3408 AND 3412 INDUSTRIAL AND EPG DIESEL ENGINES Caterpillar

The LUBRICATION AND MAINTENANCE CHART lists all serviceable items commonly ordered on this engine.

The maintenance time intervals are expressed in Service Meter Units. The Service Meter on the engine shows the total number of units the engine has run. Use the Service Meter readings for determining your maintenance schedules. Perform the maintenance at multiple intervals of the units shown. For example, when the Service Meter shows "100" on the dial, all items listed under "EVERY 10 SERVICE METER UNITS" should be serviced now for the tenth time, and all items under "EVERY 50 SERVICE METER UNITS" should be serviced for the second time.

Diesel fuels, lubricants and coolant make-up water to use are explained in the "Specifications".

NOTE:

NOTE A: The percentage of sulfur in the fuel will affect the engine oil recommendations. If the fuel has over 0.5% sulfur content, the CD engine oil must have a TBN of 20 times the percentage of fuel sulfur (TBN as measured by the ASTM D-2896 method). If the sulfur content is greater than 1.5% by weight, use an oil with a TBN of 30 and reduce the oil change interval by one half. Consult your Caterpillar dealer for correct engine oil recommendations.

NOTE B: Check fuel pressure gauge daily. Replace when FUEL PRESSURE gauge registers OUT or 20 PSI (124 kPa).

NOTE C: The element can be cleaned approximately 3 times. Carefully inspect the element after each cleaning. If engine is not equipped with air cleaner service indicator, check element every 250 Service Meter Units, or more often under dusty conditions. If after servicing the air cleaner, the exhaust smoke and/or loss of power continues, install a new element.

NOTE D: Authorized Caterpillar dealers are equipped with the necessary tools, personnel and procedures to perform these services.

NOTE E: Initial valve lash adjustment on new, rebuilt or remanufactured engines is recommended at the first scheduled oil change interval, due to initial wear and seating of valve train components. Subsequent adjustments should be made at every 2000 Service Meter Units or One year, Whichever Occurs First.

Lubrication Instructions

Crankcase Lubrication Oil

The Lubrication and Maintenance Charts list the normal oil change periods as determined by fuel sulphur content. (Make an initial oil and filter change after the first 10 service meter units of operation for reconditioned engines).

See the OIL SPECIFICATIONS to aid in the proper oil SAE viscosity selection. The proper SAE viscosity of oil to select is determined by the ambient temperature at which the engine is started and operated.

Checking Oil Level

The dipstick is stamped on both sides of the blade. One side is marked and to be read when checking the oil level with the ENGINE STOPPED. The other side is marked and to be read with the ENGINE IDLING-HOT OIL. Each side is stamped to remind you not to OVERFILL the crankcase with oil.

Checking Oil Pressure

Immediately after starting, and frequently during operation, observe the oil pressure gauge reading. The indicator should register in the NORMAL range.

If the indicator fluctuates or registers below NORMAL range:

1. Move the governor control to low idle position.

2. Check the oil level. Be sure to read the ENGINE IDLING side of the dipstick.

3. Add oil until the oil level is at the FULL mark on the ENGINE IDLING side of the dipstick. Do not overfill.

4. Check for oil leaks.

5. If necessary, stop the engine and have repairs made.

Draining Engine Oil

With engine stopped and oil warm:

1. Remove the crankcase oil drain plug.

2. Allow the oil to drain.

3. Clean and install the drain plug.

OR, if a sump pump is used:

1. Connect a suitable drain line and container to the pump outlet.

2. With engine stopped and oil warm, open the sump pump valve to the engine crankcase drain line: The two marks on the valve must be turned so that one mark points to the pump, and the second mark points to the engine drain line.

3. Operate the sump pump handle until the crankcase is empty.

4. Close the valve to the engine crankcase drain line.

Cleaning the Breather

1. Release the hose clamp and disconnect the fumes disposal tube.

2. Remove the breather assembly.

3. Wash the breather in solvent.

4. Allow to drain dry and then wipe.

5. Inspect the gasket. Install a new gasket if necessary.

6. Install the breather.

7. Connect the fumes disposal tube.

Changing Oil Filter

1. Unscrew and remove the filter.

2. Be sure the old filter gasket did not remain attached inside the filter base: Leaking will occur between the new filter gasket and this old gasket.

3. Wipe the filter base.

4. Apply a thin coat of clean oil to the gasket of the new filter.

5. Install the new filter: Hand tighten the filter 3/4turn after the filter gasket contacts the base. Use rotation index numbers, which are painted on the filter can, as a guide for proper tightening.

Filling the Crankcase

1. Fill the crankcase to the safe starting range on the ENGINE STOPPED side of the dipstick. See the Lubrication Specifications for refill capacity and proper oil viscosity.

2. Start the engine and check for oil leaks.

3. After the engine is warm, check the oil level with the engine idling.

4. Add oil if necessary to maintain the oil level at the FULL mark on the ENGINE IDLING side of the dipstick.

Fan Drive Bearings

Lubricate the fan drive bearings with lubricating grease through one fitting, 1 or 2 strokes.

LOCATION OF 4B4550 PRESSURE RELIEF FITTING AND 2D4867 FITTING SHOWN IN THE STANDARD LOCATION.

If the grease fitting is not readily accessible, it may be necessary to

1. Remove the 4B4550 Fitting (relief) from the fan mounting bracket assembly and install the 2D4867 Fitting in its place.

2. Install the 4B4550 Fitting (relief) in place of the 2D4867 Fitting.

Woodward PSG Governor Synchronizing Motor

Fill the oil cup on the synchronizing motor with clean engine oil with same viscosity as used in the engine.

Air Starting Motor

The motor oiler lubricates the vanes of the starting motor with a fine oil mist as the motor is operating.

When the oil jar becomes half empty, remove the oil filler plug and fill the jar with clean engine oil with the same viscosity as used in the engine.

Adjusting Oiler Feed

If necessary, adjust the oiler to release approximately four drops of oil per minute into the starting motor air stream.

1. The engine must be operated long enough to have the oil warm. Then stop the engine.

2. Move the governor control lever to the SHUT-OFF position.

3. Push in on the air start control and crank the engine.

4. Count the drops of oil released per minute into the air stream.

a. Turn the needle valve (the uppermost knob on the oiler) counterclockwise to increase the number of drops.

b. Turn the needle valve clockwise to decrease the number of drops.

Emptying Oil Collector Jar

Empty the oil collector jar whenever the jar becomes half full. The collector jar collects both the oil after it has lubricated the starting motor vanes, and the moisture condensation from the compressed air. Do not fill the oiler jar with this used oil.

Power Coupling Attachment

Heavy Duty Clutch Main Shaft Bearings

The heavy duty flywheel clutch main shaft bearing is oil lubricated. The remaining bearings are lubricated with grease.

Check the main shaft bearing oil reservoir level with engine stopped. Maintain the oil level at the FULL mark on the oil level gauge. Add oil through the filler tube on top of the bearing cage housing. Use the same type of oil as used in the engine crankcase. See the OIL SPECIFICATIONS.

To drain the reservoir:

Remove the drain plug located on the lower left side of the shaft bearing reservoir. Drain and install the drain plug. Fill to the FULL mark on the oil level gauge. Install the filler cap.

Enclosed Clutch Shaft Bearings (Grease Lubricated)

Lubricate the shaft bearings through 1 fitting.

Front/Rear Clutch Engaging Collar

Lubricate through 1 fitting-2 strokes.

Control Lever Shaft Bearings

Lubricate through 2 fittings-2 strokes.

Clutch Pilot Bearing

Lubricate sparingly through 1 fitting on end of shaft. If fitting is not accessible, remove the plug on the circumference of the shaft near the housing and install a grease fitting. Reinstall plug after lubricating.