Cat 3512 руководство по ремонту

• 17, SEBU7348-05 69 Maintenance Section Cooling System Coolant Sample (Level 1) — Obtain Remove the cool ing system fillercapslowlyinorder to relieve any pressure. Maintain the coolant within 13 mm (0.5 inch) below the bottom of the filler pipe. Add Coolant Note: For the proper coolant mixture to use, see this Operation and Maintenance Manual, “Refill Capacities a nd Recommendations” (Maintenance Section). 1. Stop the eng ine. Allow the engine to cool. 2. Remove the cooling system fille…

• 23, SEBU7348-05 75 Maintenance Section Engine Air Cleaner Element (Dual Element) — Clean/Replace Replace the dir ty paper air cleaner elements with clean air cleaner elements. Before installation, the air cleaner elements should be thoroughly checked for tears and/ or holes in the filter material. Inspect the gasket or the seal of the air cleaner element for damage. Maintain a supply of suitable air cleaner elements for replacement purposes. Dual Element Air Cleaners The dual element air clea…

• 56, 108 SEBU7348-05 Maintenance Section Water Pump — Inspect • Inspect the fue l system for leaks. Look for loose fuel line clamps or connections. • Inspect the pi ping for the air inlet system and the elbows for cracks and for loose clamps or connections. • Ensure that the exhaust system is properly clamped. Ensure that the connections are tight. Check for le aks. Check the condition of all connections and components of the …

• 40, 92 SEBU7348-05 Maintenance Section Hoses and Clamps — Inspect/Replace Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu- el spray may cause a fi re hazar d. Failur e to fol- low these inspection, maintenance a nd service in- structions may cause personal injury or death. NOTICE Do not bend or strike high pressure lines. Do not in- stall bent or damaged li…

• 3, Caterpillar 3512B SEBU7348-05 55 Maintenance Section Maintenance Interval Schedule i041 45318 Maintenance Interval Schedule SMCS Code: 1000; 4450; 7500 Ensure that al l safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of all maintenanc e which includes the following items: performing all adjustments, using proper lubricants, fluids, and filters, and replacing old com…

• 49, SEBU7348-05 101 Maintenance Section Overhaul (Top End) 3. Inspect the scr een assembly. Obtain a new screen assembly, if necessary. 4. Wash the scree n assembly in clean nonflammable solvent. Allow the screen assembly to dry before installation. 5. Install the screen assembly and install new O-ring seals according to the instructions in the Service Manual, “Di sassembly and Assembly” module. 6. Install the cover. …

• 8, 60 SEBU7348-05 Maintenance Section Air Starting Motor Lubricator Oil Level — Check 1. Ensure that the air supply to the lubricator is OFF. g013 33332 Illustration 39 (1) Filler plug (2) B owl (3) Drain valve 2. Slowly loosen filler plug (1) in order to release the pressure from the lubricator. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, a…

• 53, SEBU7348-05 105 Maintenance Section Radiator — Clean • The service lif e of the engine can be extended without the risk of a major catastrophe due to engine failure. • Achieve the best cost/value relationship per hour of extended service life. Overhaul Inspection Refer to the Service Manual for the disassembly and assembly procedures that are necessary in order to perform the required maintenance on the items …

• 24, 76 SEBU7348-05 Maintenance Section Engine Air Cleaner Element (Dual Element) — Clean/Replace There are two co mmon methods that are used to clean primary air cleaner elements: • Pressurized a ir • Vacuum cleaning Pressurized Air Pressurize daircanbeusedtocleanprimaryair cleaner elements that have not been cleaned more than two times. Pressurized air will not remove deposits of carbon and oil. Use filtered, dry air with a maximum pressure of 207 kPa (30 psi).…

• 44, Caterpillar 3512B 96 SEBU7348-05 Maintenance Section Maintenance Recommendations Table 2 5 Service Hours and Fuel Consumption for 3512 Engines Interval Fuel Consumption 250 service hours 43,750 L (11,560 US gal) 500 service hours 87,500 L (23,115 US gal) 1000 service hours 175,000 L (46,230 US gal) 2000 service hours 350,000 L (92,460 US gal) 3000 service hours 525,000 L (138,690 US gal) 4000 service hoursTop end overhaul 787,500 L (208,030 US gal) …

• 12, 64 SEBU7348-05 Maintenance Section Cooling System Coolant (DEAC) — Change Adjusting the Alternator Belt g010 92641 Illustration 41 Typical alternator (1) Mounting bolt (2) Adjusting nuts (3) Mounting bolt 1. Remove the drive belt guard. 2. Loosen mounting bolt (1), adjusting nuts (2) and mounting bolt (3). 3. Turn adjusting nuts (2) in order to increase or decrease the drive belt tension. 4. Tighten adjusting nuts (2). Tig…

• 7, Caterpillar 3512B SEBU7348-05 59 Maintenance Section Air Shutoff Damper — Remove/Check Note: The limit switch assemblies are items that wear and the limit switch assemblies may need to be replaced during normal maintenance intervals. i025 67801 Air Shutoff Damper — Remove/Ch eck SMCS Code: 1078-011; 1078-535 g012 86554 Illustration 36 Typical air shutoff (back view) (1) Air s hutoff gate (2) Damper assembly The vibration damper o…

• 46, Caterpillar 3512B 98 SEBU7348-05 Maintenance Section Overhaul (Major) Forthemajorov erhaul, all of the bearings, seals, gaskets, and components that wear are disassembled. The parts are cleaned and inspected. If necessary, the parts are replaced. The crankshaft is measured for wear. The crankshaft may require regrinding. Alternatively, the crankshaft may be replaced wit h a Caterpillar replacement part. Your Caterpillar dealer can provide these services and compone nts. Your Caterpillar dealer can ensure that t…

• 51, SEBU7348-05 103 Maintenance Section Overhaul Considerations • Pistons • Piston pins • Prelube pump • Pushrods • Rocker arms • Spacer plate • Software up date • Turbocharger Inspection of Components Inspect th e following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusabilit…

• 5, SEBU7348-05 57 Maintenance Section Aftercooler Core — Inspect/Clean i028 28620 Aftercooler Core — Inspect/Clea n SMCS Code: 1063-040; 1064-571 1. Remove the core. Refer to the Disassembly and Assembly Manual, “Aftercooler — Remove and Install” fo r the procedure. 2. Turn the aftercooler core on one side in order to remove de bris. Remove the debris that is accessible. NOTICE Do not use a high concentr…

• 16, 68 SEBU7348-05 Maintenance Section Cooling System Coolant Level — Check Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The r adiator a nd all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped…

• 9, SEBU7348-05 61 Maintenance Section Alternator — Inspect 1. Ensure that the fuel supply to the engine is OFF. NOTICE Do not crank the engine continuously for more than 30 seconds. Al low the starting motor to cool for two minutes before cranking the engine again. 2. Operate the air starting motor. Observe the drops of oil that are released in dome (1). Note: Some l ubricators have an adjustment screw rather th…

• 39, SEBU7348-05 91 Maintenance Section Hoses and Clamps — Inspect/Replace • Type of hose • Type of fitting material • Anticipated expansion and contraction of the hose • Anticipated expansion and contraction of the fittings Duetoextre me temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen. This can result in leaks. A constant torque hose clamp will h elp to prevent loose hose clamps. Replace hoses that are cracked…

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Major Overhaul Information

A major overhaul includes the work that is done for a top end overhaul. All other parts that are visible during the major overhaul are completely inspected. The seals and gaskets that are exposed are also replaced. The internal passages of the engine are cleaned.

Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications.

If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the following recommendations.

Components for Replacement

Replace the following components during the major overhaul. In addition, replace the components that are specified in this Operation and Maintenance Manual, «Overhaul (Top End)» topic.

• Connecting rod bearings
• Crankshaft seals
• Exhaust shields
• Gaskets and seals
• Main bearings
• Piston rings
• Valve rotators

Components for Inspection, Rebuilding or Exchanging

Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, «Index of Publications on Reusability or Salvage of Used Parts».

• Camshaft followers
• Connecting rods
• Cylinder liners
• Fuel transfer pump
• Oil pump
• Pistons
• Piston pins
• Prelube pump
• Scavenge oil pump
• Turbochargers

Inspection of Components

Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, «Index of Publications on Reusability or Salvage of Used Parts».

• Camshaft
• Camshaft bearings
• Crankshaft
• Crankshaft vibration damper
• Driven equipment (alignment)
• Gear train
• Gear train bushings
• Spacer plates

Inspect the camshaft for damage to the journals and the lobes. Inspect the following components for signs of wear and/or for signs of fatigue:

• camshaft bearings
• camshaft followers

Inspect the crankshaft for any of the following conditions:

• deflection
• damage to the journals
• bearing material that has seized to the journals

Check the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:

• rod bearing
• main bearings

Note: If the crankshaft or the camshaft are removed for any reason, use the magnetic particle inspection process to check for cracks.

Replace the crankshaft vibration damper if any of the following conditions occur:

• Engine failure due to a broken crankshaft
• Excessive wear of the front bearing for the crankshaft
• Excessive wear of the gear train that is not caused by a lack of lubrication

Inspect the gears of the gear train and inspect the gear train bushings for the following conditions:

• Worn gear teeth
• Unusual fit
• Unusual wear

In addition to the inspection of components, inspect the alignment of the driven equipment. See the Application and Installation Guide for the engine.

Cleaning of Components

Clean the oil cooler core and the aftercooler core. Then, pressure test both of these cores.

1. Remove the core.
2. Remove any debris from the core. To remove debris from the oil cooler core, turn the oil cooler core onto one end. To remove debris from the aftercooler core, turn the aftercooler core upside-down.

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   NOTICE
   Do not use a high concentration of caustic cleaner to clean the core. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner.

3. Back flush the core internally with cleaner in order to loosen foreign substances. This will also help to remove oil.

   Note: Hydrosolv Liquid Cleaners are recommended. Table 1 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer.

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   Table 1

   Hydrosolv Liquid Cleaners(1)
   Part Number	Description	Size
   1U-8812	Hydrosolv 4165	4 L (1 US gal)
   1U-5490	19 L (5 US gal)
   8T-7570	208 L (55 US gal)
   1U-8804	Hydrosolv 100	4 L (1 US gal)
   1U-5492	19 L (5 US gal)
   8T-5571	208 L (55 US gal)

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   (1)	Use these cleaners at a concentration of two to five percent and at a temperature up to 93 °C (200 °F). For more information, see Application Guide, NEHS0526, «Service Technical Group». Consult your Caterpillar dealer for assistance.

4. Steam clean the core in order to remove any residue. Flush the fins of the oil cooler core and the aftercooler core. Remove any other trapped debris.
5. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.

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   Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

6. Dry the core with compressed air. Direct the air in the reverse direction of the normal flow.
7. Inspect the components in order to ensure cleanliness. Pressure test the core. Many shops that service radiators are equipped to perform pressure tests. Repair the core, if necessary. Install the core.

Obtain Coolant Analysis

The concentration of supplemental coolant additive (SCA) should be checked regularly with test kits. The concentration of SCA can also be checked with an S·O·S coolant analysis (Level I). A more detailed coolant analysis is recommended periodically.

For example, considerable deposits are found in the water jacket areas on the external cooling system, but the concentrations of coolant additives were carefully maintained. The coolant water probably contained minerals which were deposited on the engine over time.

A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system. A full water analysis can be obtained by consulting your local water utility company or an agricultural agent. Private laboratories are also available for water analysis.

Caterpillar recommends an S·O·S coolant analysis (Level II).

S·O·S Coolant Analysis (Level II)

An S·O·S coolant analysis (Level II) is a comprehensive coolant analysis which completely analyzes the coolant. An S·O·S coolant analysis (Level II) provides the following information:

• Complete S·O·S coolant analysis (Level I).
• Properties of the coolant are visually inspected.
• Metal corrosion and contaminants are identified.
• Identification of built up impurities that can cause problems BEFORE the problems make repairs necessary.

A report of the results of the S·O·S coolant analysis (Level II) is provided. Maintenance recommendations are based on the results.

For more information about S·O·S coolant analysis, consult your Caterpillar dealer.