3512C HD Locomotive Engine Caterpillar

• Air/fuel ratio

• Ambient air conditions

• Engine application

• Fuel type

• Oil type

• Size of the oil sump

Note: For engines that operate at high load factors of 80 percent or more for extended periods of time perform the following: decrease the interval between oil changes by 20 percent and increase the API service classification of the oil. Refer to Caterpillar Publication, PEHJ0191, "CAT S·O·S Fluid Analysis" in order to 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 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 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. See the literature that is provided by the OEM of the locomotive.

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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.

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

   2. If a suction device is inserted into the oil pan, ensure that the device is clean. A clean suction device 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 coupler, 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.

Replace the Oil Filter Elements

Replace the engine oil filters when any 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.

Illustration 1	g01959342
(1) Bolts (2) Cover (3) Plug (4) Drain valve (5) Drain

Note: Drain the oil into a suitable container. Dispose of the oil according to local regulations.

1. Connect a hose to drain (5). Place the other end of the hose into a suitable container in order to collect the oil.

2. Open drain valve (4). 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 (2) 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 (1). Before removing bolts (1), pry cover (2) loose or tap the cover with a rubber mallet in order to relieve any spring pressure.

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Illustration 2	g00799721
Section view of the engine oil filter (2) Cover (6) O-ring seal (7) Spring (8) Retainer (9) Oil filter element

4. Remove cover (2) and spring (7). Remove O-ring seal (6), retainer (8), and oil filter elements (9) .

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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.

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

6. 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.

7. Install retainer (8), spring (7) and cover (2). Ensure that the retainer and the spring are properly seated between the oil filter elements and the cover.

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, small amounts of debris may be found 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, refer to this Operation and Maintenance Manual, "Refill Capacities and Recommendations" (Maintenance Section). 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 2 minutes before cranking again.

3. Start the engine according to the instructions that are provided by the OEM of the locomotive. Operate the engine at low idle for 2 minutes. Operating the engine for 2 minutes 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 10 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.