Compatible — Maintenance Section

For these models: 3500B BGX1-Up, 3500B BLF1-Up, 3500B BMB1-Up, 3500B BPJ1-Up, 3500B BRK1-Up, 3500B CMC1-Up, 3500B CNB1-Up, 3500B CPA1-Up, 3500B FDN1-Up, 3500B GAR1-Up, 3500B GZS1-Up, 3500B GZT1-Up.

Procedure

Remove the core. Refer to the Disassembly and Assembly Manual, “Aftercooler - Remove and Install” for the procedure.
Turn the aftercooler core on one side in order to remove debris. Remove the debris that is accessible. 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.
Back ﬂush the core with cleaner. Caterpillar recommends the use of Hydrosolv liquid cleaner. Table 30 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer. Table 30 Hydrosolv Liquid Cleaners(1) Part Number 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 cleaner at temperatures up to 93°C (200°F). Consult your Caterpillar dealer for more information.
Remove the drain plug.
Steam clean the core in order to remove any residue. Flush the ﬁns of the aftercooler core. Remove any other trapped debris from the inside and from the outside of the core. Note: Do not use high pressure when the ﬁns are cleaned. High pressure can damage the ﬁns.
Wash the core with hot, soapy water.
Flush the core thoroughly in order to remove residue and remaining debris. Flush the core with clean, fresh water until the water that is exiting the core is clear and free of debris. 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 less than 205 kPa (30 psi) for cleaning purposes.
Dry the core with compressed air. Direct the air in the reverse direction of the normal ﬂow.
Prior to installation, inspect any O-rings or seals for damage. If necessary, replace the O-rings or seals.
Inspect the core for trapped debris and cleanliness. If it is necessary, remove the debris and repeat the cleaning procedure.
Inspect the core for damage and perform a pressure test in order to detect leaks. Many shops that service radiators are equipped to perform pressure tests.
Install the core. Refer to Disassembly and Assembly Manual, “Aftercooler - Remove and Install” for the procedure. For more information on cleaning the core, consult your Caterpillar dealer. i01189973 Air Inlet Filter - Check SMCS Code: 1051-535 Monitor the connector contacts of the differential pressure switch for the air inlet ﬁlter. If the differential pressure rises above 15.2 mm (0.6 inch) of water, clean the ﬁlter with a solution of soap and water. Be sure that the ﬁlter is thoroughly dry b
Ensure that both air shutoff gates are latched in the OPEN position and ensure that both air shutoff switches are connected. Turn on the power to the engine control panel. Both air shutoff gates should remain open. If both air shutoff gates do not remain open, check the wiring for the air shutoff switches.
With the power for the engine control panel in the ON position, activate the “EMERGENCY STOP” switch. Both of the air shutoff gates should close. If both air shutoff gates close, proceed to step 3. If both air shutoff gates do not close, check the wiring for the air shutoff switches and check the wiring for the solenoids. Activate the “EMERGENCY STOP” switch again. When both air shutoff gates close, proceed to step 3.
Turn the power to the engine control panel to the OFF position. Ensure that the “EMERGENCY STOP” switch is in the RUN position. Latch only the right side air shutoff gate to the OPEN position. Turn the power for the engine control panel to the ON position. The right side air shutoff gate should close. If the right side air shutoff closes, proceed to step 4. If the right side air shutoff gate does not close, check the air shutoff switch for the right side air shutoff and check the wiring for the
Turn the power for the engine control panel to the OFF position. Latch only the left side air shutoff gate to the OPEN position. Turn the power for the engine control panel to the ON position. The left side air shutoff gate should close. If the left side air shutoff gate closes the test is complete. If the left side air shutoff gate does not close, check the switch and the wiring for the left side air shutoff . Note: Testing is only complete when the engine successfully passes step 1 through ste
Operate the engine normally. Ensure that the air shutoff gates continue to be latched. Engines That Are Equipped with ADEM III Engine Control Modules Note: Do not start the engine. Ensure that the engine control is in the “OFF” position.
Ensure that both air shutoff gates are latched in the OPEN position. Ensure that both air shutoff switches are connected. Turn the power for the engine control panel to the ON position. The air shutoff gates should remain in the OPEN positions. If the air shutoff gates do not remain in the OPEN positions, check the wiring for the air shutoffs. When step 1 has been successfully completed, proceed to step 2.
While the power for the engine control panel is in the ON position, activate the “EMERGENCY STOP” switch . Both air shutoff gates should close. If the air shutoff gates do not close, check the wiring for the air shutoffs and the wiring for the solenoids. Both air shutoff gates must close before proceeding to step 3.
Turn the power for the engine control panel to the OFF position. Reset the “EMERGENCY STOP” switch to the RUN position. Reset the right side air shutoff to the OPEN position. Turn the power for the engine control panel to the ON position. Select “Run/Start” on the engine control panel. The engine should fail to start. If the engine does not start, proceed to 4. If the engine starts, turn off the engine. Check the right side air shutoff. Check the wiring for the right side air shutoff. Retest th
Reset the “EMERGENCY STOP” switch to the RUN position. Set the power for the engine control panel to the ON position. Activate the“EMERGENCY STOP” switch . Both air shutoff gates should close. Set power for the engine control panel to the OFF position. Reset the “EMERGENCY STOP” switch to the RUN position. Reset the left side air shutoff to the OPEN position. Turn the power for the engine control panel to the ON position. Select “START/RUN” on the engine control panel. The engine should fail to
Turn the power for the engine control panel to the ON position. Reset both air shutoffs. Start the engine. Disconnect only the right side air shutoff. Both air shutoff gates should close. The engine should shut down. If the engine does not shut down, use the “EMERGENCY STOP” switch to stop the engine. Check the wiring for both air shutoffs. Use the above procedure in order to retest the right side air shutoff. When the procedure in step 5 is followed and results of the test are successful, recon
Turn the power for the engine control panel to the ON position. Reset both air shutoffs. Start the engine. Disconnect only the left side air shutoff. Both air shutoff gates should close. The engine should shut down. If the engine does not shut down, use the “EMERGENCY STOP” switch to stop the engine. Check the wiring for both air shutoffs. Use the above procedure in order to retest the left side air shutoff. When the procedure in 6 is followed and the results of the test are successful, reconnec
Testing is complete only when the engine successfully passes steps 1 through 6.
Reset both air shutoffs. Ensure that the “EMERGENCY STOP” switch has been reset. Operate the engine normally. 98 SEBU7508-09 Maintenance Section Air Shutoff Damper - Remove/Check i02622938 Air Shutoff Damper - Remove/Check (if equipped) SMCS Code: 1078-011; 1078-535 g01286554 Illustration 65 Typical air shutoff (back view) (1) Air shutoff gate (2) Damper assembly The vibration damper on the air shutoff minimizes the vibration of the air shutoff gate when the engine is operating and the air shut
The body of the damper should not be loosened or removed from the air shutoff when the plunger is removed. In order to remove the plunger without loosening or removing the damper, unscrew the plug with the following tools: a 6.35 mm (0.25 inch) Allen wrench and an open end wrench .
Check the seal ring for damage or wear. If necessary, replace the seal ring.
Inspect the internal parts of the vibration damper for wear or damage. Clean the components with 138-8440 component cleaner. g01286606 Illustration 67 Damper plunger
Remove the plunger from the spring. Visually inspect the exposed end of the plunger for dirt, fouling, damage, and wear. If distance “A” is less than 18.3 mm (0.72 inch) or if a visual inspection reveals dirt, fouling, damage, or wear on the active end of the plunger, replace the plunger. Insert the tapered end of a clean, undamaged plunger into the spring. Install the open end of the spring into the plug. Apply 9S-3263 thread lock or apply 9S-4030 thread lock onto the threads of the plug. Screw
Ensure that the air supply to the lubricator is OFF. g01333332 Illustration 68 (1) Filler plug (2) Bowl (3) Drain valve
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, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before open- ing any compartment or disassembling any compo- nent containing ﬂuids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to col
Place a suitable container under bowl (2) and open drain valve (3) in order to drain the oil from the bowl.
Remove bowl (2). Clean the bowl with warm water.
Dry the bowl. Inspect the bowl for cracks. If the bowl is cracked, replace the damaged bowl with a new bowl. Inspect the gasket. If the gasket is damaged, replace the gasket.
Install the bowl.
Make sure that drain valve (3) is closed.
For instructions on ﬁlling the lubricator, see this Operation and Maintenance Manual, “Air Starting Motor Lubricator Oil Level - Check” topic. i02654969 Air Starting Motor Lubricator Oil Level - Check SMCS Code: 1451-535 NOTICE Never allow the lubricator bowl to become empty. The air starting motor will be damaged by a lack of lubrica- tion. Ensure that sufﬁcient oil is in the lubricator bowl. g01333366 Illustration 69
Observe the oil level in sight gauge (3). If the oil level is less than 1/2, add oil to the lubricator bowl. Personal injury can result from removing hoses or ﬁttings in a pressure system. Failure to relieve pressure can cause personal in- jury. Do not disconnect or remove hoses or ﬁttings un- til all pressure in the system has been relieved.
Ensure that the air supply to the lubricator is OFF. Slowly loosen ﬁller plug (4) in order to release pressure from the lubricator bowl.
Remove ﬁller plug (4). Pour oil into the lubricator bowl. Use nondetergent SAE 10W oil for temperatures that are greater than 0 °C (32 °F). Use air tool oil for temperatures that are below 0 °C (32 °F).
Install ﬁller plug (4). Adjust the Lubricator Note: Adjust the lubricator with a constant rate of air ﬂow. After the adjust ment, the lubricator will release oil in proportion to variations of the air ﬂow. 100 SEBU7508-09 Maintenance Section Air Tank Moisture and Sediment - Drain
Ensure that the fuel supply to the engine is OFF. NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
Operate the air starting motor. Observe the drops of oil that are released in dome (1). Note: Some lubricators have an adjustment screw rather than a knob.
If necessary, adjust the lubricator in order to release from one to three drops of oil per second. To increase the rate, turn knob (2) counterclockwise. To decrease the rate, turn the knob clockwise. i00351324 Air Tank Moisture and Sediment - Drain SMCS Code: 1466-543-M&S Moisture and sediment in the air starting system can cause the following conditions: • Freezing • Corrosion of internal parts • Malfunction of the air starting system When opening the drain valve, wear protective gloves, a prot
Open the drain valve that is on the bottom of the air tank. Allow the moisture and sediment to drain.
Close the drain valve. i02676048 Alternator - Inspect SMCS Code: 1405-040 Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and proper battery charging. Inspect the ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system. Make repairs, as required. Check the alternator and the battery charger for proper operation. If the batteries are properly charged
Turn the key start switch to the OFF position. Remove the key and all electrical loads.
Turn OFF the battery charger. Disconnect the charger.
The NEGATIVE “-” cable connects the NEGATIVE “-” battery terminal to the ground plane. Disconnect the cable from the NEGATIVE “-” battery terminal.
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 a battery. Return used batteries to an appropriate recycling facility.
Remove the used battery.
Install the new battery. Note: Before connecting the cables, ensure that the key start switch is OFF.
Connect the cable from the starting motor to the POSITIVE “+” battery terminal.
Connect the cable from the ground plane to the NEGATIVE “-” battery terminal. i00993589 Battery - Recycle SMCS Code: 1401-005; 1401-510; 1401-535; 1401-561; 1401 Always recycle a battery. Never discard a battery. Always return used batteries to one of the following locations: • A battery supplier • An authorized battery collection facility • Recycling facility i01039758 Battery Charger - Check SMCS Code: 1401-535 Checking Before Start-Up Check the battery charger for proper operation. If the bat
Ensure that the charger is turned OFF.
Adjust the voltage of the charger in order to match the voltage of the battery.
Connect the POSITIVE “+” lead of the charger to the POSITIVE “+” battery terminal. Connect the NEGATIVE “-” lead of the charger to the NEGATIVE “-” battery terminal.
Turn ON the battery charger. 104 SEBU7508-09 Maintenance Section Battery Electrolyte Level - Check Overcharging of Batteries Overcharging reduces the service life of batteries. Use a battery charger that will not overcharge the battery. DO NOT charge the battery if the meter of the battery charger is in the RED zone. Overcharging is indicated by the following symptoms: • The battery is very warm to the touch. • A strong odor of acid is present. • The battery emits smoke or a dense vapor (gas).
Remove the ﬁller caps. Maintain the electrolyte level to the “FULL” mark on the battery. If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use artiﬁcially softened water.
Check the condition of the electrolyte with the 245-5829 Coolant Battery Tester Refractometer.
Keep the batteries clean. Clean the battery case with one of the following cleaning solutions: • A mixture of 0.1 kg (0.2 lb) of baking soda and 1 L (1 qt) of clean water • A mixture of 0.1 L (0.11 qt) of ammonia and 1 L (1 qt) of clean water Thoroughly rinse the battery case with clean water. Use a ﬁne grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause
Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF position and remove the key and all electrical loads.
Disconnect the negative battery terminal at the battery that goes to the start switch. Ensure that the cable cannot contact the terminal. When four 12 volt batteries are involved, the negative side of two batteries must be disconnected.
Tape the leads in order to help prevent accidental starting.
Proceed with necessary system repairs. Reverse the steps in order to reconnect all of the cables. i02023749 Bearing (Ball) - Lubricate (Generator) SMCS Code: 4471-086 The following ball bearings must be lubricated: no shield and single shield. Double shielded ball bearings may not require lubrication. Refer to the instructions that are located on the machine. For ball bearings, use Caterpillar 2S-3230 Bearing Lubricant. This grease is an NLGI No. 2 Grade. There is Polyurea (a thickener) in this
Remove either the louver assembly or the rear plate from the rear of the generator housing.
Remove the top grease pipe plug and remove the lower grease pipe plug.
Install a grease ﬁtting in the grease pipe.
Grease the shielded ball bearings with 2S-3230 Bearing Lubricant (53.28 mL (1.8 ounces) to
Wipe off the excess grease. Remove the top grease ﬁtting. Install the plug.
Operate the generator for one hour. This will allow the grease to expand. The expanding grease will force the excess grease from the cavity. When the excess grease is forced from the cavity, the internal pressure will be reduced. The generator should continue to operate until the grease stops purging.
Stop the engine. Install the plug in the bottom grease pipe. Wipe off the excess grease.
Install the louver assembly or install the rear plate. i01181601 Bearing (Spherical Roller) - Lubricate SMCS Code: 4471-086 Spherical roller bearings must be lubricated. For spherical roller bearings, use a Caterpillar 108-8611 Grease Cartridge. This grease is an NLGI No. 1.5 Grade. There is no molybdenum disulﬁde in this grease. There is Clay (a thickener) in this grease. At 40 °C (104.0 °F), the viscosity of the grease in a Caterpillar 108-8611 Grease Cartridge is 32 cSt. At 100 °C (212.0 °F),
Remove either the louver assembly or the rear plate from the rear of the generator housing.
Remove the top gre

Source: manual:SEBU7508-09 M.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.