3054E and 3056E Industrial Engines-Maintenance Intervals

SAFETY.CAT.COM

C-12 and C12MARINE ENGINESMaintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU7599-03-01)

2007 CaterpillarAll Rights Reserved

72Maintenance SectionMaintenance Interval Schedule

i01781391

Maintenance Interval ScheduleSMCS Code: 1000; 7500

Ensure that the Safety Information, Warnings,and Instructions are read and understoodbefore operation or maintenance procedures areperformed.

In order to determine the maintenance interval,use the value that occurs first: fuel consumption ,service hours , or calendar time .

Before each consecutive interval is performed, allof the maintenance requirements from the previousinterval must also be performed.

The normal oil change interval is every 500service hours or 12 months. Be sure to conductcontrolled oil sampling at every 250 servicehours or 6 months. The oil change interval mayneed to be reduced for some applications basedon the controlled oil sampling results. Verify theproper oil change interval for the engine aftersatisfactory completion of the controlled oilsampling.

When RequiredBattery - Replace .................................................. 76Battery or Battery Cable - Disconnect .................. 77Engine - Clean ...................................................... 85Engine Air Cleaner Element (Dual Element) -Clean/Replace .................................................... 85

Fuel System - Prime ............................................. 95Severe Service Application - Check .................... 104

DailyCooling System Coolant Level - Check ................ 81Driven Equipment - Check .................................... 84Engine Air Cleaner Service Indicator - Inspect ..... 88Engine Oil Level - Check ...................................... 90Fuel System Primary Filter/Water Separator -Drain ................................................................... 96

Power Take-Off Clutch - Check/Adjust/Lubricate ........................................................... 103

Walk-Around Inspection ...................................... 105

Every 250 Service Hours or 6 MonthsEngine Oil Sample - Obtain .................................. 90

Every 250 Service Hours or 1 YearRadiator - Clean .................................................. 103

Every 500 Service HoursAlternator and Fan Belts - Inspect/Adjust/Replace ............................................................... 76

Battery Electrolyte Level - Check .......................... 77Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 82

Every 500 Service Hours or 6 MonthsEngine Protective Devices - Check ....................... 92Fuel System Primary Filter/Water Separator Element- Replace ............................................................. 96

Fuel System Secondary Filter - Replace .............. 97Fuel Transfer Pump Strainer - Clean .................... 98Hoses and Clamps - Inspect/Replace .................. 99

Every 500 Service Hours or 1 YearAir Compressor Filter - Clean/Replace ................. 75Electronics Grounding Stud - Inspect/Clean/Tighten ................................................................ 85

Engine Oil and Filter - Change ............................. 91

Every 1000 Service HoursEngine Valve Lash - Inspect/Adjust ...................... 93Turbocharger - Inspect ........................................ 105

Every 2000 Service HoursAir Compressor - Inspect ...................................... 75Alternator - Inspect ............................................... 76

Every 2000 Service Hours or 1 YearAftercooler Core - Inspect ..................................... 74Crankshaft Vibration Damper - Inspect ................. 84Engine Mounts - Inspect ....................................... 90Fuel Injection Nozzles - Test/Exchange ................ 93Every 2000 Service Hours or 2 YearsCooling System Coolant Extender (ELC) - Add .... 81Every 3000 Service Hours or 2 YearsCooling System Coolant (DEAC) - Change .......... 78Cooling System Water Temperature Regulator -Replace ............................................................... 83

Starting Motor - Inspect ...................................... 104Water Pump - Inspect ......................................... 106

Every 4000 Service Hours or 2 YearsAftercooler Core - Clean/Test ............................... 74

Every 6000 Service Hours or 3 YearsCooling System Coolant Extender (ELC) - Add .... 81Every 6000 Service Hours or 6 YearsCooling System Coolant (ELC) - Change ............. 80

73Maintenance Section

Maintenance Interval Schedule

Every 8000 Service Hours or 1 YearEngine Crankcase Breather - Clean/Replace ....... 89

First 300 L (80 US gal) of Fuel or First 20 to40 Service HoursEngine Valve Lash - Inspect/Adjust ...................... 93Every 13 000 L (3400 US gal) of Fuel or 250Service HoursCylinder Head Grounding Stud - Inspect/Clean/Tighten ................................................................ 84

OverhaulOverhaul Considerations .................................... 100

74Maintenance SectionAftercooler Core - Clean/Test

i01546702

Aftercooler Core - Clean/TestSMCS Code: 1064-070; 1064-081

1. Remove the core. Refer to the Service Manualfor the procedure.

2. Turn the aftercooler core upside-down in orderto remove debris.

NOTICEDo not use a high concentration of caustic cleaner toclean the core. A high concentration of caustic cleanercan attack the internal metals of the core and causeleakage. Only use the recommended concentration ofcleaner.

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Table 32 lists Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 32

Hydrosolv Liquid Cleaners(1)

PartNumber Description Size

1U-5490 Hydrosolv 4165 19 L (5 US gallon)174-6854 Hydrosolv 100 19 L (5 US gallon)

(1) Use a two to five percent concentration of the cleanerat temperatures up to 93 C (200 F). Refer to ApplicationGuide, NEHS0526 or consult your Caterpillar dealer for moreinformation.

4. Steam clean the core in order to remove anyresidue. Flush the fins of the aftercooler core.Remove any other trapped debris.

5. Wash the core with hot, soapy water. Rinse thecore thoroughly with clean water.

Personal injury can result from air pressure.Personal injury can result without following prop-er procedure.When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

6. Dry the core with compressed air. Direct the airin the reverse direction of the normal flow.

7. Inspect the core in order to ensure cleanliness.Pressure test the core. Many shops that serviceradiators are equipped to perform pressure tests.If necessary, repair the core.

8. Install the core. Refer to the Service Manual forthe procedure.

For more information on cleaning the core, consultyour Caterpillar dealer.

i01468985

Aftercooler Core - InspectSMCS Code: 1064-040

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

Inspect the aftercooler for these items: damagedfins, corrosion, dirt, grease, insects, leaves, oil, andother debris. Clean the aftercooler, if necessary.

For air-to-air aftercoolers, use the same methodsthat are used for cleaning radiators.


Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the fans air flow. Hold the nozzle approximately6 mm (.25 inch) away from the fins. Slowly movethe air nozzle in a direction that is parallel with thetubes. This will remove debris that is between thetubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

Use a degreaser and steam for removal of oil andgrease. Clean both sides of the core. Wash the corewith detergent and hot water. Thoroughly rinse thecore with clean water.


Air Compressor - Inspect

After cleaning, start the engine and accelerate theengine to high idle rpm. This will help in the removalof debris and drying of the core. Stop the engine.Use a light bulb behind the core in order to inspectthe core for cleanliness. Repeat the cleaning, ifnecessary.

Inspect the fins for damage. Bent fins may beopened with a comb.

Note: If parts of the aftercooler system are repairedor replaced, a leak test is highly recommended.The FT1984 Aftercooler Testing Group is usedto perform leak tests on the aftercooler. Refer tothe Systems Operation/Testing and Adjusting,Aftercooler - Test and the Special Instruction,SEHS8622 for the proper testing procedure.

Inspect these items for good condition: welds,mounting brackets, air lines, connections, clamps,and seals. Make repairs, if necessary.

For more detailed information on cleaning andinspection, see Special Publication, SEBD0518,Know Your Cooling System.

i01183385

Air Compressor - InspectSMCS Code: 1803-040

Do not disconnect the air line from the air com-pressor governor without purging the air brakeand the auxiliary air systems. Failure to purge theair brake and the auxiliary air systems before re-moving the air compressor and/or the air linescould cause personal injury.

g00633741Illustration 32(1) Air compressor pressure relief valve

If the air compressor pressure relief valve that ismounted in the air compressor cylinder head isbypassing compressed air, there is a malfunctionin the air system, possibly ice blockage. Underthese conditions, your engine may have insuffi-cient air for normal brake operation.

Do not operate the engine until the reason for theair bypass is identified and corrected. Failure toheed this warning could lead to property damage,personal injury, or death to the operator or by-standers.

The function of the air compressor pressure reliefvalve is to bypass air when there is a malfunction inthe air compressor system.

The air compressor pressure relief valve releasesair at 1723 kPa (250 psi). It is very important thatall personnel stand clear of the air compressorpressure relief valve when compressed air isreleased. All personnel should also stay clear of theair compressor when the engine is operating andthe air compressor is exposed.

Refer to the Service Manual or refer to the OEMspecifications in order to find information concerningthe air compressor. Consult your Caterpillar dealerfor assistance.

i01544231

Air Compressor Filter -Clean/Replace(If Equipped)SMCS Code: 1803-070-FQ; 1803-510-FQ

One of the single most important aspects ofpreventive maintenance for the air compressor isthe induction of clean air. The type of maintenancethat is required for the air compressor and themaintenance interval depends on the type of airinduction system that is used. Operating conditions(dust, dirt and debris) may require more frequentservice.

Refer to the Service Manual for the type ofair compressor that is installed on the engine.Follow the maintenance recommendations that areprovided by the OEM of the air compressor. Someengines use boost air pressure so the engine aircleaner will require servicing.

76Maintenance SectionAlternator - Inspect

i00072207

Alternator - InspectSMCS Code: 1405-040

Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and proper battery charging. Inspectthe ammeter (if equipped) during engine operationin order to ensure proper battery performanceand/or proper performance of the electrical system.Make repairs, as required. Refer to the ServiceManual.

Check the alternator and the battery charger forproper operation. If the batteries are properlycharged, the ammeter reading should be very nearzero. All batteries should be kept charged. Thebatteries should be kept warm because temperatureaffects the cranking power. If the battery is too cold,the battery will not crank the engine. The battery willnot crank the engine, even if the engine is warm.When the engine is not run for long periods of timeor if the engine is run for short periods, the batteriesmay not fully charge. A battery with a low charge willfreeze more easily than a battery with a full charge.

i01150959

Alternator and Fan Belts -Inspect/Adjust/ReplaceSMCS Code: 1357-039

InspectionTo maximize the engine performance, inspect thebelts for wear and for cracking. Replace belts thatare worn or damaged.

For applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new belt tocarry more load because the older belt is stretched.The additional load on the new belt could cause thenew belt to break.

If the belts are too loose, vibration causesunnecessary wear on the belts and pulleys. Loosebelts may slip enough to cause overheating.

To check the belt tension, apply 45 N (10 lb ft)of force midway between the pulleys. A correctlyadjusted belt will deflect 10 mm (0.39 inch).

Adjustment

g00285332Illustration 33Typical example(1) Adjusting bolt(2) Mounting bolts

1. Loosen mounting bolts (2) and adjusting bolt (1).

2. Move the alternator in order to increase ordecrease the belt tension.

3. Tighten adjusting bolt (1). Tighten mounting bolts(2). Refer to the Operation and MaintenanceManual for the proper torque settings.

If new belts are installed, check the belt tensionagain after 20 hours of engine operation.

ReplacementRefer to the Service Manual for the installationprocedure and the removal procedure for the belt.

i01492550

Battery - ReplaceSMCS Code: 1401-510

Batteries give off combustible gases which canexplode. A spark can cause the combustible gas-es to ignite. This can result in severe personal in-jury or death.Ensure proper ventilation for batteries that are inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.


Battery Electrolyte Level - Check

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the key start switch to the OFF position.Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect thecharger.

3. The NEGATIVE - cable connects the NEGATIVE- battery terminal to the ground plane.Disconnect the cable from the NEGATIVE -battery terminal.

4. The POSITIVE + cable connects the POSITIVE+ battery terminal to the starting motor.Disconnect the cable from the POSITIVE +battery terminal.

Note: Always recycle a battery. Never discard abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure thatthe key start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE + battery terminal.

8. Connect the cable from the ground plane to theNEGATIVE - battery terminal.

i01639002

Battery Electrolyte Level -CheckSMCS Code: 1401-535

When the engine is not run for long periods oftime or when the engine is run for short periods,the batteries may not fully recharge. Ensure a fullcharge in order to help prevent the battery fromfreezing. If batteries are properly charged, ammeterreading should be very near zero.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

1. Remove the filler caps. Maintain the electrolytelevel to the FULL mark on the battery.

If the addition of water is necessary, use distilledwater. If distilled water is not available useclean water that is low in minerals. Do not useartificially softened water.

2. Check the condition of the electrolyte with the1U-7298 Coolant/Battery Tester ( C) or the1U-7297 Coolant/Battery Tester ( F).

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

A mixture of 0.1 kg (0.2 lb) of baking soda and1 L (1 qt) of clean water

A mixture of 0.1 L (0.11 qt) of ammonia and1 L (1 qt) of clean water

Thoroughly rinse the battery case with cleanwater.

Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fitproperly. Coat the clamps and the terminals with5N-5561 Silicone Lubricant, petroleum jelly orMPGM grease.

i01492654

Battery or Battery Cable -DisconnectSMCS Code: 1402-029

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

78Maintenance SectionCooling System Coolant (DEAC) - Change

1. Turn the start switch to the OFF position. Turn theignition switch (if equipped) to the OFF positionand remove the key and all electrical loads.

2. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal. When four12 volt batteries are involved, the negative sideof two batteries must be disconnected.

3. Tape the leads in order to help prevent accidentalstarting.

4. Proceed with necessary system repairs. Reversethe steps in order to reconnect all of the cables.

i01206425

Cooling System Coolant(DEAC) - ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

The engine overheats frequently.

Foaming is observed.

The oil has entered the cooling system and thecoolant is contaminated.

The fuel has entered the cooling system and thecoolant is contaminated.

NOTICEUse of commercially available cooling system clean-ers may cause damage to cooling system compo-nents. Use only cooling system cleaners that are ap-proved for Caterpillar engines.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulatorand the hoses, if necessary.

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.

2. Open the cooling system drain valve (ifequipped). If the cooling system is not equippedwith a drain valve, remove one of the drain plugs.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Service TechnologyGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush1. Flush the cooling system with clean water in

order to remove any debris.

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theOperation and Maintenance Manual, TorqueSpecifications topic (Maintenance Section) formore information on the proper torques.

NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.


Cooling System Coolant (DEAC) - Change

4. Start and run the engine at low idle for aminimum of 30 minutes. The coolant temperatureshould be at least 82 C (180 F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling systemdrain plugs. Allow the water to drain. Flush thecooling system with clean water. Close the drainvalve (if equipped). Clean the drain plugs. Installthe drain plugs. Refer to the Operation andMaintenance Manual, Torque Specificationstopic (Maintenance Section) for more informationon the proper torques.

Cooling Systems with HeavyDeposits or PluggingNote: For the following procedure to be effective,there must be some active flow through the coolingsystem components.

1. Flush the cooling system with clean water inorder to remove any debris.



3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity. Install the cooling system filler cap.

4. Start and run the engine at low idle for aminimum of 90 minutes. The coolant temperatureshould be at least 82 C (180 F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.


FillNOTICE

Fill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

1. Fill the cooling system with coolant/antifreeze.Refer to the Operation and MaintenanceManual, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to 1500 rpm. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolantlevel within 13 mm (0.5 inch) below the bottomof the pipe for filling. Maintain the coolant levelwithin 13 mm (0.5 inch) to the proper level on thesight glass (if equipped).

80Maintenance SectionCooling System Coolant (ELC) - Change

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap.If the gasket that is on the cooling system fillercap is not damaged, perform a pressure test. A9S-8140 Pressurizing Pump is used to performthe pressure test. The correct pressure for thecooling system filler cap is stamped on the faceof the cooling system filler cap. If the coolingsystem filler cap does not retain the correctpressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i01206445

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

The engine overheats frequently.

Foaming is observed.

The oil has entered the cooling system and thecoolant is contaminated.

The fuel has entered the cooling system and thecoolant is contaminated.

Note: When the cooling system is cleaned, onlyclean water is needed when the ELC is drainedand replaced.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulatorand the hoses, if necessary.

Drain


1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.

2. Open the cooling system drain valve (ifequipped). If the cooling system is not equippedwith a drain valve, remove the cooling systemdrain plugs.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Service TechnologyGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush1. Flush the cooling system with clean water in

order to remove any debris.



3. Fill the cooling system with clean water. Installthe cooling system filler cap.

4. Start and run the engine at low idle until thetemperature reaches 49 to 66 C (120 to 150 F).


Cooling System Coolant Extender (ELC) - Add


FillNOTICE

Fill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

1. Fill the cooling system with Extended Life Coolant(ELC). Refer to the Operation and MaintenanceManual, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to high idle. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolantlevel within 13 mm (0.5 inch) below the bottomof the pipe for filling. Maintain the coolant levelwithin 13 mm (0.5 inch) to the proper level on thesight glass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket that is on the cooling system filler capis not damaged, use a 9S-8140 PressurizingPump in order to pressure test the coolingsystem filler cap. The correct pressure for thecooling system filler cap is stamped on the faceof the cooling system filler cap. If the coolingsystem filler cap does not retain the correctpressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i00259474

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-045; 1395-081

Caterpillar Extended Life Coolant (ELC) does notrequire the frequent Supplemental Coolant Additive(SCA) additions associated with the presentconventional coolants. The Extender only needs tobe added once.

Check the cooling system only when the engine isstopped and cool.

1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. It may be necessary to drain enough coolantfrom the cooling system in order to add theExtender.

3. Add Extender according to the requirements foryour engines cooling system capacity. Refer tothe Operation and Maintenance Manual, RefillCapacities in the Maintenance Section for thecapacity of the cooling system for your engine.Refer to the Operation and Maintenance Manual,Cooling System Specifications information forthe Caterpillar ELC Extender additions.

4. Clean the cooling system filler cap. Inspect thecooling system filler cap gaskets. Replace thecooling system filler cap if the cooling systemfiller cap gaskets are damaged. Install thecooling system filler cap.

i01197583

Cooling System Coolant Level- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

82Maintenance SectionCooling System Supplemental Coolant Additive (SCA) - Test/Add

g00285520Illustration 34Cooling system filler cap


1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel to the proper level in the sight glass.

g00103639Illustration 35Typical filler cap gaskets

3. Clean the cooling system filler cap and check thecondition of the filler cap gaskets. Replace thecooling system filler cap if the filler cap gasketsare damaged. Reinstall the cooling system fillercap.

4. Inspect the cooling system for leaks.

i01463635

Cooling System SupplementalCoolant Additive (SCA) -Test/AddSMCS Code: 1352-045; 1395-081

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and the eyes. Do not drink cooling systemcoolant additive.

Note: Test the concentration of the SupplementalCoolant Additive (SCA) or test the SCA concentrationas part of an SOS Coolant Analysis.

Test for SCA ConcentrationCoolant/Antifreeze and SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Use the 8T-5296 Coolant Conditioner Test Kit oruse the 4C-9301 Coolant Conditioner Test Kit inorder to check the concentration of the SCA. Referto the Operation and Maintenance Manual for moreinformation.

Water and SCA

NOTICEDo not exceed the recommended eight percent sup-plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Refer to the Operationand Maintenance Manual, Water/SupplementalCoolant Additive (SCA) topic (MaintenanceSection). Refer to the Operation and MaintenanceManual, Conventional Coolant/Antifreeze CoolingSystem Maintenance topic (Maintenance Section).

SOS Coolant AnalysisSOS coolant samples can be analyzed at yourCaterpillar dealer. SOS Coolant Analysis is aprogram that is based on periodic samples.


Cooling System Water Temperature Regulator - Replace

Level 1

Level 1 is a basic analysis of the coolant. Thefollowing items are tested:

Glycol Concentration

Concentration of SCA

pH

Conductivity

The results are reported, and recommendationsare made according to the results. Consult yourCaterpillar dealer for information on the benefits ofmanaging your equipment with an SOS CoolantAnalysis.

Level 2

This level coolant analysis is recommendedwhen the engine is overhauled. Refer to theOperations and Maintenance Manual, OverhaulConsiderations for further information.

Add the SCA, If Necessary

NOTICEDo not exceed the recommended amount of sup-plemental coolant additive concentration. Excessivesupplemental coolant additive concentration can formdeposits on the higher temperature surfaces of thecooling system, reducing the engines heat transfercharacteristics. Reduced heat transfer could causecracking of the cylinder head and other high temper-ature components. Excessive supplemental coolantadditive concentration could also result in radiatortube blockage, overheating, and/or accelerated waterpump seal wear. Never use both liquid supplementalcoolant additive and the spin-on element (if equipped)at the same time. The use of those additives togethercould result in supplemental coolant additive concen-tration exceeding the recommended maximum.


1. Slowly loosen the cooling system filler cap inorder to relieve the pressure. Remove the coolingsystem filler cap.

Note: Always discard drained fluids according tolocal regulations.

2. If necessary, drain some coolant from the coolingsystem into a suitable container in order to allowspace for the extra SCA.

3. Add the proper amount of SCA. Refer to theOperation and Maintenance Manual for moreinformation on SCA requirements.

4. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets are damaged, replace the old coolingsystem filler cap with a new cooling system fillercap. Install the cooling system filler cap.

i00912898

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime.

A water temperature regulator that fails in apartially opened position can cause overheating orovercooling of the engine.

A water temperature regulator that fails in theclosed position can cause excessive overheating.Excessive overheating could result in cracking ofthe cylinder head or piston seizure problems.

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup insidethe cylinders. This excessive carbon buildup couldresult in an accelerated wear of the piston rings andwear of the cylinder liner.

84Maintenance SectionCrankshaft Vibration Damper - Inspect

NOTICEFailure to replace your water temperature regulatoron a regularly scheduled basis could cause severeengine damage.

Caterpillar engines incorporate a shunt design coolingsystem and require operating the engine with a watertemperature regulator installed.

If the water temperature regulator is installed incor-rectly, the engine may overheat, causing cylinder headdamage. Ensure that the new water temperature reg-ulator is installed in the original position. Ensure thatthe water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket orcylinder head surface.

Refer to the Service Manual for the replacementprocedure of the water temperature regulator, orconsult your Caterpillar dealer.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling systemto a level that is below the water temperatureregulator housing.

i01196868

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040

Damage to the crankshaft vibration damper orfailure of the crankshaft vibration damper canincrease torsional vibrations. This can result indamage to the crankshaft and to other enginecomponents. A deteriorating damper can causeexcessive gear train noise at variable points in thespeed range.

The damper is mounted to the crankshaft which islocated behind the belt guard on the front of theengine.

Removal and InstallationRefer to the Service Manual for the damperremoval procedure and for the damper installationprocedure.

i01684727

Cylinder Head Grounding Stud- Inspect/Clean/TightenSMCS Code: 7423-040; 7423-070; 7423-079

g00738038Illustration 36Typical example for location of cylinder head grounding stud(1) Cylinder head grounding stud

Inspect the wiring harness for good connections.

The cylinder head grounding stud must have a wireground to the battery. Tighten the cylinder headgrounding stud at every oil change. Ground wiresand straps should be combined at engine grounds.All grounds should be tight and free of corrosion.

Clean the cylinder head grounding stud and theterminals with a clean cloth.

If the connections are corroded, clean theconnections with a solution of baking soda andwater.

Keep the cylinder head grounding stud and thestrap clean and coated with MPGM grease orpetroleum jelly.

i00174798

Driven Equipment - CheckSMCS Code: 3279-535

Refer to the OEM specifications for more informationon the following maintenance recommendations forthe driven equipment:

Inspection

Adjustment

Lubrication

Other maintenance recommendations


Electronics Grounding Stud - Inspect/Clean/Tighten

Perform any maintenance for the driven equipmentwhich is recommended by the OEM.

i01646937

Electronics Grounding Stud -Inspect/Clean/TightenSMCS Code: 7423-040; 7423-070; 7423-079

g00395898Illustration 37Typical exampleElectrical grounding stud (top view)

Inspect the wiring harnesses for good connectionsand condition.

The electrical grounding stud must have a wireground to the battery. Tighten the electricalgrounding stud at every oil change. Ground wiresand straps should be combined at engine grounds.All grounds should be tight and free of corrosion.

Clean the electrical grounding stud and theterminals for the electrical ground strap with aclean cloth.

If the connections are corroded, clean theconnections with a solution of baking soda andwater.

Keep the electrical grounding stud and thestrap clean and coated with MPGM grease orpetroleum jelly.

i01646701

Engine - CleanSMCS Code: 1000-070

Personal injury or death can result from high volt-age.

Moisture can create paths of electrical conductiv-ity.

Make sure that the electrical system is OFF. Lockout the starting controls and tag the controls DONOT OPERATE.

NOTICEAccumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Periodic cleaning of the engine is recommended.Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides thefollowing benefits:

Easy detection of fluid leaks

Maximum heat transfer characteristics

Ease of maintenance

Note: Caution must be used in order to preventelectrical components from being damaged byexcessive water when you clean the engine. Avoidelectrical components such as the alternator, thestarter, and the ECM.

i01553486

Engine Air Cleaner Element(Dual Element) - Clean/ReplaceSMCS Code: 1054-037; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

86Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

Servicing the Air Cleaner ElementsIf the air cleaner element becomes plugged, theair can split the material of the air cleaner element.Unfiltered air will drastically accelerate internalengine wear. Your Caterpillar dealer has the properair cleaner elements for your application. Consultyour Caterpillar dealer for the correct air cleanerelement.

Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

Operating conditions (dust, dirt and debris) mayrequire more frequent service of the air cleanerelement.

The air cleaner element may be cleaned up tosix times if the element is properly cleaned andinspected.

The air cleaner element should be replacedat least one time per year. This replacementshould be performed regardless of the numberof cleanings.

Replace the dirty paper air cleaner elements withclean air cleaner elements. Before installation, theair cleaner elements should be thoroughly checkedfor tears and/or holes in the filter material. Inspectthe gasket or the seal of the air cleaner element fordamage. Maintain a supply of suitable air cleanerelements for replacement purposes.

Dual Element Air CleanersThe dual element air cleaner contains a primaryair cleaner element and a secondary air cleanerelement. The primary air cleaner element can beused up to six times if the element is properlycleaned and inspected. The primary air cleanerelement should be replaced at least one timeper year. This replacement should be performedregardless of the number of cleanings.

The secondary air cleaner element is not serviceableor washable. The secondary air cleaner elementshould be removed and discarded for every threecleanings of the primary air cleaner element. Whenthe engine is operating in environments that aredusty or dirty, air cleaner elements may requiremore frequent replacement.

g00736431Illustration 38(1) Cover(2) Primary air cleaner element(3) Secondary air cleaner element(4) Turbocharger air inlet

1. Remove the cover. Remove the primary aircleaner element.

2. The secondary air cleaner element should beremoved and discarded for every three cleaningsof the primary air cleaner element.

Note: Refer to Cleaning the Primary Air CleanerElements.

3. Cover the turbocharger air inlet with tape inorder to keep dirt out.

4. Clean the inside of the air cleaner cover andbody with a clean, dry cloth.

5. Remove the tape for the turbocharger air inlet.Install the secondary air cleaner element. Installa primary air cleaner element that is new orcleaned.

6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.


Engine Air Cleaner Element (Dual Element) - Clean/Replace

Cleaning the Primary Air CleanerElements

NOTICECaterpillar recommends certified air filter cleaningservices that are available at Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to removedust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary air cleaner element can be used upto six times if the element is properly cleaned andinspected. When the primary air cleaner element iscleaned, check for rips or tears in the filter material.The primary air cleaner element should be replacedat least one time per year. This replacementshould be performed regardless of the number ofcleanings.

Use clean primary air cleaner elements while dirtyelements are being cleaned.

NOTICEDo not clean the air cleaner elements by bumping ortapping. This could damage the seals. Do not use el-ements with damaged pleats, gaskets or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air cleaner elementsbefore cleaning. Inspect the air cleaner elementsfor damage to the seal, the gaskets, and the outercover. Discard any damaged air cleaner elements.

There are two common methods that are used toclean primary air cleaner elements:

Pressurized air

Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean primary aircleaner elements that have not been cleaned morethan two times. Pressurized air will not removedeposits of carbon and oil. Use filtered, dry air witha maximum pressure of 207 kPa (30 psi).

g00281692Illustration 39

Note: When the primary air cleaner elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the streamof air directly at the primary air cleaner element. Dirtcould be forced further into the pleats.

Note: Refer to Inspecting the Primary Air CleanerElements.

Vacuum CleaningVacuum cleaning is a good method for cleaningprimary air cleaner elements which require dailycleaning because of a dry, dusty environment.Cleaning with pressurized air is recommendedprior to vacuum cleaning. Vacuum cleaning will notremove deposits of carbon and oil.

Note: Refer to Inspecting the Primary Air CleanerElements.

88Maintenance SectionEngine Air Cleaner Service Indicator - Inspect

Inspecting the Primary Air CleanerElements


Inspect the clean, dry primary air cleaner element.Use a 60 watt blue light in a dark room or in asimilar facility. Place the blue light in the primaryair cleaner element. Rotate the primary air cleanerelement. Inspect the primary air cleaner element fortears and/or holes. Inspect the primary air cleanerelement for light that may show through the filtermaterial. If it is necessary in order to confirm theresult, compare the primary air cleaner elementto a new primary air cleaner element that has thesame part number.

Do not use a primary air cleaner element that hasany tears and/or holes in the filter material. Do notuse a primary air cleaner element with damagedpleats, gaskets or seals. Discard damaged primaryair cleaner elements.

Storing Primary Air Cleaner ElementsIf a primary air cleaner element that passesinspection will not be used, the primary air cleanerelement can be stored for future use.


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An airflow restrictionmay result. To protect against dirt and damage,wrap the primary air cleaner elements in VolatileCorrosion Inhibited (VCI) paper.

Place the primary air cleaner element into a boxfor storage. For identification, mark the outside ofthe box and mark the primary air cleaner element.Include the following information:

Date of cleaning

Number of cleanings

Store the box in a dry location.

i01175055

Engine Air Cleaner ServiceIndicator - InspectSMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differentialgauge for inlet air pressure. The differential gaugefor inlet air pressure displays the difference in thepressure that is measured before the air cleanerelement and the pressure that is measured afterthe air cleaner element. As the air cleaner elementbecomes dirty, the pressure differential rises. If yourengine is equipped with a different type of serviceindicator, follow the OEM recommendations in orderto service the air cleaner service indicator.

The service indicator may be mounted on the aircleaner element or in a remote location.

g00103777Illustration 42Typical service indicator


Engine Crankcase Breather - Clean/Replace

Observe the service indicator. The air cleanerelement should be cleaned or the air cleanerelement should be replaced when one of thefollowing conditions occur:

The yellow diaphragm enters the red zone.

The red piston locks in the visible position.

Test the Service IndicatorService indicators are important instruments.

Check for ease of resetting. The service indicatorshould reset in less than three pushes.

Check the movement of the yellow core when theengine is accelerated to the engine rated speed.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If thenew service indicator will not reset, the hole for theservice indicator may be plugged.

The service indicator may need to be replacedfrequently in environments that are severely dusty, ifnecessary. Replace the service indicator annuallyregardless of the operating conditions. Replace theservice indicator when the engine is overhauled,and whenever major engine components arereplaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 Nm (18 lb in).

i01682944

Engine Crankcase Breather -Clean/ReplaceSMCS Code: 1317-070; 1317-510

3054E and 3056E Engines

g00891577Illustration 433056E closed breather system(1) Hose clamps(2) Hose(3) Breather assembly

NOTICEEnsure that the components of the breather assemblyare installed in the correct positions. If not installedcorrectly, engine damage can result.

Note: Keep the area around vent hole clean. Do notrestrict the vent hole.

1. Loosen hose clamps(1). Remove the hoses(2)from the breather assembly (3).

2. Remove two bolts that hold the breatherassembly (3)to the cylinder block. Remove thebreather assembly (3) from the engine.

90Maintenance SectionEngine Mounts - Inspect

3. Discard the breather assembly (3). Install a newbreather assembly (3) by using the two bolts.Refer to the Operation and Maintenance Manual,Torque Specifications for the correct torques.

4. Install the hoses (2)and tighten the hose clamps(1). Refer to the Operation and MaintenanceManual, Standard Torque for Constant TorqueHose Clamps for the correct torques.

i00687861

Engine Mounts - InspectSMCS Code: 1152-040

Inspect the engine mounts for deterioration and forproper bolt torque. Engine vibration can be causedby the following conditions:

Improper mounting of the engine

Deterioration of the engine mounts

Any engine mount that shows deterioration shouldbe replaced. Refer to the Service Manual for therecommended torques. Refer to your Caterpillardealer for more information.

i00623423

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

g00110310Illustration 44(Y) ADD mark. (X) FULL mark.

NOTICEPerform this maintenance with the engine stopped.

1. Maintain the oil level between ADD mark (Y)and FULL mark (X) on oil level gauge (1). Donot fill the crankcase above FULL mark (X).

NOTICEOperating your engine when the oil level is above theFULL mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oils lubricating char-acteristics and could result in the loss of power.

2. Remove the oil filler cap and add oil, if necessary.Clean the oil filler cap. Install the oil filler cap.

i01534451

Engine Oil Sample - ObtainSMCS Code: 1000-008; 1348-554-SM;

7542-554-OC, SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using SOS oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine.

Obtain the Sample and the Analysis


Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

Engine model

Service hours on the engine

The number of hours that have accumulatedsince the last oil change

The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of theoil in the crankcase, obtain a warm, well mixed oilsample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.


Engine Oil and Filter - Change

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.

NOTICEDo not use the same vacuum sampling pump for ex-tracting oil samples that is used for extracting coolantsamples.

A small residue of either type sample may remain inthe pump and may cause a false positive analysis forthe sample being taken.

Always use a designated pump for oil sampling and adesignated pump for coolant sampling.

Failure to do so may cause a false analysis whichcould lead to customer and dealer concerns.

If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEHP6001,How To Take A Good Oil Sample. Consult yourCaterpillar dealer for complete information andassistance in establishing an SOS program foryour engine.

i01591548

Engine Oil and Filter - ChangeSMCS Code: 1318-510; 1348-044


Do not drain the oil when the engine is cold. Asthe oil cools, suspended waste particles settleon the bottom of the oil pan. The waste particlesare not removed with the draining cold oil. Drainthe crankcase with the engine stopped. Drain thecrankcase with the oil warm. This draining methodallows the waste particles that are suspended in theoil to be drained properly.

Failure to follow this recommended procedure willcause the waste particles to be recirculated throughthe engine lubrication system with the new oil.

Drain the Engine OilAfter the engine has been run at the normaloperating temperature, stop the engine. Use one ofthe following methods to drain the engine crankcaseoil:

If the engine is equipped with a drain valve, turnthe drain valve knob counterclockwise in order todrain the oil. After the oil has drained, turn thedrain valve knob clockwise in order to close thedrain valve.

If the engine is not equipped with a drain valve,remove the oil drain plug in order to allow the oilto drain. If the engine is equipped with a shallowsump, remove the bottom oil drain plugs fromboth ends of the oil pan.

After the oil has drained, the oil drain plugs shouldbe cleaned and installed.

Replace the Oil Filter

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

1. Remove the oil filter with a 1U-8760 ChainWrench.

2. Cut the oil filter open with a 175-7546 Oil FilterCutter Gp. Break apart the pleats and inspect theoil filter for metal debris. An excessive amount ofmetal debris in the oil filter may indicate earlywear or a pending failure.

92Maintenance SectionEngine Protective Devices - Check

Use a magnet to differentiate between theferrous metals and the nonferrous metals thatare found in the oil filter element. Ferrous metalsmay indicate wear on the steel and cast ironparts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is notuncommon to find small amounts of debris in theoil filter. Consult your Caterpillar dealer in orderto arrange for a further analysis if an excessiveamount of debris is found in the oil filter.

g00103713Illustration 45Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mountingbase. Ensure that all of the old oil filter gasketis removed.

4. Apply clean engine oil to the new oil filter gasket.

NOTICEDo not fill the oil filters with oil before installing them.This oil would not be filtered and could be contaminat-ed. Contaminated oil can cause accelerated wear toengine components.

5. Install the oil filter. Tighten the oil filter until theoil filter gasket contacts the base. Tighten the oilfilter by hand according to the instructions thatare shown on the oil filter. Do not overtighten theoil filter.

Fill the Engine Crankcase1. Remove the oil filler cap. Refer to the Operation

and Maintenance Manual for more information onlubricant specifications. Fill the crankcase withthe proper amount of oil. Refer to the Operationand Maintenance Manual for more informationon refill capacities.

NOTICEIf equipped with an auxiliary oil filter system or a re-mote oil filter system, follow the OEM or filter manu-facturers recommendations. Under filling or overfillingthe crankcase with oil can cause engine damage.

NOTICETo prevent crankshaft bearing damage, crank the en-gine with the fuel OFF. This will fill the oil filters beforestarting the engine. Do not crank the engine for morethan 30 seconds.

2. Start the engine and run the engine at LOWIDLE for two minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain backto the sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the ADDand FULL marks on the oil level gauge.

i00626013

Engine Protective Devices -CheckSMCS Code: 7400-535

Alarms and shutoffs must function properly. Alarmsprovide timely warning to the operator. Shutoffs helpto prevent damage to the engine. It is impossibleto determine if the engine protective devices arein good working order during normal operation.Malfunctions must be simulated in order to test theengine protective devices.

A calibration check of the engine protective deviceswill ensure that the alarms and shutoffs activateat the setpoints. Ensure that the engine protectivedevices are functioning properly.


Engine Valve Lash - Inspect/Adjust

NOTICEDuring testing, abnormal operating conditionsmust besimulated.

The tests must be performed correctly in order to pre-vent possible damage to the engine.

To prevent damage to the engine, only authorizedservice personnel or your Caterpillar dealer shouldperform the tests.

Visual InspectionVisually check the condition of all gauges, sensorsand wiring. Look for wiring and components thatare loose, broken, or damaged. Damaged wiringor components should be repaired or replacedimmediately.

i00869628

Engine Valve Lash -Inspect/AdjustSMCS Code: 1102-025

The initial valve lash adjustment on new engines,rebuilt engines, or remanufactured engines isrecommended at the first scheduled oil change.The adjustment is necessary due to the initial wearof the valve train components and to the seating ofthe valve train components.

This maintenance is recommended by Caterpillaras part of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuringthe valve lash. To obtain an accurate measurement,allow the valves to cool before this maintenanceis performed.

Refer to the Service Manual for more information.

i00626014

Fuel Injection Nozzles -Test/ExchangeSMCS Code: 1254-013; 1254-081

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

Fuel injection nozzles are subject to tip wear. Tipwear is a result of fuel contamination. Tip wear cancause the following problems:

Increased fuel consumption

Black smoke

Misfire

Rough running

Fuel Injection nozzles should be cleaned, inspected,tested, and replaced, if necessary. Refer to SpecialInstruction, SEHS7292 for using the 8S-2245Injection Cleaning Tool Group. Consult yourCaterpillar dealer about cleaning the fuel injectionnozzle and testing the fuel injection nozzle.

94Maintenance SectionFuel System - Prime

NOTICENever wire brush or scrape a fuel injection nozzle.Wire brushing or scraping a fuel injection nozzle willdamage the finely machine orifice. Proper tools forcleaning and testing the fuel injection nozzles can beobtained from Caterpillar dealers.

The following items are symptoms of a malfunctionof the fuel injection nozzle:

Abnormal engine operation

Smoke emission

Engine knock

Each fuel injection nozzle must be isolated one at atime in order to determine the malfunctioning fuelinjection nozzle.

1. Start the engine.

2. Loosen each fuel line nut one at a time at the fuelinjection pump. A cloth or similar material mustbe used in order to prevent fuel from spraying onthe hot exhaust components. Tighten each nutbefore loosening the next nut.

3. A defective fuel injection nozzle may be identifiedwhen a fuel line nut is loosened and the followingconditions are present:

The exhaust smoke is partially eliminated orthe exhaust smoke is completely eliminated.

Engine performance is not affected.

A fuel injection nozzle that is suspected ofbeing defective should be removed. A newfuel injection nozzle should be installed in thecylinder in order to determine if the removed fuelinjection nozzle is defective.

Removal and Installation of theFuel Injection NozzlesFor the removal and the installation of fuel injectionnozzles, special tooling is required. Refer to theService Manual for more information. Consult yourCaterpillar dealer for assistance.

i01782319

Fuel System - PrimeSMCS Code: 1258-548

S/N: 3041-Up

3054EIf air enters the fuel system, the air must be purgedfrom the fuel system before the engine can bestarted. Air can enter the fuel system when thefollowing events occur:

The fuel tank is empty or the fuel tank has beenpartially drained.

The low pressure fuel lines are disconnected.

A leak exists in the low pressure fuel system.

The fuel filter is replaced.

Use the following procedure in order to remove airfrom the fuel system:

1. Turn the key switch to the RUN position. Leavethe key switch in the RUN position for threeminutes.

2. Turn the key switch to the OFF position.


Note: Damage to the fuel injection pump, to thebattery, and to the starter motor can occur if thestarter motor is used excessively to purge the airfrom the fuel system.

3. Loosen flare nuts (1) for the high pressure fuellines on all of the fuel injection nozzles.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

95Maintenance SectionFuel System - Prime

4. Observe the connection at the flare nut. Operatethe starting motor and crank the engine until thefuel is free of air.

5. Tighten flare nuts (1) to a torque of 30 Nm(22 lb ft).

6. The engine is now ready to start. Operate theengine at low idle for a minimum of five minutesimmediately after air has been removed from thefuel system.

Note: Running the engine for this period of time willhelp ensure that the pump is completely free of air.

i01781667

Fuel System - PrimeSMCS Code: 1258-548

S/N: 3561-Up

3056EIf air enters the fuel system, the air must be purgedfrom the fuel system before the engine can bestarted. Air can enter the fuel system when thefollowing events occur:

The fuel tank is empty or the fuel tank has beenpartially drained.

The low pressure fuel lines are disconnected.

A leak exists in the low pressure fuel system.

The fuel filter is replaced.

Use the following procedure in order to remove airfrom the fuel system:


1. Loosen nut (2) on the fuel injection pump (1).


Note: If the drive cam for the fuel priming pump isin the position of maximum cam lift, the priminglever will not operate. Rotate the crankshaft by handone revolution.

2. Operate the priming lever (4) on the primingpump (3) until the fuel flows out of nut (2) freeof air.

3. Tighten nut (2) to a torque of 23 Nm (17 lb ft).


4. If the fuel line for the air inlet heater has beendrained, loosen nut (5). Observe the connectionat the flare nut. Operate the priming lever on thefuel priming pump until the fuel is free of air.

5. Tighten nut (5) to a torque of 22 Nm (16 lb ft).

96Maintenance SectionFuel System Primary Filter/Water Separator - Drain


Note: Damage to the fuel injection pump, to thebattery, and to the starter motor can occur if thestarter motor is used excessively to purge the airfrom the fuel system.

6. Loosen flare nuts (6) for the high pressure fuellines on all of the fuel injection nozzles.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

7. Observe the connection at the flare nut. Operatethe starting motor until the fuel is free of air.

8. Tighten flare nuts (6) to a torque of 27 Nm(20 lb ft).

9. The engine is now ready to start. Operate theengine at low idle for a minimum of five minutesimmediately after air has been removed from thefuel system.

Note: Running the engine for this period of time willhelp ensure that the pump is completely free of air.

i01746816

Fuel System PrimaryFilter/Water Separator - DrainSMCS Code: 1260-543; 1263-543

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

NOTICEThe water separator is not a filter. The water separa-tor separates water from the fuel. The engine shouldnever be allowed to run with the water separator morethan half full. Engine damage may result.

g00741109Illustration 51(1) Cap(2) Locking ring(3) Element(4) Water separator bowl(5) Drain

1. Open drain (5). Catch the draining water in asuitable container. Dispose of the draining waterproperly.

2. Close drain (5).

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering the fuelsystem.

i01685084

Fuel System PrimaryFilter/Water Separator Element- ReplaceSMCS Code: 1260-510-FQ; 1263-510-FQ



Fuel System Secondary Filter - Replace


Turn the fuel supply valve to the OFF position beforeperforming this maintenance. Place a tray under thefuel filter in order to catch any fuel that might spill.Clean up any spilled fuel immediately.

g00802952Illustration 52(1) Cap(2) Fuel filter base(3) Quick release collar(4) Fuel filter(5) Drain valve for fuel filter

1. Close the fuel supply valve.

2. Clean the outside of the fuel filter assembly.Open drain valve (5) and drain the fuel and waterfrom fuel filter (4) into a suitable container.

Note: If the fuel filter element is not equipped witha drain, remove cap (1). Remove the nylon insertin order to reduce the level of fuel in the fuel filterelement. A reduction in the level of fuel in thefuel filter element will help prevent fuel from beingspilled when the element is removed.

NOTICEDo not use a tool in order to remove the fuel filter.Attempting to remove the fuel filter with a filter wrenchor a filter strap could damage the locking ring.

3. Hold fuel filter (4) and rotate quick release collar(3) counterclockwise. Remove quick releasecollar (3). The used element should be removedand discarded.

Note: If the element is equipped with a sedimentbowl, remove the sediment bowl from the element.Thoroughly clean the sediment bowl. Inspect theO-ring seals. Install new O-ring seals, if necessary.Install the sediment bowl to the new element. Handtighten the sediment bowl. Hand tightening is theonly method that should be used.

NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

4. Ensure that the fuel filter base is clean. Push anew fuel filter fully into the fuel filter base.

5. Hold the fuel filter in place. Fit locking ring (3)into position. Rotate the locking ring clockwise inorder to fasten the fuel filter to the fuel filter base.

Note: If the nylon insert was removed, install thenylon insert and install cap (1).

6. Prime the fuel system. Refer to the Operationand Maintenance Manual in the MaintenanceSection for more information.

i01713207

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE



Turn the fuel supply valve to the OFF position beforeperforming this maintenance. Place a tray under thefuel filter in order to catch any fuel that might spill.Clean up any spilled fuel immediately.

98Maintenance SectionFuel Transfer Pump Strainer - Clean

g00802952Illustration 53(1) Cap(2) Fuel filter base(3) Quick release collar(4) Fuel filter(5) Drain valve for fuel filter

1. Close the fuel supply valve.

2. Clean the outside of the fuel filter assembly.Open drain valve (5) and drain the fuel and waterfrom fuel filter (4) into a suitable container.

Note: If the fuel filter element is not equipped witha drain, remove cap (1). Remove the nylon insertin order to reduce the level of fuel in the fuel filterelement. A reduction in the level of fuel in thefuel filter element will help prevent fuel from beingspilled when the element is removed.

NOTICEDo not use a tool in order to remove the fuel filter.Attempting to remove the fuel filter with a filter wrenchor a filter strap could damage the locking ring.

3. Hold fuel filter (4) and rotate quick release collar(3) counterclockwise. Remove quick releasecollar (3). The used element should be removedand discarded.

Note: If the element is equipped with a sedimentbowl, remove the sediment bowl from the element.Thoroughly clean the sediment bowl. Inspect theO-ring seals. Install new O-ring seals, if necessary.Install the sediment bowl to the new element. Handtighten the sediment bowl. Hand tightening is theonly method that should be used.

NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

4. Ensure that the fuel filter base is clean. Push anew fuel filter fully into the fuel filter base.

5. Hold the fuel filter in place. Fit locking ring (3)into position. Rotate the locking ring clockwise inorder to fasten the fuel filter to the fuel filter base.

Note: If the nylon insert was removed, install thenylon insert and install cap (1).

6. Prime the fuel system. Refer to Operation andMaintenance Manual, Fuel System - Prime.

i01190897

Fuel Transfer Pump Strainer -CleanSMCS Code: 1256-070-STR



Cleaning the Strainer and theSediment Chamber for the FuelTransfer PumpTurn the fuel supply valve to the OFF position beforethe maintenance is performed.

g00286056Illustration 54(1) Fuel transfer pump(2) Cover and seal(3) Strainer


Hoses and Clamps - Inspect/Replace

1. Remove the cover and seal (2) from the top offuel transfer pump (1). Remove strainer (3).

2. Use nonflammable solvent in order to cleanthe strainer, the cover, and the seal. Carefullywash any sediment from the chamber of the fueltransfer pump.

3. Assemble the clean, dry fuel transfer pump.

NOTICEEnsure that the lift pump cover is secure so that airdoes not enter the fuel system.

4. Turn the fuel supply to the ON position.

5. Prime the fuel system. Refer to the Operationand Maintenance Manual for more information onpriming the fuel system.

i00907072

Hoses and Clamps -Inspect/ReplaceSMCS Code: 7554-040; 7554-510

Inspect all hoses for leaks that are caused by thefollowing conditions:

Cracking

Softness

Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubesand hoses carefully. Tighten all connections to the rec-ommended torque.

Check for the following conditions:

End fittings that are damaged or leaking

Outer covering that is chafed or cut

Exposed wire that is used for reinforcement

Outer covering that is ballooning locally

Flexible part of the hose that is kinked or crushed

Armoring that is embedded in the outer covering

A constant torque hose clamp can be used inplace of any standard hose clamp. Ensure that theconstant torque hose clamp is the same size asthe standard clamp.

Due to extreme temperature changes, the hosewill heat set. Heat setting causes hose clamps toloosen. This can result in leaks. A constant torquehose clamp will help to prevent loose hose clamps.

Each installation application can be different. Thedifferences depend on the following factors:

Type of hose

Type of fitting material

Anticipated expansion and contraction of thehose

Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps


1. Stop the engine. Allow the engine to cool.

2. Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.

Note: Drain the coolant into a suitable, cleancontainer. The coolant can be reused.

3. Drain the coolant from the cooling system toa level that is below the hose that is beingreplaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

Note: For torques on hose clamps, see thisOperation and Maintenance Manual, TorqueSpecifications (Maintenance Section).

7. Install the hose clamps with a torque wrench.

100Maintenance SectionOverhaul Considerations

Note: For the proper coolant to use, see thisOperation and Maintenance Manual, CoolantRecommendations (Maintenance Section).

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler caps gaskets. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

10. Start the engine. Inspect the cooling system forleaks.

i01515272

Overhaul ConsiderationsSMCS Code: 7595-043

Reduced hours of operation at full load will resultin a lower average power demand. A decreasedaverage power demand should increase both theengine service life and the overhaul interval.

The need for an overhaul is generally indicated byincreased fuel consumption and by reduced power.

The following factors are important when a decisionis being made on the proper time for an engineoverhaul:

The need for preventive maintenance

The quality of the fuel that is being used

The operating conditions

The results of the SOS analysis

Oil Consumption as an OverhaulIndicatorOil consumption, fuel consumption, andmaintenance information can be used to estimatethe total operating cost for your Caterpillar engine.Oil consumption can also be used to estimatethe required capacity of a makeup oil tank that issuitable for the maintenance intervals.

Oil consumption is in proportion to the percentageof the rated engine load. As the percentage of theengine load is increased, the amount of oil that isconsumed per hour also increases.

The oil consumption rate (brake specific oilconsumption) is measured in grams per kW/h(lb per bhp). The brake specific oil consumption(BSOC) depends on the engine load. Consult yourCaterpillar dealer for assistance in determining thetypical oil consumption rate for your engine.

When an engines oil consumption has risen tothree times the original oil consumption rate dueto normal wear, an engine overhaul should bescheduled. There may be a corresponding increasein blowby and a slight increase in fuel consumption.

Overhaul OptionsBefore Failure Overhaul

A planned overhaul before failure may be the bestvalue for the following reasons:

Costly unplanned downtime can be avoided.

Many original parts can be reused according tothe standards for reusable parts.

The engines service life can be extended withoutthe risk of a major catastrophe due to enginefailure.

The best cost/value relationship per hour ofextended life can be attained.

After Failure Overhaul

If a major engine failure occurs and the enginemust be removed, many options are available. Anoverhaul should be performed if the engine blockor the crankshaft needs to be repaired.

If the engine block is repairable and/or thecrankshaft is repairable, the overhaul cost shouldbe between 40 percent and 50 percent of the costof a new engine with a similar exchange core.

This lower cost can be attributed to three aspects:

Specially designed Caterpillar engine features

Caterpillar dealer exchange components

Caterpillar Inc. remanufactured exchangecomponents

Overhaul RecommendationTo minimize downtime, Caterpillar Inc. recommendsa scheduled engine overhaul by your Caterpillardealer before the engine fails. This will provide youwith the best cost/value relationship.


Overhaul Considerations

Note: Overhaul programs vary according to theengine application and according to the dealerthat performs the overhaul. Consult your Caterpillardealer for specific information about the availableoverhaul programs and about overhaul services forextending the engine life.

If an overhaul is performed without overhaul servicefrom your Caterpillar dealer, be aware of thefollowing maintenance recommendations.

Rebuild or ExchangeCylinder Head Assembly, Oil Pump, and FuelTransfer Pump

These components should be inspected accordingto the instructions that are found in variousCaterpillar reusability publications. The SpecialPublication, SEBF8029 lists the reusabilitypublications that are needed for inspecting theengine parts.

If the parts comply with the established inspectionspecifications that are expressed in the reusableparts guideline, the parts should be reused.

Parts that are not within the established inspectionspecifications should be dealt with in one of thefollowing manners:

Salvaging

Repairing

Replacing

Using out-of-spec parts can result in the followingproblems:

Unscheduled downtime

Costly repairs

Damage to other engine parts

Reduced engine efficiency

Increased fuel consumption

Reduced engine efficiency and increased fuelconsumption translates into higher operating costs.Therefore, Caterpillar Inc. recommends repairingout-of-spec parts or replacing out-of-spec parts.

Inspection and/or ReplacementCrankshaft Bearings and Crankshaft Seals

The following components may not last until thesecond overhaul.

Thrust bearings

Main bearings

Rod bearings

Crankshaft seals

Caterpillar Inc. recommends the installation of newparts at each overhaul period.

Inspect these parts while the engine is disassembledfor an overhaul.

Inspect the crankshaft for any of the followingconditions:

Deflection

Damage to the journals

Bearing material that has seized to the journals

Check the journal taper and the profile of thecrankshaft journals. Check these components byinterpreting the wear patterns on the followingcomponents:

Rod bearing

Main bearings

Inspect the camshaft for damage to the journalsand to the lobes.

Note: If the camshaft is removed for any reason, usethe magnetic particle inspection process to checkfor cracks in the camshaft.

Inspect the following components for signs of wearor for signs of scuffing:

Camshaft bearings

Lifters

Caterpillar Inc. recommends replacing thecrankshaft vibration damper.

Oil Cooler Core

During an overhaul, Caterpillar Inc. recommendsthe removal of the oil cooler core. Clean the oilcooler core. Then, pressure test the oil cooler core.

NOTICEDo not use caustic cleaners to clean the core.

Caustic cleaners can attack the internal metals of thecore and cause leakage.

102Maintenance SectionOverhaul Considerations

Note: Use this cleaning procedure to clean the oilcooler core.

1. Remove the oil cooler core.

2. Remove any debris from the oil cooler core. Toremove debris from the oil cooler core, turn theoil cooler core onto one end.

3. Flush the oil cooler core internally with cleaner inorder to loosen foreign substances. This will alsohelp to remove oil from the oil cooler core.

Note: Caterpillar Inc. recommends the use ofHydrosolv Liquid Cleaners. Table 33 lists theHydrosolv Liquid Cleaners that are available fromyour Caterpillar dealer.

Table 33

Hydrosolv Liquid CleanersPart

Number Description Size

1U-5490 Hydrosolv4165 19 L (5 US gal)1U-5492 Hydrosolv100 19 L (5 US gallon)

4. Use steam to clean the oil cooler core. Thisremoves any remaining residue from the cleaner.Flush the fins of the oil cooler core. Remove anyother trapped debris.

5. Wash the oil cooler core with hot, soapy water.Rinse the oil cooler core thoroughly with cleanwater.


Maximum

3054E and 3056E Industrial Engines-Maintenance Intervals

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