3500B High Displacement Generator Set Engines Caterpillar

• Air/fuel ratio

• Ambient air conditions

• Engine application

• Fuel type

• Oil type

• Size of the oil sump

Note: Decrease the interval between oil changes by 20 percent and/or increase the API service classification of the oil for engines that operate at high load factors of 80 percent or more for extended periods of time. Refer to Caterpillar Publication, PEDP7035, "S·O·S Fluid Analysis Interpetation Guide" in order to fully understand optimizing oil change intervals.

The S·O·S oil analysis program analyzes used oil in order to determine if the oil change interval is suitable for your specific engine. In the absence of S·O·S oil analysis, change the engine oil and filters according to the interval that is listed in Table 1.

Drain the Oil

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Do not drain the oil when the engine is cold. As the oil cools, suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed when the cold oil is drained. Drain the crankcase when the oil is warm. This draining method allows proper draining of the waste particles that are suspended in the oil.

Failure to follow this recommended procedure will allow the waste particles to be recirculated through the engine lubrication system with the new oil.

1. After the engine has been operated at normal operating temperature, STOP the engine.

2. Drain the oil according to the equipment on the engine.

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   NOTICE
   Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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   Illustration 1	g00750439
   (1) Oil drain

   1. Open oil drain (1). After the oil has drained, close the oil drain.

   2. 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.

   3. If a suction device that attaches to the oil drain is used, ensure that the suction device is clean. Attach the suction device to the oil drain. Open the oil drain. After the oil has drained, close the oil drain and remove the suction device.

   4. If the oil drain valve has a “quick connect” coupling, attach the coupling. Open the drain valve in order to drain the crankcase. After the oil has drained, close the drain valve. Disconnect the coupling.

3. Replace the engine oil filter elements before filling the crankcase with new oil.

Replace the Oil Filter Elements

Replace the engine oil filters when either of the following conditions occur:

• Every oil change

• The engine oil filter differential pressure reaches 103 kPa (15 psi).

• The oil filter elements have been used for 1000 service hours.

Note: Do not attempt to clean the used oil filters. Used oil filters will retain waste particles. The used oil filters would not filter the oil properly.

Service tools are available to aid in the service of oil filters. Consult your Caterpillar dealer for the part names and the part numbers. Follow the instructions that are supplied with the service tools. If the service tools are not used, perform the following appropriate procedure.

Replacing the Engine Oil Filters With the Engine Stopped

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Perform the following procedure after the oil has been drained.

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Illustration 2	g00750438
(1) Drain (2) Drain valve (3) Plug (4) Bolts (5) Cover

1. Connect a hose to drain (1). Place the other end of the hose into a suitable container in order to collect the oil.

2. Open drain valve (2). Remove plug (3). Allow the oil to drain. Clean the plug and install the plug. Close the drain valve. Remove the hose from the drain.

   Note: Some oil will remain in the housing after the oil has been drained. This oil will pour out of the housing when cover (5) is removed. Prepare to catch the oil in a suitable container. Clean up any spilled oil with absorbent towels or pillows. DO NOT use absorbent particles to clean up the oil.

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   Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

3. Be alert to the spring force. Gradually loosen but do not remove bolts (4). Before removing the bolts, pry the cover (5) loose or tap the cover with a rubber mallet in order to relieve any spring pressure. Remove cover (5).
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   Illustration 3	g00750440
   Section view of the engine oil filter (5) Cover (6) O-ring seal (7) Spring (8) Retainer (9) Oil filter element

4. Remove cover (5) and spring (7). Remove O-ring seal (6), retainer (8), and oil filter elements (9).

5. Clean cover (5), spring (7), O-ring seal (6), and retainer (8). Clean the inside of the oil filter housing.
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   NOTICE
   Caterpillar oil filters are built to Caterpillar specifications. 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 recommended by Caterpillar.

6. Ensure that the new oil filter elements are in good condition. Install the new oil filter elements.

7. 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.

8. Install retainer (8), spring (7) and cover (5). Ensure that the retainer and the spring are properly seated between the oil filter elements and the cover.

9. Start the engine according to this Operation and Maintenance Manual, "Starting The Engine" procedure (Operation Section). Check for oil leaks.

Replacing the Engine Oil Filters During Engine Operation

If the engine is equipped with duplex oil filters, the engine oil filter elements can be changed while the engine is operating. This is useful if the oil filter elements require more frequent replacement than the engine oil.

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Filter contains hot pressurized fluid when engine is running. Follow instructions on control valve to avoid personal injury. If rapid air movement exists to blow fluid, Stop the engine to avoid fire.

1. Move the control valve to the "AUX RUN" position in order to change the main oil filter elements. Move the selector valve to the "MAIN RUN" position in order to change the auxiliary oil filter elements.

2. Allow the oil pressure gauge for the oil filter that is being changed to reach a "ZERO" pressure reading.

3. Perform Step 1 through Step 8 of "Replacing the Engine Oil Filters With the Engine Stopped".

4. Open the "FILL" valve for a minimum of five minutes in order to fill the new oil filter elements.

5. Close the "FILL" valve. Rotate the control valve to the "RUN" position for the oil filter that was serviced.

Inspect the Used Oil Filter Elements

Cut the used oil filter element open with a utility knife. Remove the metal wrap. Cut the filter element free from the end caps. Spread apart the pleats and inspect the element for metal debris. An excessive amount of debris in the element may indicate early wear or a pending failure.

Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the element. Ferrous metals may indicate wear on the steel and the cast iron parts of the engine. Nonferrous metals may indicate wear on the aluminum parts, the brass parts, or the bronze parts of the engine. Parts that may be affected include the following components: main bearings, rod bearings, turbocharger bearings and cylinder heads.

Aluminum debris may indicate problems with the bearings of the front gears. If aluminum debris is found, inspect the crankshaft vibration damper and the bearings of the front idler gear.

Due to normal wear and friction, it is not uncommon to find small amounts of debris in the oil filter element. If an excessive amount of debris is found in the oil filter element, consult your Caterpillar dealer in order to arrange for further oil analysis.

Fill the Crankcase

1. Remove the oil filler cap. Fill the crankcase through the oil filler tube only. For the amount of oil to use, see this Operation and Maintenance Manual (Maintenance Section), "Refill Capacities and Recommendations". Clean the oil filler cap. Install the oil filler cap.
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   NOTICE
   To prevent crankshaft or bearing damage, crank engine with fuel off to fill all filters before starting. Do Not crank engine for more than 30 seconds.

2. Close the fuel supply line and crank the engine until the oil pressure gauge indicates 70 kPa (10 psi). Open the fuel supply line. Allow the starting motor to cool for two minutes before cranking again.

3. Follow this Operation and Maintenance Manual, "Starting The Engine" procedure (Operation Section). Operate the engine at low idle for two minutes. This will ensure that the lubrication system has oil and that the oil filters are filled with oil. Inspect the engine for oil leaks. Ensure that the oil level is at the "FULL" mark on the "LOW IDLE" side of the oil level gauge.

4. Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes.

5. Remove the oil level gauge and check the oil level. Maintain the oil level to the "FULL" mark on the "ENGINE STOPPED" side of the oil level gauge.