Service Tips
Tips for Tier III Engine Maintenance
Keeping your fuel system clean is critical to proper engine operation
The Tier III engine’s diesel fuel injection systems requires an extremely high fuel pressure—often over 25,000 psi—to function correctly. Without the high pressure, the burn pattern is not sufficient to produce the low contaminant emissions required by federal regulations.
Fuel systems tolerances between components have been reduced to assure that regulatory requirements are met. It is important to control contaminants in the fuel system to assure that all parts are working properly. Additional damage to the engine can occur due to contaminated fuel, and this type of damage may not be covered by warranty or may void the engine’s warranty.
Below are some helpful tips to keep contaminants from entering your fuel system.
• Do not pre-fill the fuel filters. Fuel used for this purpose is usually
contaminated and has not been filtered. It can damage critical fuel system parts. For Tier III engines, the filter must be kept clean and installed without pre-filling. Refer to your equipment manual for proper procedures, or use an electric fuel pump to fill the filter with filtered fuel.
• All maintenance procedures should be completed by a trained, qualified service technician. Case Power and Equipment’s technicians have been certified to service Tier III engines.
• The work environment must be sterile and free of airborne contaminants. A modern injector’s internal drillings are quite small and extremely susceptible to clogging. Any type of plugging in an injector can cause dribbling and, possibly, engine damage.
• The high pressure in the Tier III engine’s fuel injection systems operation can transform small particles of dirt, dust and rust into extremely abrasive contaminants that can severely damage components. Many modern injectors cannot be serviced but must be completely replaced if damaged.
• Do not use compressed air to clean dirt from fuel system fittings. Use an electrical contact cleaner or a spray parts cleaner. Keep exposed fuel system parts clean. Diesel fuel attracts airborne particles. The fitting frequently will have a residue where the work is being completed, even when there’s a small amount of fuel at the fitting.
• Many engines require secondary fuel filtration at a level of 3 microns. A filter’s micron rating indicates the size of the smallest particles that the filter will capture. Micron is an abbreviation for micrometer, one millionth of a meter. A human hair measures .003 mm/3/1000” in diameter. A micron measures 0.00004 mm/4/100,000”.
• Frequently clean all tools used for fuel system troubleshooting and repair. They may be overlooked as a possible source for contamination. Residual oil or fuel on the tools will attract airborne contaminants. Always clean tools before using them.
• Cap and plug fuel lines, fittings, and ports any time the fuel system is opened to help avoid contamination. Though the repair may only take a short time, airborne contaminants can drift in from an adjacent bay, through an inadvertent bump against the engine housing or off someone’s dirty clothing.
Additional Tips
Low Sulfur Fuel Requirements—It is always important to use the correct low sulfur fuel with your Tier III engine. Refer to your operator’s manuals to identify the sulfur requirements for all of your equipment.
Engine Maintenance—The fuel system components for the Tier III engines are much more expensive than those for the older engines, particularly the injection pumps. By following all recommended procedures for engine maintenance, the need for component replacement due to improper usage is unlikely, however.
Warranty Coverage Requirements—When procedures detailed in the operator’s manual have not been followed, and the manufacturer refuses to cover repairs under warranties, the equipment owner is liable for these repair expenses. Warranties will not cover damage from water, contamination, or use of incorrect fuel for injection pumps.
Machine Winterization Tips
Cold weather can really take a toll on your equipment. Case Power and Equipment has created a few helpful tips to help you avoid 2 am breakdowns and make sure your machine is ready for winter.
Check chain tanks, final drives, swing gear baths and gear boxes for water
Water will freeze during the winter, causing chains to break. Floating ice chunks will also harm gear boxes. Check each area for water at least once before the temperature falls below freezing.
Check freezing point of coolant
Make sure you’re using coolant that complies with ASTM standard D-621, with a freeze point low enough for your climate. If coolant freezes, it can crack the engine block and ruin the engine. For detailed information about coolant, read our coolant tips.
Add fuel conditioner
Fuel conditioner prevents your fuel from freezing and makes sure your engine starts in the cold. It’s like adding Heet to your car. The amount of conditioner required varies, based on the brand and model of the machine. Check the manufacturer’s recommendations. Make sure you match the fuel conditioner to the type of fuel you’re using (e.g., low sulfur).
Check the fuel filter
If the fuel filter is clogged, moisture can build up and freeze in the winter, causing your machine to run improperly or fail to start. Most filters have water traps that should be emptied before cold weather arrives. Keep an extra set of fuel filters in your cab to avoid downtime due to fuel problems.
Check cold start aids
Diesel engines spray ether into the air system to help the engine start in cold weather. For older machines that have ether spray bottles, check the bottle to make sure it contains a sufficient amount. For new machines with an automatic ether system, check to see whether it is functioning properly by visually inspecting the connections and hoses for cracks or loose connections.
Check for proper functionality of block heater
Block heaters keep fluids at the appropriate temperature and viscosity. If the block heater isn’t working, oil can thicken, making it harder to turn the engine over and adding stress on the battery. Check the block heater by plugging it in and touch the hoses to make sure they are warm.
Inspect lights, wipers, belts, cutting edges and back up alarms
It’s much easier to make repairs without needing to deal with the cold, snow and ice. Inspect your equipment thoroughly and take the time to test the lights, wipes, belts, cutting edges, back up alarms and anything that might be an inconvenience to fix during the winter.
Inspect air pre-cleaners
Large dust particles and debris can build up during the summer. If these particles are not removed, snow and ice could collect around them, allowing moisture into the air system, which could cause engine failure.
Check battery and connections
Corrosion around battery connections causes less voltage to be transmitted, and increases the strain on the battery. Corroded connections can drain the battery, preventing your machine from starting. Periodic inspections for corrosion could reduce the chance of being inconvenienced with a drained battery.
Operator Safety Tips
Follow these guidelines to help reduce injuries due to operator error. Contact the Case Power and Equipment location nearest you for all your safety equipment needs
Check pins and bushings – Pins and bushings can loosen over time, causing a safety hazard. Establish a maintenance routine which includes checking, tightening and replacing pins and bushings.
Maintain 3 points of contact – Getting in and out of machines is the number one cause of injury. Insure you always have 3 points of contact with the machine while climbing into or out of the machine.
Know your surroundings – Check your mirrors and use a spotter, if necessary, to stay centered on ramps.
Rope off your swing radius – Use a spotter to help rope off the swing radius of your machine and keep bystanders out of harm’s way.
Know the limits of your machine – Machines can tip over, even on level ground. Know your machine’s capabilities. Just because you made it up a slope, doesn’t mean you can make it back down.
Mark overhead or underground hazards – When digging, be sure to mark all hazards and proceed with caution. When working above ground, identify all potential hazards overhead.
Travel in reverse with caution – Use wide angle mirrors, and adjust them whenever you begin operation to minimize blind spots. Always be aware of the machine’s perimeter, stepping out of the cab to view surroundings, if necessary.
Always strap in – Always use a seat belt or harness, even when the cab is closed.
Use the proper machine – Avoid using machines for functions they weren’t designed to do, especially lifting functions.
Lock-out/tag-out – Any elevated load or object is subject to lock-out/tag-out procedures, as defined by OSHA. Be sure the controls are locked when leaving a load suspended.
Maintenance Tips for Skid Steer Tires
A few simple maintenance routines can extend the life of your skid steer tires dramatically.
Clean your Tires
Hose down your tires routinely so they are easy to inspect. Look for bubbles, bumps, cracks, and anything that might be lodged in the rubber.
Check the Tread
A quick visual inspection will also reveal any uneven wear. On skid steers, one set of tires may wear faster (the front or rear), depending on how they are operated. Rotate the tires as soon as you notice any uneven wear, which will extend the life of all four tires.
Operate with All Four Tires Engaged
There is less wear on the tires and the machine when the skid steer is operated with all four tires engaged on the ground. When the bucket is too far beneath a load, the front tires may lift slightly off the ground, placing stress on the back tires.
Keep the Tires on the Ground
Skid steer tires are designed for operation on ground, not on road surfaces. Consequently, the tires will wear out faster when they are driven on roads rather than on the ground.
Watch for Debris
Skid steers are operating in areas that are often full of debris. Drive carefully and avoid litter. Pneumatic tires can go flat, and foam-filled tires can leak if punctured.
Protect the Rims
Avoid popping off retaining rims, which can occur by catching the rim on an object. It’s inexpensive to replace a rim, but the downtime associated with unnecessary maintenance can be quite expensive.
Monitor the Pressure
With pneumatic tires, if the tire pressure is too low, you will waste fuel, and if it’s too high, you increase the chance of flats. In either case, uneven wear can result. Keep a reliable tire gauge handy and check the pressure every day or once a week, depending on how often you are operating the skid steer. Check your owner’s manual for the acceptable tire pressure range.
Store Properly
Constant exposure to sunlight can cause tires to expand and crack. Store tires in a cool, dry place.
Buy Consistent Brands
Avoid installing different brands or models of tires on the same machine. Each brand has its own distinct design and combining brands can cause uneven wear on both your tires and your skid steer.
Cutting Edge Tips
Operating Tips
Avoid back dragging
Back dragging reduces cutting edge life by causing it to break before it wears down.
Minimize excessive down pressure
Buckets last longer if the operator minimizes the amount of pressure applied when the bucket is engaged with the ground.
Avoid using blades in wet conditions
Blades wear faster in wet conditions.
Equipment Tips
Use corner attachments
Corner guards increase the bucket’s strength. Not using corner guards can cause premature wear.
Use a thicker edge
More powerful machines can use thicker edges, and, in most cases, they should.
For grader blades, consider using single bevel curved blades instead of double bevel curved
The leading bevel on double bevel curved blades wears out quickly, turning it into a single bevel curved blade. Single bevel curved blades last longer and are more cost effective.
Use proper bolts and nuts
Loose bolts and nuts cause the cutting edge to be loose on the moldboard, which can lead to breakage. Use Grade 8 bolts or higher; lower quality may stretch and loosen.
Rotate the cutting edge consistently
Flipping the blade regularly can double the blade life. The flipping interval depends upon what type of material it’s used for, and the application.
Protect snowplow cutting edges with a standard flat blade
The steel in carbide snow plow blades can erode, causing the carbide inserts to fall out.
Inspection Tips
Inspect loader edge position
The base edge is the primary support for the bucket system, while the primary engagement edge should be the bolt-on cutting edge. If the base edge is worn out, the bucket is not as stable.
Inspect loader wear plates and replace when needed
Increase the life of the bucket and cutting edge by replacing wear plates regularly.
Routinely inspect and secure bolts
Loose cutting edges can easily be damaged and may fall off and damage surrounding equipment.
Coolant Tips
Coolant is important in your equipment’s cooling systems to prevent freezing, corrosion, cavitation and rust. A periodic coolant analysis can provide important information about the health of your machine.
What’s in coolant?
Nearly all heavy-duty antifreeze is about 95% ethylene glycol and 5% water and additives. About 1% of all antifreeze sold is made from propylene glycol, an alternative to ethylene glycol which is less toxic, but more expensive. By mixing glycol with various ratios of water, coolant is created. Typically, coolant is 30 – 50% glycol.
Formulations differ with the additive package that’s blended into the ethylene glycol. All of these additives fight rust, scale and corrosion but may have different chemical compositions. In diesel engines the additives also protect wet cylinder sleeves from cavitation.
What to look for when buying coolant
• Make sure the coolant you purchase for your diesel engines states that it complies with ASTM standard D-6210on the package.
• Deionized water is preferred and the coolant should be prediluted, so there is no need to add water.
• Pick an antifreeze type, avoid mixing it with other types, and follow the maintenance recommendations suggested for
that coolant.
Maintenance Recommendations
• Periodic visual test
Check color—should be clear, indicating no rust is present, and correct, showing that it has not mixed with another
antifreeze type.
• Test additive concentrations with a coolant analysis test by taking a sample and submitting it for analysis.
The recommended interval for testing is 1,000 hours. Cowin Equipment Company has easy to use sample kits available.
• Sample strips are available to test additive concentrations yourself. Using paper chemically sensitive test strips, you can see
problems from color changes which indicate freeze/boil point (glycol content), nitrite (or nitrite/molybdate) levels and,
in some instances, pH.
Clean Fuel Tips
Avoid Fuel Contamination to Extend Engine Life
Dirt and dust in your fuel system can reduce engine life by 50%.
These contaminants cause more than 85% of all failures in fuel systems.
Even tiny amounts of dirt and dust in your machine’s fuel system can become obstructions to the engine’s normal processes. Newer engines are even more susceptible to damage, because the fuel injection pressure is higher, and the smallest particles can impair normal engine functions.
Areas of Potential Damage
When dirt and dust are introduced to an area in the engine where quick, sliding movements are important, wear can be accelerated when these small particles interfere with the sliding movement. Examples of these parts are inner and outer valves, nozzle needles and seats, and command piston sliding portions. Two areas where dirt and dust can cause particularly harmful damage are at the interface between the injector barrel and plunger and on the control valves.
Interface between Injector Barrel and Plunger
The amount of fluid required to keep the operation smooth and continuous between the injector barrel and plunger is just 2.5 microns. The introduction of dirt or dust into this area could cause significant interference with this movement.
Control Valves
A decrease in engine power occurs when the control valves, which maintain fuel pressure, begin leaking. Such leaks are caused when contaminants wear away seals.
How to stop dirt and dust from entering the fuel line
Fueling
Properly maintain all fueling equipment. When you refuel, always replace the nozzle back onto the pump, rather than letting it fall on the ground where it could gather dust.
Operation
Construction equipment often operates in a dusty environment. You can prevent dust from entering the fuel system by making sure the vent tube and fuel tank caps are tightly sealed.
Service
While servicing your equipment, minimize the possibility of exposing the engine to the air, which will minimize the risk of introducing dirt and dust into the fuel system. Whenever you change filters, refuel or make any type of engine repairs, accomplish these tasks indoors, if possible, where there is less chance of contamination.
Filters
Change filters promptly at the manufacturer’s suggested intervals—clogged filters cannot prevent dirt from circulating through your engine. Use filters that are approved by the equipment manufacturer—learn why in our filter podcast. Follow instructions carefully when changing both the main filters and the prefuel filters, so that dust does not enter the fuel system during this process. Always check seals to detect possible leaks.
Tips for Changing Filters
Main Filter
Do not fill the filter element with fuel when changing the main filter to avoid introducing dust during the replacement process. Also, check to insure that the o-ring fits properly. Operate the priming pump to fill the new filter with fuel.
Prefuel Filter
Fill the new filter cartridge for the prefuel filter with fuel before installing it. Check to make sure the cap is attached to the new filter cartridge, then pour fuel into the cartridge (do not use the center hole). Once the cartridge is full of fuel, take off the cap and discard it. Install the prefuel filter cartridge onto the filter holder after applying a thin layer of engine oil to the packing surface of the cartridge. When the packing surface on the cartridge comes in contact with the sealing surface of the filter holder, tighten the filter cartridge ½ to ¾ turn.
How to prevent water from entering the fuel line
At night, condensation can occur due to a drop in the temperature while the equipment is not operating, and water may enter the fuel tank. To avoid the formation of condensation, at the end of each day, the tank should be filled up. Before beginning to operate your equipment each day, drain the water and sediment that has accumulated at the bottom of the tank. Similarly, about ten minutes after refueling, water and sediment should be drained from the fuel tank.
Attachment Maintenance Tips
Keep Costs Down by Extending the Life of Your Attachments
Hydraulic Hammers
Complete a Regular Three Part Inspection
- Check for leaks in the attachment’s fittings or hoses
Prior to use, inspect hoses for cracks and check that shielding is in place. Make sure your fittings are not loose and your hoses and fittings are free of contaminants. - Inspect critical points for proper lubrication and function
Power wash the attachment to remove dirt, sand or other contaminants. Once clean, follow the manufacturer’s guidelines for proper special grease or oil lubricant requirements for proper bushing wear. These contain special agents designed specifically for manufacturers’ units, and standard grease is not acceptable for most hammers. - Make sure the locking mechanism is operating correctly
The locking mechanism should not be stiff or bent to ensure proper locking and unlocking of the attachment. Check for damage whenever attachments are changed. Never pry with tool while operating.
Best Practices
- Keep hydraulic hose ends out of the dirt
- Make sure your hammer’s in and out ports are closed on the jobsite – dust and sand can easily enter if left open
- On a weekly basis, or every 10 hours, remove and inspect the retaining pin and tool
- On a monthly basis, or every 50 hours, inspect the tool shank and bushings, carefully checking for wear
- Every 50 hours, inspect hydraulic hoses
- Hammers should be serviced annually or every 600 hours
Buckets & Teeth
Bucket Inspections
Buckets require extra care – a well maintained bucket can cut down on costs by digging and breaking out more efficiently, which reduces fuel consumption and increases the rate of job completion. Prior to use, carefully check the following parts of your bucket:
- Mounting Hinges
Inspect for cracks. A small crack can quickly become much larger – if you see any cracks, get them fixed immediately. - Front Leading Edges and Corners
Visually check to see if they are getting thinner or if there are signs of cracking. If so, the corners can be re-plated and thickened to increase the life of the bucket. If left unchecked, the corner could fail during heavy digging and the bucket edge can be torn out completely and would have to be replaced. - Bucket Edges
Any signs of distress? If so, can it still be serviced? If you are working with a bucket with reversible edges, you may want to consider rotating them. - Bucket Teeth
Check if they are worn or need rotating. Teeth that are regularly rotated last longer, saving you money. Corner teeth tend to wear faster – move them to the center to increase their life. Many styles of teeth can be turned upside down – the lower edge wears faster and if they are turned over they will wear more evenly. - Lost Teeth?
Do not use a bucket with a missing tooth. Not using a full set of teeth will wear away the adapter nose and result in poor contact when new teeth are installed. - Correct Bucket Teeth?
There are a wide range of bucket teeth that can be used for a variety of applications – make sure you have the correct teeth for the job, such as penetration teeth for rock or abrasive teeth for coal. - Lubrication
Is the bucket properly greased? Insert some lubrication into the proper bucket pin locations. Simple lubrication is the cheapest and best form of maintenance. Also, - Check pins and bushings for wear at this time
Worn pins & bushings cause more stress on the machine, and rapidly lead to expensive and more in depth repairs when let go too long. Also, worn pins & bushings result in less control of the machine during operation.
Filter Tips
About Filters
Changing filters regularly is essential for your equipment to perform its best. Recommended intervals for filter changes vary between 250 and 500 hours. It can be tempting to select a bargain filter brand, but an inferior filter can make a big difference in the long term health of your equipment. Saving a few dollars on a filter is just not worth the damage that can be caused to your equipment by an inferior filter.
Here are the basics of filters.
Why are filters used?
Filters are used to keep fuel, oil and hydraulic fluids clean as they circulate throughout your machine’s systems, lubricating the parts and dispersing heat. There are fuel filters, engine oil filters, transmission filters and hydraulic fuel filters.
Why are filters important?
Small particles from component wear and dirt are picked up by oil and hydraulic fluids as they flow through the equipment. If these contaminants are not separated from the fluids, they could cause tremendous damage to a machine. Using the correct filters will actually help maximize machine performance and extend the life of your machine.
A filter should capture contaminants and dirt effectively and perform well during the entire interval between filter changes.
What affects a filter’s performance?
There are three components of a filter that are important.
1. The filter media
The fluids pass through filter material or media where contaminants are trapped. Naturally, what the filter media is made of is important. The material must be strong enough to last through the interval between changes. So, it must be tough and not fall apart during its lifetime.
2. Filter construction
The filter must be constructed so that it traps extremely fine particles but doesn’t get clogged and become ineffective. Inadequate capacity in a filter will trigger the bypass valve to open too early, and unfiltered fluids will enter the system.
3. Filter canister
The filter canister should be strong enough to avoid collapse under high pressure. Collapsing would permit unfiltered fluids to flow through the system.
Before you buy a filter
Ask your parts representative whether the filter you plan to purchase meets the equipment manufacturer’s requirements.
Hydraulic Hose Tips
Choose the right hose
When choosing a hydraulic hose you should pay close attention to the following characteristics:
• Working Pressure – Choose a hose that is suitable for the working pressure of the machine
• Wire or Sheathing – Install wire or sheathing when fabricated if the hose will be used in an area exposed to damage from pinching or crushing
• Fluid – Make sure you use a hose compatible with the fluids that are used in the machine
• Size/Inner Diameter – Choosing the right size hose is important in order to avoid unwanted friction. When fluid rubs against the inner surface of the hose, friction is created, which creates heat, increases back pressure and reduces the rate of flow
• Match the Fluid Viscosity to the Operating Temperature – In order to achieve maximum component life, the fluid’s viscosity grade should be correctly matched to the operating temperature range of the hydraulic system
Keep your hose operating correctly
Follow these maintenance tips to ensure optimal performance and reduce risks, labor costs, and downtime
Pre-Use Inspection – To be completed before each use
- Check hydraulic hoses for signs of deterioration – Look for indications of wear, such as cracking, blisters and bubbles. Catching signals early helps avoid hose failures later on
- Inspect seals used in fittings and adapters – Seals wear down, harden and age with regular use. Check for signs of wear and replace as needed
- Timeframe for replacement varies – There is no set time to replace hydraulic hoses. Rate of deterioration depends on a variety of factors including usage, pressure, and the type of hydraulic liquid
- Semi-Annual Maintenance Checks – At a minimum, hydraulic hoses should be thoroughly inspected by a certified technician every six months
Storage and Safety Tips
- Keep fittings clean – Avoid getting sand, dirt or other substances on your fittings and clean before each connection
- Use caps and plugs when not in use – Use of caps or plugs on your hydraulic hoses keeps them clean and saves time later when you have to re-attach them
- Store in the shade – Keep hoses stored out of direct sunlight. The sun accelerates deterioration and high pressures can result when the oil expands in the hose, making connection more difficult
- Detach carefully – A pressure relief tool is the best implement to remove a pressure-locked hose. Do not hit hoses on the floor to release pressure
- Always wear safety goggles when working with hydraulic hoses
What if a hose fails?
Usually hoses fail due to misapplication, deterioration or improper maintenance. If the hose fails, be extremely careful:
- Shut down the machine immediately to avoid additional damage
- Allow machine to release pressure – Pressure is not released immediately and machines need time to release pressure to a level suitable for a proper inspection
- Do not search for the leak using your hands – Hydraulic fluids can penetrate the skin and pose a significant risk to your health
- Carefully replace the hose and test for proper operation
