. Include the following
information:
• Date of cleaning
• Number of cleanings
Store the box in a dry location.
i01397717
Typical precleaner
Storing Air Cleaner Elements (1) Wing nut
(2) Cover
If an air cleaner element that passes inspection will (3) Body
not be used, the air cleaner element can be stored
for future use. Remove wing nut (1) and cover (2). Check for an
accumulation of dirt and debris in body (3). Clean the
body, if necessary.
g00281694
Illustration 47
i02331290
NOTICE
Engine Crankcase Breather - Care must be taken to ensure that fluids are contained
Clean during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
(If Equipped) collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
SMCS Code: 1317-070 nent containing fluids.
g00824297
Illustration 49
(1) Crankcase breathers
(2) Fumes filter
NOTICE
Keep all parts clean from contaminants.
g00597465
Illustration 51
(4) O-ring seal
SEBU8101-07 77
Maintenance Section
Engine Mounts - Check
3. Remove O-ring seals (4) from the valve covers. Replacing the Fumes Filter Element
Discard the O-ring seals.
g00824321
Illustration 53
g00597466
Illustration 52 (1) Bolt
(5) Crankcase breather (2) Canister
(6) Clamp (3) Element
(7) Hose tee
1. Loosen four bolts (1).
4. Remove two clamps (6). Remove both breathers
from hose tee (7). 2. Remove canister (2).
Inspect the hose tee for cracks. If the tee is 3. Discard element (3).
cracked, discard the old tee and obtain a new tee
for installation. 4. Place a new element into the canister. Install the
canister.
5. Clean the breather elements with clean,
nonflammable solvent. 5. Tighten the bolts.
6. Place clamps (6) over the parts of hose tee (7) • Improper mounting
that will receive breathers (5). Install the breathers
into the tee. Tighten the clamps. For the proper • Loose bolts
torque, refer to the Specifications, SENR3130.
• Deterioration of the isolators
7. Coat new O-ring seals (4) with clean engine oil.
Ensure that the mounting bolts are tightened
Place the O-ring seals on the valve covers.
to the proper torque. For standard torques, see
Specifications, SENR3130, “Torque Specifications”.
8. Place clamps (3) around the parts of the breathers
that will be attached to the valve covers. Install
Ensure that the isolators are free of oil and
both breathers as a unit. Tighten the clamps.
contamination. Inspect the isolators for deterioration.
Ensure that the bolts for the isolators are tightened to
9. Place clamp (1) on the part of the hose tee that
the proper torque.
will receive tube (2). Install the tube. Tighten the
clamp. For the proper torque, refer to the Service
Manual, “Specifications”.
78 SEBU8101-07
Maintenance Section
Engine Oil Filter Differential Pressure - Check
Replace any isolator that shows deterioration. For 1. Remove filler cap (1) in order to ensure that the
more information, see the literature that is provided crankcase pressure is equal to the atmospheric
by the OEM of the isolators. Also see the Application pressure.
and Installation Guide for the engine. Consult your
Caterpillar dealer for assistance. Excess pressure or a slight vacuum will affect
engine oil level that is measured.
i01256787
2. Ensure that engine oil level gauge (2) is seated.
Engine Oil Filter Differential
Pressure - Check
SMCS Code: 1308-535
g01208341
Illustration 54
(1) Filler cap
(2) Engine oil level gauge (dipstick)
SEBU8101-07 79
Maintenance Section
Engine Oil Sample - Obtain
• Fuel type
NOTICE
• Oil type Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
• Size of the oil sump ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
The S·O·S oil analysis program analyzes used oil in ing any compartment or disassembling any compo-
order to determine if the oil change interval is suitable nent containing fluids.
for your specific engine. In the absence of S·O·S oil
analysis, change the engine oil and engine oil filters Refer to Special Publication, NENG2500, “Caterpillar
according to the interval that is listed in Table 21. Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
Table 21 products.
3500C Engine Oil Change Intervals
Dispose of all fluids according to local regulations and
Engine Sump Capacity Oil Change mandates.
Interval
Engines With a Standard Sump 2. Drain the oil according to the equipment on the
engine.
3508C 227 L (60 US gal)
Every 500 Service
3512C 318 L (84 US gal)
Hours
3516C 405 L (107 US gal)
Engines With a Deep Sump
3508C 443 L (117 US gal)
Every 1000
3512C 625 L (165 US gal)
Service Hours
3516C 807 L (213 US gal)
g00328285
Illustration 56
Hot oil and components can cause personal in- (1) Oil drain
jury.
a. Open oil drain (1). After the oil has drained,
Do not allow hot oil or components to contact close the oil drain.
skin.
b. If a suction device is inserted into the oil pan,
ensure that the suction device is clean. This
will prevent dirt from entering into the oil pan.
Be careful not to strike the engine oil suction
tubes or the piston cooling jets.
SEBU8101-07 81
Maintenance Section
Engine Oil and Filter - Change
Note: Do not attempt to clean the used oil filters. 2. Open drain valve (2). Remove plug (3). Allow the
Used oil filters will retain waste particles. The used oil oil to drain. Clean the plug and install the plug.
filters would not filter the oil properly. Close the drain valve. Remove the hose from the
drain.
Service tools are available to aid in the service of oil
filters. Consult your Caterpillar dealer for the part Note: Some oil will remain in the housing after the oil
names and the part numbers. Follow the instructions has been drained. This oil will pour out of the housing
that are supplied with the service tools. If the service when cover (5) is removed. Prepare to catch the oil
tools are not used, perform the following appropriate in a suitable container. Clean up any spilled oil with
procedure. absorbent towels or pillows. DO NOT use absorbent
particles to clean up the oil.
Replacing the Engine Oil Filters With the
Engine Stopped
Personal injury can result from parts and/or cov-
ers under spring pressure.
Hot oil and components can cause personal in- Spring force will be released when covers are re-
jury. moved.
Do not allow hot oil or components to contact Be prepared to hold spring loaded covers as the
skin. bolts are loosened.
Perform the following procedure after the oil has 3. Be alert to the spring force. Gradually loosen but
been drained. do not remove bolts (4). Before you remove the
bolts, pry the cover (5) loose or tap the cover
Note: Use this procedure if the engine oil filters do with a rubber mallet in order to relieve any spring
not have a control valve. pressure. Remove cover (5).
82 SEBU8101-07
Maintenance Section
Engine Oil and Filter - Change
g00350932
Illustration 58
Section view of the engine oil filter g00396660
Illustration 59
(5) Cover Spin-on oil filters
(6) O-ring seal
(7) Spring
(8) Retainer
1. Remove the spin-on oil filter with a 1U-8760
(9) Oil filter element Chain Wrench.
NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters Illustration 60
g00103713
recommended by Caterpillar. Mounting base and gasket
6. Ensure that the new oil filter elements are in good 2. Clean the sealing surface of the mounting base.
condition. Install the new oil filter elements. Ensure that all of the old gasket is removed.
7. Inspect the O-ring seal. Ensure that the surfaces 3. Apply clean engine oil to the gasket of the new
for the O-ring seal are clean. Install a new oil filter.
O-ring seal if the old O-ring seal is damaged or
deteriorated. NOTICE
Do not fill the oil filters with oil before installing them.
8. Install retainer (8), spring (7) and cover (5). Ensure This oil would not be filtered and could be contaminat-
that the retainer and the spring are properly seated ed. Contaminated oil can cause accelerated wear to
between the oil filter elements and the cover. engine components.
NOTICE 4. Stop the engine and allow the oil to drain back into
If the engine is equipped with an auxiliary oil filter the sump for a minimum of ten minutes.
system, extra oil must be added when filling the
crankcase. If equipped with an auxiliary oil filter 5. Remove the oil level gauge and check the oil level.
system that is not supplied by Caterpillar, follow the Maintain the oil level to the “FULL” mark on the
recommendations of the OEM. “ENGINE STOPPED” side of the oil level gauge.
i00626013
Ensure that the engine can not be started while
Engine Protective Devices - this maintenance is being performed. To help pre-
Check vent possible injury, do not use the starting motor
to turn the flywheel.
SMCS Code: 7400-535
Hot engine components can cause burns. Allow
Alarms and shutoffs must function properly. Alarms additional time for the engine to cool before mea-
provide timely warning to the operator. Shutoffs help suring/adjusting valve lash clearance.
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation. Valve Bridge
Malfunctions must be simulated in order to test the
engine protective devices. Check the valve bridge and adjust the valve bridge,
if necessary. Perform the procedure for both valve
A calibration check of the engine protective devices bridges for each cylinder. After the valve bridge is
will ensure that the alarms and shutoffs activate checked for each cylinder, proceed with the valve
at the setpoints. Ensure that the engine protective lash adjustment, if necessary.
devices are functioning properly.
NOTICE
During testing, abnormal operating conditions must be
simulated.
g00736817
Illustration 61
The valve bridge adjustment must be performed
before making a valve lash adjustment. If the valve (1) Fuel priming pump plunger
lash is within the tolerance, an adjustment of the
valve lash is NOT necessary. 2. Turn the fuel priming pump plunger
counterclockwise in order to release the
For the valve lash setting, see the engine's lock plate from the retainer.
Specifications manual. For the procedure to
set the valve lash, see the engine's Systems 3. Operate the fuel priming pump until the air in the
Operation/Testing and Adjusting manual. fuel system has been pumped through the fuel
return line back to the fuel tank.
NOTICE
Priming Procedure for Dry Starting
The camshafts must be correctly timed with the crank- If the air cannot be completely purged from the fuel
shaft before an adjustment of the lash for the fuel in- system and the engine will not start, see Special
jector is made. The timing pins must be removed from Instruction, SEHS9586, “3500 EUI Fuel Priming
the camshafts before the crankshaft is turned or dam- Procedure”.
age to the cylinder block will be the result.
i01256795
Inspect the adjustment of the lash for the fuel injector
according to the Testing And Adjusting, “Fuel Injector Fuel System Fuel Filter
Adjustment”. Adjust the lash for the fuel injector, if
necessary. Differential Pressure - Check
SMCS Code: 1261-535
i01398238
Observe the fuel filter differential pressure frequently
Fuel System - Prime during engine operation.
SMCS Code: 1250-548; 1258-548 Fuel Filter Differential Pressure (Restriction) –
This indicates the difference in fuel pressure between
1. Open the fuel supply valve. Ensure that the engine the inlet side and the outlet side of the fuel filter.
will not start during the priming procedure. Turn As the fuel filter element becomes plugged, the
the start switch to the OFF position. difference in pressure between the two sides of the
fuel filter increases.
86 SEBU8101-07
Maintenance Section
Fuel System Primary Filter - Clean/Inspect/Replace
i01398258
g00736845
Illustration 62
Fuel System Primary Filter - (1) Filter case
Clean/Inspect/Replace (2) Nut
SMCS Code: 1260-510; 1260-571 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.
Fuel leaked or spilled onto hot surfaces or elec- 4. Remove the element and wash the element in
trical components can cause a fire. To help pre- clean, nonflammable solvent. Allow the element to
vent possible injury, turn the start switch off when dry. Inspect the element. Install a new element if
changing fuel filters or water separator elements. the old element is damaged or deteriorated.
Clean up fuel spills immediately.
5. Clean the inside of the filter case. Allow the filter
1. Stop the engine. Ensure that the engine will not case to dry.
start during this procedure.
6. Inspect the O-ring seals. Obtain new seal rings if
2. Shut off the fuel supply valve to the engine. the old seal rings are damaged or deteriorated.
Ensure that the sealing surfaces for the seals are
clean. Install the seals.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
NOTICE
clean the area around a fuel system component that
Do not fill the fuel filters with fuel before installing them.
will be disconnected. Fit a suitable cover over discon-
The fuel would not be filtered and could be contami-
nected fuel system component.
nated. Contaminated fuel will cause accelerated wear
to fuel system parts.
NOTICE
Use a suitable container to catch any fuel that might 7. Place the element in the filter case. Slide the filter
spill. Clean up any spilled fuel immediately. case over the mounting bolt.
2. Shut off the fuel supply valve to the engine. 5. Be alert to the spring force. Gradually loosen but
do not remove bolts (4). Before removing bolts (4),
pry cover (5) loose in order to relieve any spring
NOTICE
pressure. Remove cover (5). Remove the O-ring
Do not allow dirt to enter the fuel system. Thoroughly
seal on the inside of the cover. Remove the fuel
clean the area around a fuel system component that
filter elements.
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
6. Clean cover (5) and clean the O-ring seal. Clean
the inside of the fuel filter housing.
NOTICE
Use a suitable container to catch any fuel that might 7. Install new fuel filter elements.
spill. Clean up any spilled fuel immediately.
8. Inspect the O-ring seal. Ensure that the surfaces
for the O-ring seal are clean. Install a new
O-ring seal if the old O-ring seal is damaged or
deteriorated.
• 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 7. Install the hose clamps with a torque wrench.
• Outer covering that is ballooning locally Note: Refer to the Specifications, SENR3130,
“Torque Specifications” in order to locate the proper
• Flexible part of the hose that is kinked or crushed torques.
• Armoring that is embedded in the outer covering 8. Refill the cooling system.
A constant torque hose clamp can be used in place 9. Clean the cooling system filler cap. Inspect the
of any standard hose clamp. Ensure that the constant cooling system filler cap's gaskets. Replace
torque hose clamp is the same size as the standard the cooling system filler cap if the gaskets are
clamp. damaged. Install the cooling system filler cap.
Due to extreme temperature changes, the hose will 10. Start the engine. Inspect the cooling system for
heat set. Heat setting causes hose clamps to loosen. leaks.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
i01257067
Each installation application can be different. The
differences depend on the following factors: Instrument Panel - Inspect
SMCS Code: 7451-040
• Type of hose
• Type of fitting material Record the Performance of the
• Anticipated expansion and contraction of the hose
Engine
Records of engine performance are an important
• Anticipated expansion and contraction of the element of a maintenance program. Record
fittings
information about the engine operation on a daily
basis. This will help to reveal the trends of the engine
Replace the Hoses and the Clamps performance.
Table 22
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
SEBU8101-07 91
Maintenance Section
Maintenance Recommendations
Table 23
Maintenance Interval Schedule
Service Hours and Fuel Consumption for 3508C Engines (1)
Interval Rated Up To 1300 RPM Rated 1301 To 1600 RPM Rated 1601 To 1800 RPM
250 Service Hours 22700 L (6000 US gal) 27700 L (7200 US gal) 32000 L (8500 US gal)
500 Service Hours 45400 L (12000 US gal) 54400 L (14400 US gal) 64000 L (17000 US gal)
1000 Service Hours 89000 L (23500 US gal) 109000 L (28800 US gal) 128000 L (34000 US gal)
2000 Service Hours 178000 L (47000 US gal) 218000 L (57600 US gal) 257000 L (68000 US gal)
3000 Service Hours 267500 L (70500 US gal) 327500 L (84000 US gal) 386500 L (102000 US gal)
6000 Service Hours 535000 L (141000 US gal) 654000 L (173000 US gal) 774000 L (204000 US gal)
Top End Overhaul 11000 Service Hours 9000 Service Hours 7500 Service Hours
1000000 L (264000 US gal)
Second Top End 22000 Service Hours 18000 Service Hours 15000 Service Hours
Overhaul
2000000 L (528000 US gal)
Major Overhaul 33000 Service Hours 27000 Service Hours 22500 Service Hours
3000000 L (792000 US gal)
(1) Fuel consumption is based on a load factor of approximately 60 percent.
Table 24
Maintenance Interval Schedule
Service Hours and Fuel Consumption for 3512C Engines (1)
Interval Rated Up To 1300 RPM Rated 1301 To 1600 RPM Rated 1601 To 1800 RPM
250 Service Hours 33400 L (8800 US gal) 41000 L (10800 US gal) 48500 L (12800 US gal)
500 Service Hours 66800 L (17600 US gal) 82000 L (21600 US gal) 97000 L (25600 US gal)
1000 Service Hours 133500 L (35000 US gal) 164000 L (43200 US gal) 194000 L (51200 US gal)
2000 Service Hours 267000 L (70000 US gal) 328000 L (86400 US gal) 388000 L (102400 US gal)
3000 Service Hours 398000 L (105000 US gal) 491000 L (129600 US gal) 582000 L (153600 US gal)
6000 Service Hours 796000 L (210000 US gal) 982000 L (259200 US gal) 1164000 L (307200 US gal)
Top End Overhaul 11000 Service Hours 9000 Service Hours 7500 Service Hours
1500000 L (395000 US gal)
Second Top End 22000 Service Hours 18000 Service Hours 15000 Service Hours
Overhaul
3000000 L (790000 US gal)
Major Overhaul 33000 Service Hours 27000 Service Hours 22500 Service Hours
4500000 L (1185000 US gal)
(1) Fuel consumption is based on a load factor of approximately 60 percent.
SEBU8101-07 93
Maintenance Section
Maintenance Recommendations
Table 25
Maintenance Interval Schedule
Service Hours and Fuel Consumption for 3516C Engines (1)
Interval Rated Up To 1300 RPM Rated 1301 To 1600 RPM Rated 1601 To 1800 RPM
250 Service Hours 44000 L (11600 US gal) 53000 L (14000 US gal) 64500 L (17000 US gal)
500 Service Hours 88000 L (23200 US gal) 106000 L (28000 US gal) 129000 L (34000 US gal)
1000 Service Hours 176000 L (46500 US gal) 212000 L (56000 US gal) 258000 L (68000 US gal)
2000 Service Hours 352000 L (93000 US gal) 424000 L (112000 US gal) 516000 L (136000 US gal)
3000 Service Hours 528700 L (139500 US gal) 636700 L (168100 US gal) 773000 L (204000 US gal)
6000 Service Hours 1056000 L (279000 US gal) 1272000 L (336000 US gal) 1548000 L (408000 US gal)
Top End Overhaul 11000 Service Hours 9000 Service Hours 7500 Service Hours
2000000 L (528000 US gal)
Second Top End 22000 Service Hours 18000 Service Hours 15000 Service Hours
Overhaul
4000000 L (1056000 US gal)
Major Overhaul 33000 Service Hours 27000 Service Hours 22500 Service Hours
6000000 L (1584000 US gal)
(1) Fuel consumption is based on a load factor of approximately 60 percent.
Use the actual records of fuel consumption, when Oil Consumption as an Overhaul
possible. If the actual records are not available, use Indicator
the following procedure in order to estimate the fuel
consumption. Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
1. Estimate the average percent of the load for the operating cost for your Caterpillar engine. Oil
operation of the engine. consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
2. Refer to the fuel consumption data in the Technical for the maintenance intervals.
Marketing Information (TMI) for your engine. This
will determine the fuel consumption for the percent Oil consumption is in proportion to the percentage
of the load that was estimated in Step 1. Use this of the rated engine load. As the percentage of the
figure as variable “F” for the equation in Table engine load is increased, the amount of oil that is
26. For more information about the Technical consumed per hour also increases.
Marketing Information (TMI) for your engine,
consult your Caterpillar dealer. The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
Table 26
bhp). The brake specific oil consumption (BSOC)
Equation For Calculating Overhaul Intervals depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
F/R = H
consumption rate for your engine.
“F” is the estimated total amount of fuel consumption of
the engine. When an engine's oil consumption has risen to
“R” is the rate of fuel consumption in liters per hour or three times the original oil consumption rate due
gallons per hour. to normal wear, an engine overhaul should be
scheduled. There may be a corresponding increase
“H” is the number of estimated hours until the overhaul in blowby and a slight increase in fuel consumption.
interval.
Severe Operation
Severe operation is the use of an engine that
exceeds current published standards for that engine.
Caterpillar maintains standards for the following
engine parameters:
• Horsepower
94 SEBU8101-07
Maintenance Section
Overhaul (Major)
Your Caterpillar dealer can provide these services • Exhaust manifold seals
and components. Your Caterpillar dealer can ensure
that the components are operating within the • Exhaust manifold bellows
appropriate specifications.
• Fuel pressure regulating valve
Replacement of Components • Fuel priming pump
Replace the following components during the major • Fuel transfer pump
overhaul:
• Inlet manifold gaskets
• Camshaft bearings
• Inlet manifold seals
• Connecting rod bearings
• Oil cooler core
• Crankshaft seals
• Oil pump
• Crankshaft thrust washers
• Pistons
• Electronic unit injectors
• Piston pins
• Gear train bushings
• Prelube pump
• Gear train bearings
• Pushrods
• Main bearings
• Rocker arms
• Piston rings
• Spacer plate
96 SEBU8101-07
Maintenance Section
Overhaul (Major)
A top end overhaul involves the removal, the • Use of fuels that are not recommended in this
inspection, and the rework of the cylinder head Operation and Maintenance Manual, “Refill
components. Some additional components are Capacities and Recommendations”
replaced and serviced.
• Extreme ambient temperatures that reduce the
Your Caterpillar dealer can provide these services ability of the fuel to provide lubrication
and components. Your Caterpillar dealer can ensure
that the components are operating within the • Frequent plugging of the fuel filters
appropriate specifications.
• Insufficient maintenance of the fuel tank or the
Note: The driven equipment may also require service fuel storage tank that can allow excessive water,
when the engine is overhauled. Refer to the literature sediment, etc.
that is provided by the OEM of the driven equipment.
• Insufficient maintenance of the fuel filters
98 SEBU8101-07
Maintenance Section
Overhaul (Top End)
Cylinder Head Assembly Note: Approximately 1 L (1 qt) of oil will remain in the
housing after the sump has been completely drained.
Inspect the cylinder head assembly according to This oil will pour out of the housing when cover (1) is
the instructions that are in Caterpillar reusability removed. Prepare to catch the oil in a pan. Clean up
publications. Refer to Guidelines for Reusable any spilled oil with absorbent towels or pillows. DO
Parts and Salvage Operations, SEBF8029, “Index NOT use absorbent particles to clean up the oil.
of Publications on Reusability or Salvage of Used
Parts”. 1. Remove the screen assembly according to the
instructions in the Service Manual, “Disassembly
Your Caterpillar dealer can provide these services and Assembly” module. Discard the used O-ring
and components. Your Caterpillar dealer can ensure seals.
that the components are operating within the
appropriate specifications. 2. Wash the screen assembly in clean nonflammable
solvent. Allow the screen assembly to dry before
The use of out-of-spec parts will cause unscheduled installation.
downtime and/or costly repairs.
3. Remove side covers in order to gain access to
Unit Injectors the sump. Clean the bottom of the sump with
absorbent towels or pillows. When the bottom of
Replace the unit injectors. Consult your Caterpillar the sump is clean, install the side covers.
dealer about exchanging the unit injectors. Your
Caterpillar dealer can provide these services and 4. Inspect the screen assembly for good condition.
components. Obtain a new screen assembly, if necessary.
Install the screen assembly. Install new O-ring
The wear of unit injectors is affected by the following seals.
considerations:
Replacement of Components
• Quality of the fuel
Replace the following components during the top
• Quality of the filtration of the fuel end overhaul:
The wear of the unit injectors can result in elevated • Electronic unit injectors
levels of exhaust emissions and/or poor engine
performance. The misfire of a single cylinder is not Inspection, Reconditioning or
typically attributed to normal wear. This condition can
be repaired by replacing the faulty unit injector.
Exchanging of Components
The following list of circumstances indicate that the Inspect the following components according to
the instructions that are in Caterpillar reusability
unit injectors should be inspected more frequently:
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
• Use of fuels that are not recommended in this of Publications on Reusability or Salvage of Used
Operation and Maintenance Manual, “Refill
Parts”.
Capacities and Recommendations”
Recondition the worn components or exchange the
• Extreme ambient temperatures that reduce the components, if necessary. Your Caterpillar dealer can
ability of the fuel to provide lubrication
provide these services and components.
• Frequent plugging of the fuel filters
• Camshaft followers
• Insufficient maintenance of the fuel tank or the
fuel storage tank that can allow excessive water, • Connecting rods
sediment, etc.
• Connecting rod bearings
• Insufficient maintenance of the fuel filters
• Cylinder head assembly
Oil Suction Screen • Cylinder liners
Clean the oil suction screen after the oil has been • Scavenge oil pump
drained.
• Engine wiring harness
100 SEBU8101-07
Maintenance Section
Overhaul Considerations
Extreme Ambient Temperatures • Inspection of all the parts that are visible during
the disassembly
Extended operation in environments that are
extremely cold or hot can damage components. Valve • Replacement of the seals and gaskets that are
components can be damaged by carbon buildup if removed
the engine is frequently started and stopped in very
cold temperatures. Extremely hot inlet air reduces • Cleaning of the internal passages of the engine
the performance capabilities of the engine. and the engine block
Note: See this Operation and Maintenance Manual, • Inspecting the alignment of the driven equipment
“Cold Weather Operation” topic (Operation Section),
or see Supplement, SEBU5898, “Cold Weather Most owners will save money by overhauling the
Recommendations”. engine at the intervals that are recommended in this
Operation and Maintenance Manual. Consider the
Cleanliness graph in Illustration 64.
• Operating the engine beyond the guidelines for the (Y) Cost
engine rating (X) Time
(1) Cost of maintenance and repair that is planned
(2) Cost of maintenance and repair that is not planned
• Operating the engine at loads that are greater than
the rated load In Illustration 64, line (1) represents the maintenance
and repair costs for an owner that followed the
• Operating the engine at speeds that are greater recommendations for inspection, maintenance, and
than the rated speed repair. The peaks represent overhauls.
• Use of the engine for an application that is not Line (2) represents the maintenance and repair
approved costs for an owner that chose to operate beyond
the recommended intervals. The initial cost of the
Improper Maintenance Practices “repair-after-failure” philosophy is lower. Also, the
first overhaul was delayed. However, the peaks are
• Extension of maintenance intervals significantly higher than the peaks for the customer
that used the “repair-before-failure” philosophy.
• Not using recommended fuel, lubricants, and
coolant/antifreeze The higher peaks result from two key factors:
Your Caterpillar dealer can provide the parts that are A dirty radiator will not be able to transfer heat
needed to rebuild the engine at the least possible efficiently. This can lead to overheating of the engine.
cost. Clean the radiator according to the instructions that
are provided by the OEM of the radiator.
SEBU8101-07 103
Maintenance Section
Starting Motor - Inspect
i00908982 i01261768
More frequent inspection and replacement of the Periodic inspection and cleaning is recommended for
starting motor may be required for the following the turbocharger compressor housing (inlet side).
conditions:
Fouling of the compressor can contribute to loss of
• Operation in harsh environments engine power, increased black smoke and overall
loss of engine efficiency.
• Applications that require frequent stops and starts
If the turbocharger fails during engine operation,
If the starting motor fails, the engine may not start in damage to the turbocharger compressor wheel
an emergency situation. A scheduled inspection of and/or to the engine may occur. Damage to the
the starting motor is recommended. turbocharger compressor wheel could allow parts
from the compressor wheel to enter an engine
The starting motor pinion and the flywheel ring gear cylinder. This can cause additional damage to the
must be in good condition in order for the engine pistons, the valves, and the cylinder head.
to start properly. The engine will not start if the
starting motor pinion does not engage the flywheel NOTICE
ring gear. The teeth of the starting motor pinion and Turbocharger bearing failures can cause large quan-
the flywheel ring gear can be damaged because of tities of oil to enter the air inlet and exhaust systems.
irregular engagement. Loss of engine lubricant can result in serious engine
damage.
Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the Minor leakage of a turbocharger housing under ex-
teeth of the starting motor pinion and the flywheel tended low idle operation should not cause problems
ring gear. Look for patterns of wear on the teeth. as long as a turbocharger bearing failure has not oc-
Look for teeth that are broken or chipped. If damaged curred.
teeth are found, the starting motor pinion and the
flywheel ring gear must be replaced. If damaged When a turbocharger bearing failure is accompanied
teeth are found, the air circuit for the starting motor by a significant engine performance loss (exhaust
must be examined in order to determine the cause smoke or engine rpm up at no load), do not continue
of the problem. engine operation until the turbocharger is repaired or
replaced.
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
wheel, there is a possibility of a failed turbocharger • Ensure that cooling lines are properly clamped and
tight. Check for leaks. Check the condition of all
oil seal.
pipes.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil • Inspect the water pump for coolant leaks.
may also be the result of a restriction of the line for
Note: The water pump seal is lubricated by coolant
the inlet air (plugged air filters), which causes the
in the cooling system. It is normal for a small amount
turbocharger to slobber.
of leakage to occur as the engine cools down and
the parts contract.
4. Inspect the bore of the turbine housing for
corrosion.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
5. Clean the turbocharger housing with standard
water pump and the installation of water pump and/or
shop solvents and a soft bristle brush.
seals, refer to the Service Manual for the engine or
consult your Caterpillar dealer.
6. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
i00632301 pan, the oil filters and the valve cover.
Walk-Around Inspection • Inspect the fuel system for leaks. Look for loose
fuel line clamps.
SMCS Code: 1000-040
• Inspect the piping for the air inlet system and the
Inspect the Engine for Leaks and elbows for cracks and for loose clamps.
for Loose Connections • Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
A walk-around inspection should only take a few
minutes. When the time is taken to perform these Belts for multiple groove pulleys must be replaced as
checks, costly repairs and accidents can be avoided. matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
For maximum engine service life, make a thorough The older belts are stretched. The additional load on
inspection of the engine compartment before starting the new belt could cause the belt to break.
the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections and • Drain the water and the sediment from fuel tanks
trash buildup. Make repairs, as needed: on a daily basis in order to ensure that only clean
fuel enters the fuel system.
SEBU8101-07 105
Maintenance Section
Water Pump - Inspect
i02624237
The following standard conditions of “ISO3046/1”, Use the following guidelines in order to determine the
“DIN6271”, and “BS5514” are also applicable: applicable engine rating.
i01028392
• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
i00912149
Maintenance Records
SMCS Code: 1000; 4450
i01176304
Maintenance Log
SMCS Code: 1000; 4450
Table 27
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity
Service Item Date Authorization
Hours Of Fuel
SEBU8101-07 111
Reference Information Section
Reference Materials
i02814640 Coolants
Reference Material Special Publication, PEDP7036, “S·O·S Fluid
Analysis”
SMCS Code: 1000; 4450
Special Publication, PMEP5027, “Label - ELC
The following publications can be obtained from any Radiator Label”
Caterpillar dealer.
Data Sheet, PEHP0067, “Cat ELC (Extended Life
Lubricants Coolant)”
Special Publication, PELJ0179, “Caterpillar Engine Data Sheet, PEHP7057, “Coolant Analysis”
Crankcase Fluid-1 Specifications (Cat ECF-1)” All
international markets Data Sheet, PEHP9554, “Cat DEAC (Diesel Engine
Antifreeze/Coolant)”
Data Sheet, PEHJ0059, “Cat DEO (SAE 10W-30
and SAE 15W-40)” North America: Canada, Mexico, Special Publication, PELJ0176, “Cat ELC (Extended
and United States Life Coolant) 223-9116 Dilution Test Kit”
Data Sheet, PEHJ0021, “Cat DEO (SAE 10W-30 Special Publication, SEBD0518, “Know Your Cooling
and SAE 15W-40)” Worldwide except North America, System”
Egypt, Saudi Arabia, and Brazil
Special Publication, SEBD0970, “Coolant and Your
Data Sheet, PEHJ0072, “Cat DEO (SAE 10W-30 and Engine”
SAE 15W-40)” (Brazil)
Miscellaneous
Data Sheet, PEHJ0091, “Cat DEO (SAE 10W-30 and
SAE 15W-40)” Egypt and Saudi Arabia Service Manual, RENR9350, “3500C Engines”
Special Publication, PEGJ0035, “Grease Selection Troubleshooting Guide, RENR9364, “3500C
Guide” Engines”
Data Sheet, PEHP0002, “Cat Advanced 3Moly Specifications, RENR9362, “3500C Engines”
Grease” NLGI grade 2
Systems Operation Testing and Adjusting,
Data Sheet, NEHP6015, “Cat High Speed Ball RENR9363, “3500C Engines”
Bearing Grease” NLGI grade 2
Disassembly and Assembly, RENR9365, “3500C
Data Sheet, PEHJ0088, “Cat Multipurpose Grease” Generator Set Engine”
NLGI grade 2
Special Instruction, SEHS9031, “Storage Procedure
Special Publication, SEBD0640, “Oil and Your for Caterpillar Products”
Engine”
Special Instruction, SEHS7332, “Do Not Operate
Special Publication, SEBU5898, “Cold Weather Tag”
Recommendations”
Special Instruction, SEHS7633, “Battery Test
Special Publication, PEPD7036, “S·O·S Fluid Procedure”
Analysis”
Special Publication, NENG2500, “Caterpillar Dealer
Special Publication, PEHP6001, “How To Take A Service Tools Catalog”
Good Oil Sample”
Special Publication, SEBF8029, “Index to Guidelines
Fuels for Reusable Parts and Salvage Operations”
Engine Data Sheet, LEKQ4219, “Fuel Special Publication, SEBF8062, “Guideline for
Recommendations for Caterpillar Diesel Reusable Parts - Cleaning and Inspection of Air
Engines” Filters”
Special Publication, SEBD0717, “Diesel Fuels and Specifications, SENR3130, “Torque Specifications”
Your Engine”
112 SEBU8101-07
Reference Information Section
Reference Materials
i03637502
Decommissioning and
Disposal
SMCS Code: 1000; 1021; 4450; 7002
Index
A Cooling System Coolant Level - Check ................. 64
Add Coolant ....................................................... 65
After Starting Engine ............................................. 46 Engines That Are Equipped With a Sight
Engaging the Driven Equipment ........................ 46 Gauge .............................................................. 64
Warm-up ............................................................ 46 Engines That Are Not Equipped With a Sight
After Stopping Engine............................................ 50 Gauge .............................................................. 65
Alarms and Shutoffs .............................................. 32 Cooling System Coolant Sample (Level 1) -
Alternator - Inspect ................................................ 59 Obtain .................................................................. 65
Cooling System Coolant Sample (Level 2) -
Obtain .................................................................. 66
B Cooling System Supplemental Coolant Additive
(SCA) - Test/Add.................................................. 66
Batteries - Replace ................................................ 59 Cooling Systems that Use Conventional
Before Starting Engine .................................... 13, 42 Coolant............................................................. 67
Walk-Around Inspection..................................... 42 Cooling Systems that Use Water and SCA........ 67
Belts - Inspect/Adjust/Replace............................... 59 Cooling System Water Temperature Regulator -
Adjusting the Alternator Belt .............................. 60 Replace................................................................ 68
Adjusting the Fan Drive Belt .............................. 60 Crankshaft Vibration Damper - Inspect ................. 68
Inspection........................................................... 59 Dampers With Sampling Ports........................... 69
Replacement...................................................... 60 Dampers Without Sampling Ports...................... 69
Burn Prevention..................................................... 10 Removal and Installation.................................... 69
Batteries.............................................................. 11 Crushing Prevention and Cutting Prevention ........ 13
Coolant............................................................... 10 Customer Assistance........................................... 107
Oils...................................................................... 11 Outside of the USA and of Canada.................. 107
USA and Canada ............................................. 107
Customer Service ................................................ 107
C
Engine Mounts - Check ......................................... 77 Fuel Tank Water and Sediment - Drain ................. 88
Engine Oil and Filter - Change .............................. 80 Drain the Water and the Sediment..................... 88
Drain the Oil ....................................................... 80 Fuel Storage Tanks ............................................ 88
Fill the Crankcase .............................................. 83 Fuel Tank ........................................................... 88
Inspect the Used Oil Filter Elements.................. 84
Replace the Oil Filter Elements ......................... 81
Replacing the Engine Oil Filters During Engine G
Operation ......................................................... 83
Engine Oil Filter Differential Pressure - Check ...... 78 Gauges and Indicators .......................................... 23
Engine Oil Level - Check ....................................... 78 Gauge Cluster Modules ..................................... 24
Engine Oil Sample - Obtain ................................... 79 Main Module ...................................................... 23
Obtain the Sample and the Analysis.................. 79 General Hazard Information .................................... 7
Engine Operation................................................... 47 Asbestos Information ........................................... 9
Operating the Engine and the Driven Containing Fluid Spillage ..................................... 9
Equipment ........................................................ 47 Dispose of Waste Properly ................................ 10
Partial Load Operation ....................................... 47 Fluid Penetration.................................................. 9
Engine Protective Devices - Check ....................... 84 Lines, Tubes, and Hoses ................................... 10
Visual Inspection................................................ 84 Pressurized Air and Water ................................... 8
Engine Rating Conditions .................................... 106
Engine Rating Definitions .................................... 106
Engine Ratings .................................................... 106 H
Engine Starting ................................................ 14, 42
Ether .................................................................. 14 Hoses and Clamps - Inspect/Replace ................... 88
Engine Stopping .............................................. 14, 49 Replace the Hoses and the Clamps .................. 89
Engine Valve Lash - Inspect/Adjust ....................... 84
Engine Valve Lash ............................................. 85
Valve Bridge....................................................... 84 I
Operation Section.................................................. 21
Ordering Replacement Parts ............................... 108
116 SEBU8101-07
Index Section
Overhaul (Major).................................................... 94 T
Cleaning of Components ................................... 96
Inspection of Components ................................. 96 Table of Contents..................................................... 3
Inspection, Reconditioning or Exchanging of Turbocharger - Inspect ........................................ 103
Components..................................................... 95 Cleaning and Inspecting .................................. 104
Obtain a Coolant Analysis.................................. 96 Removal and Installation.................................. 103
Replacement of Components ............................ 95
Overhaul (Top End) ............................................... 97
First Top End Overhaul ...................................... 97 W
Top End Overhaul (Second)............................... 98
Overhaul Considerations ..................................... 100 Walk-Around Inspection ...................................... 104
Overhaul Information ....................................... 101 Inspect the Engine for Leaks and for Loose
Severe Operation............................................. 100 Connections ................................................... 104
Warranty Information ............................................ 112
Engine Protection Plans.................................... 112
P Water Pump - Inspect .......................................... 105
Welding on Engines with Electronic Controls ........ 55
Plate Locations and Film Locations....................... 19
Engine Identification........................................... 19
Information Plate................................................ 19
Serial Number Plate........................................... 19
Product Description ............................................... 17
Product Identification Information .......................... 19
Product Information Section .................................. 16
Product Lifting........................................................ 21
Product Storage..................................................... 22
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
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