3306 Industrial Engines – Lip Type Seals

Lip type seals are used to seal the bearing supported sealing journals and the contact surfaces in an oil compartment.

Sealing Journal Storage

Best storage practice for sealing journals

Acceptable storage practice for sealing journals

Sealing journals should be stored with a sealing journal cap and in conformance with the storage and shelf life as per Contamination Control Guidelines, PEBJ0002, “Caterpillar Dealer Contamination Control Compliance Guide”. A cap provides protection to the critical areas of the sealing journal. The use of a cap reduces the risk of damage and contamination to the part.

Bore Storage

Bores should be stored in a manner that will reduce contamination and risk damage to the inside of the bore. Storage should also conform to Contamination Control Guidelines, PEBJ0002, “Caterpillar Dealer Contamination Control Compliance Guide”.

Handling of the Seal


Proper handling of lip seal

Many seals are pre-lubricated. Do not remove the lubrication on pre-lubricated seals.

Lip seals should only be handled on the outer edge. To avoid contamination, the sealing surface should not be touched. Refer to Illustration 6 for proper handling.

Many seals come with a polytetrafluoroethylene (PTFE) coating on the seal. Do not remove the coating or damage the coating in any way. Handle with proper and adequate care.

Note: PTFE is more commonly referred to as Teflon from Dupont.

Handling of Mating Components

Lip seals are sensitive to the quality of the mating components. Mating component surfaces should be checked for the presence of defects that would compromise sealing, and not be used if such defects are found. These defects include:

Burrs

Nicks/Large scratches

Contamination such as: paint, metal shavings (for example: machining chips) and dirt

Liquid contamination (grease, and so on.)

Other debris

Poor surface finish or porosity

Visual Out-of-Roundness

Clean cardboard or plastic separators are recommended to prevent damage during the transportation and storage of finish-mating components.

Mating components should be handled in such a way to reduce the risk of damage or contamination.

Assembly Aids

Refer to the D & A manual for instruction in the use of any assembly aids.

The fluid being sealed is the proper lubricant for use with lip seals and the mating components of lip seals.

It will not be necessary to obtain an assembly aid to remove supplier-applied sealant build-up if proper tooling care and contamination control techniques are followed.

Assembly Tooling

Types of Lip Seal Tooling

When installing lip-type seals, it is important that proper tooling and tooling care need to be followed.

Refer to the respective D & A manual for the tooling used to install the lip-type seal.

Tooling – Care

Before using the tooling check the tool for damage. Tools with damage such as nicks, gouges, missing material, or deformation must be replaced immediately.

Tools should be cleaned daily to remove contamination. If contamination is present, use a clean lint-free wipe to remove the debris. To maintain cleanliness and prevent tool damage, storage fixtures should be cleaned as a part of daily 5S activities.

Note: 5S activities refer to Caterpillar Production System (CPS) For Dealers related to “Sort, Set, Shine, Standardize, and Sustain”.

For more details refer to:

Referencehttps://dealer.cat.com/cda/files/2498665/7/030%20R_Module %2017%205S_Visual%20Workplace%20v3.ppt

Do not use a chemical remover to remove supplier-applied sealant build-up from the seal tooling. Various chemicals can deteriorate the coatings on the lip-seals.

Refer to “Loctite Maintenance and Solutions Heavy Equipment Guide for Cat Dealers” to determine which chemical removers can be used.

Cleaned tooling should be stored in ergonomically designed designated areas that prevent damage to the tools.

Tooling – Inspection

All tooling should be inspected before use for damage. An improperly maintained tool can cause seal damage and increase the risk of leaking due to improper seating of the seal. Tools with damage such as sharp edges, nicks, burrs, “mushroomed” driver heads (applicable to lip seal drivers), should be reconditioned or replaced prior to further use.

Tooling – Storage

To help protect the seal tooling from damage, it is important that proper lip-seal tooling storage needs to be provided. Placing seal tooling on a metal surface can severely damage the tool due to metal-to-metal contact.

Seal tooling should be stored on a soft, forgiving surface such as nylon, HDPE, and so on.

Do not store tools in a basket to avoid the damage to the tools critical. Proper storage facilities must be provided to all workstations to reduce risk of damage to tool.

Regular inspection of the storage surface and/or racks is required and shall accompany the maintenance schedule for the seal tooling.

Properly label tooling to reduce risk of misuse or misplacement.

Tooling – Maintenance & Damage Reporting

All seal-specific tooling should be placed on a routine maintenance schedule similar to the torque-tooling schedule.

A formal reporting process shall be established at every dealer to report damaged tooling.

To reduce the risk of downtime and use of an unapproved tool due to tooling damage, replacement tooling shall be in inventory and available for immediate use. Damaged tools should be replaced immediately since using a damaged tool increases the risk of seal damage or leaks.

Preassembly Inspection Of Critical Components

Complete a 1-second inspection for seal and mating components for damage and contamination. A 1-second inspection is a quick visual inspection of the part and mating component to determine if damage is present to either part prior to assembly.

Lip Type Seals – Assembly

Seal Lubrication Application

Use an eyedropper or spray bottle for lubrication of the seals. Apply a thin film of lubricant to the designated seal surfaces. Do not use bristle brushes, foam pads, or cotton swab type applicators, as these will contaminate surfaces of the seal.

For elastomeric seals the sealing lip and sealing journal should be lubricated using the fluid to be sealed. Do not over-lubricate. Over-lubrication may cause oil/grease to drip or wash down after assembly, which may give the appearance of a leaking seal.

Note: PTFE seals are intended for dry installation. Do not lubricate the sealing lip and the journal. Common applications for these seals are in crankshafts and water pumps. Refer to appropriate engineering drawing for material specification.

Lubrication Location

For elastomeric seals the sealing lip and sealing journal should be lubricated using the fluid to be sealed.

For rubber outside diameter seals, also lubricate the outside diameter.

For metal outside diameter seals, do not lubricate the outside diameter.

Note: Do not remove grease from pre-greased seals.

Sealant Use

Some applications may require the use of sealant, commonly referred to as Loctite. Apply sealant to bore directly, if required.

Refer to “Loctite Maintenance and Solutions Heavy Equipment Guide for Cat Dealers” for a list of acceptable sealants part numbers and the application for use.

Also refer to “Doing it Right Loctite User Guide” for the best application of adhesives and sealants.

Referencehttps://dealer.cat.com/cda/files/2722133/7/DoItRightLoctiteGuide.pdf

Do not apply sealant directly to seal.

Do not use sealant with rubber outer diameter seals.

When assembled, the shaft and seal must be lubricated with the lubricant being sealed. In water/glycol applications, glycerin is an appropriate substitute.

Note: PTFE seals MUST BE INSTALLED DRY for proper wear-in.

Assembly Tooling Use

Do not bottom the installation tool on housings with as-cast surfaces.

Use the correct seal assembly tool as specified on the Assembly Work Order.

04. January 2018 by samuel07042012
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3208 Diesel Truck Engine Crankcase Ventilation Valve

(1) Torque for hose clamps … 2.3 ± 0.2 N·m (20 ± 2 lb in)

(2) Torque for bolts … 3.4 ± 0.5 N·m (30 ± 4 lb in)

17. August 2017 by samuel07042012
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Air Filter Inspection

Visually inspect the filter for damage and failures in the filter seal, gasket, and outer cover before cleaning the filters. Do not use any failed filters or any damaged filters. PowerCore air filters require inspection of the beads of glue for damage and inspection of the filter paper for damage.


Illustration 8 g01158840

Typical damage to an axial air filter element

Do not use this air filter again.


Illustration 9 g01158864

Typical example of a reusable axial air filter element

Reuse this air filter until a replacement can be installed.


Illustration 10 g01158870

Typical damage to an air filter element with a radial seal.

Do not use this air filter again.


Illustration 11 g01158874

This gasket will give a good seal.

Reuse this air filter until a replacement can be installed.


Illustration 12 g01158877

This gasket is badly damaged.

Do not use this air filter again.


Illustration 13 g01158878

A typical example of a reusable gasket for an air filter with an axial seal.

Reuse this air filter until a replacement can be installed.


Illustration 14 g01158879

This gasket is badly damaged.

Do not use this air filter again.


Illustration 15 g01158880

A typical example of a reusable air filter element with an axial seal.

Reuse this air filter until a replacement can be installed.


Illustration 16 g01158882

A typical example of a reusable air filter element with a radial seal.

Reuse this air filter until a replacement can be installed.


Illustration 17 g01158884

A typical example of a reusable air filter element with a radial seal.

Reuse this air filter until a replacement can be installed.


Illustration 18 g01158885

A typical example of the beads of glue that are on a reusable PowerCore air filter with a radial seal.

Reuse this air filter until a replacement can be installed.

15. August 2017 by samuel07042012
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Air Filter Restriction Indicator

Note: The air filter indicators need annual replacement.

Use an air filter restriction indicator (Illustrations 6 and 7) to determine when a filter should be replaced. The two types of restriction indicators are the flag type and the graduated type.


Illustration 6 g01158832

These graduated restriction indicators are found on newer engines.


Illustration 7 g01158835

A flag type air filter restriction indicator (older style).

Inspect the indicators daily for cracks, holes, or loose fittings. If the indicator is damaged, the indicator must be repaired or replaced when any of these conditions are present.

See the appropriate Operation and Maintenance Manual for further information.

15. August 2017 by samuel07042012
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Caterpillar Certified Procedure to Inspect and Clean Air Filters

Caterpillar Products:Commercial Engines 3500B and 3500C
Caterpillar Products:Machine Engines with Electronic Unit Injectors 3500 Series
Caterpillar Products:Machine Engines with Mechanical Unit Injectors 3500 Series
Caterpillar Products:Machine Engines 3500B Series All 3500 Series
Caterpillar Products: Engines with ACERT Technology
Engine: Commercial with Mechanical Unit Injection 3126
Engine: Machine with Mechanical Unit Injection 3126
Engine: Truck with Mechanical Unit Injection 3116
Engine:14.6 L 3406
Engine: 3114 3116 3126 3126 and 3126B 3126B 3408 3412
Engine:Commercial with Electronic Unit Injection (EUI) 3500
Engine:Commercial with Mechanical Unit Injection (MUI) 3500
Engine:Commercial with Mechanical Unit Injection 3114 3116
Engine:Commercial 3406B 3406C 3500 and 3500B 3500 and 3500B Engines with Standard Displacement 3500B and 3500C High Displacement All Diesel G3500 Family
Engine:Generator Set 3500 Series
Engine:Industrial, Marine, and Generator Set that Use Flash Programming All
Engine:Machine with Mechanical Unit Injection 3114 3116 3500 Series
Engine:Machine 3066 3114 3126 3500B Series All 3412
Engine:Marine 3500 Series
Engine:Truck with Hydraulic Electronic Unit Injection (HEUI) 3116 3126 3126B
Engine:Truck with Mechanical Unit Injection 3114
Engine:Truck 3406B 3406C Electronically Controlled
Engine:Trucks that Use Flash Programming All
Engine:with Jake Brake Retarders Built Prior to 1999 All
Engine: 3114 Truck Engines 3116 Truck Engines 3126 Truck Engine 3126B Truck Engine 3126E Truck Engines 3208 Truck Engines 3408E and 3412E All 3600 All G3600 All Gas Engines C7 On-Highway C9 On-Highway Equipped with Air Compressors
Industrial Engine:with Turbochargers All
Industrial Engine: 3003 3013 3014 3024 3114 3116 3126 3126B 3176 3204 3208 3304 Diesel 3306 Diesel 3406 Diesel 3406C 3408 3408 Diesel 3412 C-10 C-12 C-15 C-16 C-9
Machine Engines: 3408E 3412E
Machine Engines:with Mechanical Unit Injection 3500 Series
Machine Engines: 3003 3013 3014 3024 3046 3054 3054B 3054C 3054E 3056 3056 and 3064 3056E 3066 3114 3116 3126 3126B 3176 3176C 3196 3204 3208 3304 3306 3406 3406B 3406C 3406E 3408 3412 3456 3508 3512 3516 All C-12 C-15 C-16 C-9
Marine Engine:with Turbochargers All
Marine Engine: 3116 3126 3126B 3208 3304 3306 3406 3408 3412 C-12 C-9
Truck Engines:Truck All
Truck Engines: 3176 3406E C-10 C-12 C-15 C-16

Introduction

Note: Caterpillar recommends using air in low pressure and high volume to clean air filters.

The following information is found in this guideline.

Reusability of filters

Cleaning indicators

Inspection and cleaning methods

Correct packaging and storage

Call (309) 636-8500 for additional information on your filter.

PowerCore is a registered trademark of Donaldson Company Inc.

Tooling and Equipment

Contact the Caterpillar Service Technology Group for questions regarding tooling and equipment.

Caterpillar Service Technology Group
501 S.W. Jefferson Avenue
Peoria, Illinois 61630

1-800-542-8665 (USA)

1-800-541-8665 (Illinois)

1-800-523-8665 (Canada)

1-309-675-6618 (Fax)

Types of Air Filter Elements

Air Filters Which Can Be Cleaned

Illustrations 1, 2, 3, and 4 show the primary elements of the air filters that can be cleaned until a new filter is installed. These filters have a folded paper design which can withstand cleaning.

Note: Air filters with axial seals and radial seals can be cleaned.


Illustration 1 g01158809

Nomenclature of panel type air filters which can be cleaned.

(1) Gasket

(2) Metal screen

(3) Dirty side

(4) Clean side


Illustration 2 g01158816

A typical example of an air filter element with an axial seal which can be cleaned.

(5) Clean side

(6) Axial seal

(7) Metal screen

(8) End cap

Illustration 3 g01158817

A typical example of an air filter element with a radial seal.


Illustration 4 g01158818

An example of a PowerCore air filter element with a radial seal.

Air Filters Which Cannot Be Cleaned

There are some types of air filters that cannot be cleaned, such as secondary air filters. The following air filters cannot be cleaned and should be replaced:

Secondary air filters

Filters with damage to the filter paper

Rebuilt air filters

Standby filters for engines

Air filters for fire pumps

Illustration 5 g01158824

Secondary air filters cannot be washed.

15. August 2017 by samuel07042012
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3116 and 3126 HEUI Truck Engines Turbocharger – Inspect

An inspection/check of your turbocharger will minimize unscheduled downtime and reduce the chance for potential damage to other engine parts.

Removal and Installation

For removal and installation, or repair/replacement options of turbochargers, see your Caterpillar dealer. Refer to the Service Manual for this engine or consult your Caterpillar dealer for the procedure and specifications.

1. Remove the exhaust outlet and air inlet piping from the turbocharger. Visually check for oil leaks.

2. Turn the turbine and compressor wheel by hand. The assembly should turn freely.

3. Inspect the turbine wheel and compressor wheel for contact with the turbocharger housing. There should NOT be any visible signs of contact between the turbine or compressor wheels and the turbocharger housing.

4. Check the compressor wheel for cleanliness. If only the blade side of the wheel is dirty, dirt and/or moisture is passing through the air filtering system. If oil is found only on the back side of the wheel, it indicates a possible turbocharger oil seal leak.

The leak may be the result of extended engine operation at low idle or an inlet air line restriction (plugged air filters), which causes the engine to “slobber”.

Maintain the compressor wheel/turbine housing by cleaning with standard shop solvents and a soft bristle brush.

5. Check the end play and bearing clearance on the turbine wheel and shaft. If the measurements are not within specifications (see the Service Manual), the turbocharger must be repaired or replaced.
6. When installing or replacing V-band clamps, position the gap (tightening screw) down if possible so any accumulation of moisture will drain away.

13. August 2017 by samuel07042012
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3116 and 3126 HEUI Truck Engines Fuel System – Prime

Prime the fuel system in order to fill the fuel filter and purge trapped air. The fuel system requires priming after:

* being run dry
* storage
* fuel filter replacement

Engines Equipped With A Fuel Priming Pump
1. Unlock and operate the priming pump until a resistance is felt. A considerable number of pump strokes may be required.

2. Push in and lock the priming pump.

3. Promptly start the engine. If the engine runs rough, continue to operate the engine at low idle until the engine operates smoothly.

NOTE: If the engine will not start, or once started, continues to misfire or smoke, further priming may be necessary.

Engines Not Equipped With A Fuel Priming Pump

(1) Plug. (2) Fuel filter.

If the engine is not equipped with a fuel priming pump, it may be necessary to fill the fuel filter with CLEAN fuel. The following procedure will allow only filtered fuel to enter the fuel system.

1. Remove plug (1) in order to fill fuel filter (2). Ensure that air is able to vent from the plug fitting while the fuel filter is being filled. Clean up any spilled fuel immediately. Clean plug (1). Install plug (1).
2. Start the engine and immediately increase the engine rpm to 1/2 of rated rpm.

3. Maintain the engine rpm until the engine operates smoothly.

4. Reduce the engine rpm to low idle.

13. August 2017 by samuel07042012
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3116 and 3126 HEUI Truck Engines Engine Oil and Oil Filter – Change

(1) Shallow oil sump.

(2) Deep oil sump.

The scheduled oil change interval depends on the size of the oil sump. For the scheduled oil change interval, refer to “Maintenance Schedule – Engines with Shallow Oil Sump” or refer to “Maintenance Schedule – Engines with a Deep Oil Sump”.

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

Failure to follow this recommended procedure would result in these waste particles being recirculated through your engine lubrication system with the new oil.

After the engine has been operating at normal operating temperature, stop the engine. Attach a DO NOT OPERATE or a similar warning tag to the ignition key switch. Catch the oil in a suitable container. Have the used oil recycled, or dispose of the used oil properly.

1. Remove the oil drain plug. Allow the oil to drain.

2. Clean the oil drain plug. Install the oil drain plug. Tighten the oil drain plug to 25 ± 5 N·m (18 ± 4 lb ft).

Replace Oil Filter

NOTE: Change the oil filter at every oil change. Make sure to use the correct Caterpillar oil filter for your engine arrangement.

1. Remove the oil filter with a 1U-8760 Chain Wrench.


Element with debris.

Cut the oil filter case open with a 4C-5084 Oil Filter Cutter. Inspect the exposed oil filter element. Spread the oil filter element pleats apart and inspect the oil filter element for metal debris. 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 present, consult your Caterpillar dealer to arrange for further analysis.


Typical oil filter mounting base and gasket.

2. Clean the sealing surface of the oil filter mounting base. Ensure that all of the old gasket is removed.

3. Apply clean engine oil to the new oil filter gasket.
4. Install the new oil filter until the gasket contacts the oil filter mounting base. Tighten the oil filter 3/4 of a turn (270 degrees) more by hand. Do not overtighten.

Fill Crankcase

NOTE: Refer to Lubricant Specifications, Lubricant Viscosities and Refill Capacities for the proper oil and quantity to use.
1. Remove the oil filler cap. Fill the crankcase with the proper amount of new oil. Clean the oil filler cap. Install the oil filler cap.
2. Start the engine. Operate the engine long enough to ensure that the lubrication system (including auxiliary filters, etc) has oil and that the oil filter(s) are filled. Inspect for oil leaks.

3. Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes. Check the oil level. Maintain the oil level to the FULL mark on the ENGINE STOPPED side of the oil level gauge.

Oil Change Intervals

There are many circumstances when the proper conditions exist that may allow adjustment to the normal oil change interval. Many conditions exist that can affect the selection of an optimum oil change interval. The fundamental requirement in this decision must be to maintain the lubrication oil in an acceptable condition that provides continual engine protection. The quality of oil and amount of oil available is balanced against the oil’s ability to absorb combustion by-products.

Due to manufacturing tolerances, engine application, and maintenance variations, all engines do not consume fuel and oil at the same rate. The amount of fuel consumed is in direct relation to the maximum oil change interval selected. It is essential to include an S·O·S Oil Analysis before an oil change interval adjustment is considered. For more information on extending oil change intervals, consult your Caterpillar dealer.

If no S·O·S Oil Analysis results are available, the Oil Change Interval Graph can be used to determine oil change intervals.

Graph Instructions:

1. Determine the engine’s oil capacity. This includes the oil sump capacity and the oil filter(s) capacity. Engines that have less oil capacity require more frequent oil changes than engines with more oil capacity.

2. Determine the level of sulfur that is in the fuel. Engines that use fuels with higher fuel sulfur levels require more frequent oil changes than engines that use fuel with lower fuel sulfur levels. The graph line numbers (1) and (2), described in the caption below the graph, define the oil change interval.

3. Locate the engine’s oil capacity on the Y axis. Follow the horizontal line to the intersection with line (1) or (2). The engine’s oil change interval is found directly below the intersection, on the X axis.

Example: An oil capacity of 31 L (33 qt) was determined, along with fuel with 0.5 percent sulfur. The oil change interval is approximately every 8855 km (5500 mi) or 220 Service Hours. The same engine, if using fuel with less than 0.5 percent sulfur, has an oil change interval at every 16 100 km (10,000 miles) or 420 Service Hours.

Oil Change Interval Graph


(Y) Oil sump and oil filter(s) capacity in liters (quarts).

(X) Distance, time, or fuel consumed between oil changes.

(1) CG-4 or CF-4 oils used with 0.5 to 1.0 percent fuel sulfur.

(2) CG-4/CF-4 oils used with fuel sulfur of less than 0.5 percent.

(3) Kilometers (miles) between oil changes.

(4) Service hours between oil changes.

(5) Liters (US gal) of fuel consumed between oil changes.

 

13. August 2017 by samuel07042012
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3116 and 3126 HEUI Truck Engines Engine Crankcase Breather – Clean

Perform this maintenance at every other oil change interval (500 Service Hours), or more often if needed.


(1) Hose clamp. (2) Hose. (3) Bolt. (4) Breather.

1. Loosen hose clamp (1). Slide hose (2) from breather (4).

2. Loosen bolt (3). Remove breather (4) and O-ring seal.

3. Wash breather (4) in clean, nonflammable solvent. Allow the breather to dry.

4. Install a new O-ring seal.

5. Install the breather in reverse order of removal. Tighten bolt (3) to 7 ± 2 N·m (62 ± 18 lb in).

6. Slide hose (2) on to breather (4). Tighten hose clamp (1). Refer to the Torque Specifications.

13. August 2017 by samuel07042012
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3116 and 3126 HEUI Truck Engines Engine Engine Air Cleaner Service Indicator – Inspect

This engine may be equipped with a service indicator, mounted between the air cleaner and the air inlet manifold. The engine may be equipped with a different indicator.

An air cleaner differential pressure gauge may be located in the on the gauge panel. The air cleaner differential pressure gauge indicates the difference of air pressure between the inlet (dirty) side and the engine (clean) side of the filter element. The pressure difference between the two sides increases as the filter element becomes plugged.

Typical service indicator.

Observe the service indicator. A colored piston showing in the window indicates the need for servicing the air cleaner. Clean or replace the filter element when the yellow diaphragm enters the red zone or the red piston locks in the visible position. If the service indicator shows red at any time, clean the filter element or install a new filter element.

Inspect the service indicator daily for cracks, holes, or loose fittings. If any of these conditions are present, repair or replace the service indicator.

Test Service Indicator

Service indicators are inexpensive but important instruments.

Check for ease of resetting. The service indicator should reset in less than three pushes.

If the service indicator does not reset easily, the service indicator should be replaced. If the new service indicator will not reset, the indicator sensor hole may be plugged.

Severely dusty environments may require frequent service indicator replacements. Replace the service indicator yearly, regardless of operating conditions. Replace the service indicator at Overhaul, and whenever major engine components are replaced.

NOTE: When you install a new service indicator, excessive force may crack the top of the service indicator. Tighten the service indicator to a torque of 2 N·m (18 lb in).

Service Air Cleaner

If your filter element becomes plugged, the air can split the filter element material. Unfiltered air will drastically accelerate internal engine wear.

* Service the air cleaner when required by the service indicator. After servicing the air cleaner, reset the service indicator by pushing on the piston plunger.
* Check the precleaner (if equipped) daily for accumulation of dirt and debris. Remove any dirt and debris as needed.
* Operating conditions (dust, dirt and debris) may require more frequent filter element maintenance.

Replace dirty paper elements with new ones. Keep spare filter elements on hand for replacement. The filter element should be thoroughly checked for rips or tears in the filter material. Check for air cleaner seal/gasket damage, and replace the filter element at least every year.

13. August 2017 by samuel07042012
Categories: 3126 | Leave a comment

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