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3406C Industrial Engines-Maintenance Intervals - Safety

1. 00ssseeeeees 77 Engine Valve Rotators Inspect ce eeeeeeeees 77 Fuel Ratio Control Inspect Adjust eee 79 Turbocharger Inspect oo eee ceeeeeeeteeeeeeenteeeeeenaaes 87 Every 190 000 L 50 000 US gal of Fuel or 5000 Service Hours Air Compressor INSP Ct ccececceeeeeeeeteeeeeeees 60 Alternator Inspect ooo eee eeeeeeeeeeeeeneeeeeennaeeeeeeaas 62 Fuel Injection Nozzles Test Exchange 5 78 Starting Motor Inspect eeesceeeeeeeeeeeeeeeneeeees 87 Water Pump Inspect eee eeeeeeeeeeeeeeeeeeeeeeeeeeaes 89 Every 228 000 L 60 000 US gal of Fuel or 6000 Service Hours or 6 Years Cooling System Coolant ELC Change 67 Every 380 000 L 100 000 US gal of Fuel or 10 000 Service Hours Overhaul Considerations 0 cccceeeeece eee ee eens 83 60 Maintenance Section Aftercooler Core Clean Test 101371758 Aftercooler Core Clean Test Air To Air Aftercooler SMCS Code 1064 070 1064 081 Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the aftercooler for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the aftercooler if necessary For air to air aftercoolers use the same methods that are used for cleaning radiators A WARNING Personal injury can result from air pressure Personal injury can result witho
2. 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 100259474 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1395 081 Caterpillar Extended Life Coolant ELC does not require the frequent Supplemental Coolant Additive SCA additions associated with the present conventional coolants The Extender only needs to be added once Check the cooling system only when the engine is stopped and cool 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Extender 3 Add Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance M
3. NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water Ensure that cooling lines are properly clamped and tight Check for leaks Check the condition of all pipes e Inspect the water pump for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pump and the installation of water pump and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve cover e Inspect the fuel system for leaks Look for loose fuel line clamps e Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps e Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multi
4. Cooling System Coolant ELC Change 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove the cooling system drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Service Technology Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with clean water Install the cooling system filler cap 4 Start and run the engine at low idle until the tempera
5. Install the oil cooler core For more information about cleaning the cores consult your Caterpillar dealer Obtain Coolant Analysis The concentration of supplemental coolant additive SCA should be checked regularly with test kits or with S O S Coolant Analysis Level 1 Further coolant analysis is recommended when the engine is overhauled 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 that 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 Inc recommends an S O S Coolant Analysis Level 2 S O S Coolant Analysis Level 2 An S O S Coolant Analysis Level 2 is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system An S O S Coolant Analysis Level 2 provides the following information e Complete S O S Coolant Analysis Level 1 e Visual inspection of properties e Identification of metal corrosion e Identification of contaminants e Identification of built up impurities corrosion and scale S O
6. e Deterioration of the engine mounts Any engine mount that shows deterioration should be replaced Refer to the Service Manual for the recommended torques Refer to your Caterpillar dealer for more information 100623423 Engine Oil Level Check SMCS Code 1348 535 FLV A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin ADD FULL Illustration 38 g00110310 Y ADD mark X FULL mark NOTICE Perform this maintenance with the engine stopped 1 Maintain the oil level between ADD mark Y and FULL mark X on oil level gauge 1 Do not fill the crankcase above FULL mark X NOTICE Operating your engine when the oil level is above the FULL mark could cause your crankshaft to dip into the oil The air bubbles created from the crankshaft dipping into the oil reduces the oil s lubricating char acteristics and could result in the loss of power 2 Remove the oil filler cap and add oil if necessary Clean the oil filler cap Install the oil filler cap Engine Oil Sample Obtain SMCS Code 1000 008 1348 554 SM 7542 554 OC SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine Obtain the Sample and the Analysis A W
7. from oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause additional damage to the pistons the valves and the cylinder head 87 Maintenance Section Starting Motor Inspect NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartridge must be balanced due to high rpm Severe Service Applications can accelerate component wear Severe Service Applications
8. Crankshaft Vibration Damper Inspect SMCS Code 1205 040 Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine Rubber Damper Your engine may be equipped with a rubber damper The rubber damper uses a ring which is mounted in rubber in order to reduce vibrations in the crankshaft Inspect the damper and repair or replace the damper for any of the following reasons e There is deterioration and cracking of the rubber e There is slippage of the outer ring from the original position e The engine has had a failure because of a broken crankshaft e Analysis of the oil has revealed that the front main bearing is badly worn e There is a large amount of gear train wear that is not caused by lack of oil Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement 71 Maintenance Section Crankshaft Vibration Damper Inspect Visconic Damper Your engine may be equipped with a visconic damper The visconic damper has a weight that is located inside a fluid filled case The weight moves in the case in order to limit torsional vibr
9. General Service All of the battery cells have Batteries a low level of electrolyte Caterpillar Premium High Output Batteries When the plates of the battery are inspected through the filler holes the plates may appear to be warped This is caused by an excessive temperature The battery may not pass a load test Caterpillar Maintenance Free Batteries The battery may not accept a charging current The battery may not pass a load test Checking After Stopping Ensure that the battery charger is connected properly Observe the meter of the charger Record the amperage 101206425 Cooling System Coolant DEAC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated NOTICE Use of commercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines 65 Maintenance Section Cooling System Coolant DEAC Change Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the
10. a torque of 2 Nem 18 Ib in i00906289 Engine Crankcase Breather Clean SMCS Code 1317 070 NOTICE Perform this maintenance with the engine stopped If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage 74 Maintenance Section Engine Mounts Inspect Illustration 37 g00463048 Typical example 1 Hose clamp 2 Breather assembly 3 Retaining clamp 1 Loosen hose clamp 1 and remove the hose from breather assembly 2 2 Loosen the retaining clamp 3 Remove breather assembly 2 and the seal 3 Wash the breather element in solvent that is clean and nonflammable Allow the breather element to dry before installation 4 Install a breather element that is clean and dry Install breather assembly and seal 2 and install clamp 3 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for the proper torques 5 Install the hose Install hose clamp 1 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for the proper torques i00687861 Engine Mounts Inspect SMCS Code 1152 040 Inspect the engine mounts for deterioration and for proper bolt torque Engine vibration can be caused by the following conditions e Improper mounting of the engine
11. be avoided e Many original parts can be reused according to the standards for reusable parts e The engine s service life can be extended without the risk of a major catastrophe due to engine failure e The best cost value relationship per hour of extended life can be attained After Failure Overhaul If a major engine failure occurs and the engine must be removed many options are available An overhaul should be performed if the engine block or the crankshaft needs to be repaired If the engine block is repairable and or the crankshaft is repairable the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core This lower cost can be attributed to three aspects e Specially designed Caterpillar engine features e Caterpillar dealer exchange components e Caterpillar Inc remanufactured exchange components Overhaul Recommendation To minimize downtime Caterpillar Inc recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails This will provide you with the best cost value relationship Note Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life 84 Maintenance Section Overhaul Considerations If an overhaul is perfo
12. closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface Refer to the Service Manual for the replacement procedure of the water temperature regulator or consult your Caterpillar dealer Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 100894991
13. covers are installed 78 Maintenance Section Fan Drive Bearing Lubricate 1 Start the engine according to this Operation and Maintenance Manual Engine Starting procedure Operation Section Operate the engine at low idle 2 Observe the top surface of each valve rotator The valve rotators should turn slightly when the valves close If a valve fails to rotate consult your Caterpillar dealer 100175571 Fan Drive Bearing Lubricate SMCS Code 1359 086 BD Illustration 40 g00123252 Typical Fan Drive Bearing Grease Fitting Lubricate the fan drive bearing grease fitting with Bearing Lubricant Special Purpose Grease or the equivalent Inspect the fan drive pulley assembly If the shaft is loose an inspection of the internal components should be performed Refer to the Service Manual 101370585 Fuel Control Linkage Check Lubricate SMCS Code 1257 086 1257 535 Check the fuel control linkage for proper operation If necessary adjust the fuel control linkage Refer to the Service Manual for the adjustment procedures Illustration 41 g00723120 Typical grease fittings on the fuel control linkage Some fuel control linkages require lubrication Lubricate the grease fittings with 1P 0808 Multipurpose Grease or the equivalent 100626014 Fuel Injection Nozzles Test Exchange SMCS Code 1254 013 1254 081 A WARNING Fuel leaked or spilled onto hot surfaces
14. in a remote location Illustration 36 g00103777 Typical service indicator Observe the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments 73 Maintenance Section Engine Air Cleaner Service Indicator Inspect e Check for ease of resetting The service indicator should reset in less than three pushes e Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to
15. of fluid per 30 seconds into the starting motor air stream 1 Ensure that the fuel supply to the engine is OFF 2 Turn adjustment knob 3 clockwise until the adjustment knob locks 3 Turn adjustment knob 3 counterclockwise for 1 4 turns 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 4 Crank the starting motor for ten seconds and observe the exhaust air from the mufflers of the starting motor Look for oil mist A slight oil mist should be barely visible If no mist is observed or if the mist is excessive rotate adjustment knob 3 in increments of 1 16 in order to increase or decrease the oil mist Repeat the starting motor cranking and observe until the mist is satisfactory Note Drip rates should only be made under an average steady flow condition Once a steady flow condition is established the lubricator will automatically adjust the drip rate in proportion to the variations in air flow 100847451 Air Tank Moisture and Sediment Drain If Equipped SMCS Code 1466 543 M amp S Moisture and sediment in the air starting system can cause the following conditions e Freezing e Corrosion of internal parts e Malfunction of the air starting system 62 Maintenance Section Alternator Inspect A WARNING When opening the drain valve wear protective gloves a protective face shield pr
16. prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank during the following conditions e Weekly e Oil change e Refill of the tank 82 Maintenance Section Hoses and Clamps Inspect Replace This will helo prevent water or sediment from being pumped from the storage tank into the engine fuel tank If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used i00907072 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Inspect all hoses for leaks that are caused by the following conditions e Cracking e Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps NOTICE Do not bend or strike high pressure lines Do not in stall bent or d
17. require more frequent inspections of the cartridge Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 88 Maintenance Section Walk Around Inspection 3 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 there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharge
18. system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters Prime the fuel system in order to fill dry fuel filters You must also prime the fuel system after any one of the following conditions exist e The fuel system has run dry e The engine has been in prolonged storage e The fuel filter has been cleaned e The fuel filter has been replaced Note If the engine does not have a fuel priming pump refer to Step 4 1 Unlock the priming pump and operate the priming pump until a resistance is felt This procedure will probably require a considerable amount of priming 2 Push in the plunger and hand tighten the plunger 80 Maintenance Section Fuel System Primary Filter Clean Replace NOTICE Do not crank the engine for more than 30 seconds Al low the starter to cool for two minutes before cranking again Turbocharger damage can result if the engine rpm is not kept low until the oil gauge display verifies that the oil pressure is sufficient 3 Crank the engine If the engine starts and the engine runs rough run the engine at low idle Continue running the engine until the engine runs smoothly NOTICE During periodic service DO NOT remove the fuel filter plug that is in the fuel filter base in order to purge air from the fuel system The periodic removal of the fuel filter plug will result in increased wear on the threads in the fuel filter base This wear leads to fuel leaka
19. the sample being taken Always use a designated pump for oil sampling and a designated pump for coolant sampling Failure to do so may cause a false analysis which could lead to customer and dealer concerns 75 Maintenance Section Engine Oil and Filter Change If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEHP6001 How To Take A Good Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine 100652130 Engine Oil and Filter Change SMCS Code 1318 510 1348 044 A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase with the engine stopped Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil Drain the Engine Oil After th
20. to loosen foreign substances This will also help to remove oil from the oil cooler core Note Caterpillar Inc recommends the use of Hydrosolv Liquid Cleaners Table 35 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer Table 35 HydrosolvLiquid Cleaners Part ae Number Description Size 1U 8812 4 L 1 US gallon Hydrosolv4165 1U 5490 19 L 5 US gallon 8T 7570 208 L 55 US gallon 1U 8804 4 L 1 US gallon Hydrosolv100 1U 5492 19 L 5 US gallon 8T 5571 208 L 55 US gallon 4 Use steam to clean the oil cooler core This removes any remaining residue from the cleaner Flush the fins of the oil cooler core Remove any other trapped debris 5 Wash the oil cooler core with hot soapy water Rinse the oil cooler core thoroughly with clean water A WARNING 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 85 Maintenance Section Overhaul Considerations 6 Dry the oil cooler core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the components in order to ensure cleanliness The oil cooler core should be pressure tested Repair the oil cooler core if necessary
21. water pump the water temperature regulator and the hoses if necessary Drain A WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove one of the drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Service Technology Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Mainte
22. 3406C INDUSTRIAL ENGINES Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU6993 02 01 2007 Caterpillar CATERPILLAR All Rights Reserved 01369886 Maintenance Interval Schedule SMCS Code 1000 7500 Before performing any operation or maintenance procedures ensure that the Safety Information warnings and instructions are read and understood To determine the maintenance intervals use fuel consumption service hours or calendar time which ever occurs first Before each consecutive interval is performed all of the maintenance requirements from the previous interval must be performed When Required Battery Replace oe eeeeceeeeeeeeeeeeeeeeeeeeeeeeneeees 63 Battery or Battery Cable Disconnect 64 Engine Cleaneci csu tres nanona eanan 72 Engine Air Cleaner Element Single Element Inspect Replace oo eee ceeeeeenneeeeeeeeteeeeeenaeeeeeenaes 72 Fuel System Prime cccccceeeeceeeeeeeeeteeeeeeeees 79 Daily Air Starting Motor Lubricator Oil Level Check 61 Air Tank Moisture and Sediment Drain 61 Cooling System Coolant Level Check 68 Driven Equipment Check ccceeeeeeeeeeeeereees 71 Engine Air Cleaner Service Indicator Inspect 73 Engine Oil Level Check sessen 74 Power Take Off Clutch Check Adjust Lubricate 86 Walk Around Inspection ceeeeeeeeeeeeeeeeenteeeeeeneaes 88 Every Week Batte
23. A battery with a low charge will freeze more easily than a battery with a full charge 100165437 Alternator Belt Inspect Adjust Replace SMCS Code 1357 036 1357 510 Inspection To maximize the engine performance inspect the belt for wear and for cracking Check the belt tension Adjust the belt tension in order to minimize belt slippage Belt slippage will decrease the life of the belt To check the belt tension apply 110 N 25 Ib of force midway between the pulleys A correctly adjusted belt will deflect 13 to 19 mm 0 50 to 0 75 inch Adjustment Illustration 31 g00122875 Typical Adjusting Nuts 1 and Mounting Bolt 2 1 Remove the belt guard 2 Loosen mounting bolt 2 and adjusting nuts 1 3 Turn adjusting nuts 1 in order to increase or decrease the belt tension 4 Tighten adjusting nuts 1 Tighten mounting bolt 2 Refer to the Operation and Maintenance Manual for the proper torques 5 Reinstall the belt guard If new belts are installed check the belt adjustment again after 30 minutes of engine operation at the rated rom Replacement For applications that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belts are stretched The additional load on the new belt could cause the new belt to break Refer to the Service Manual for more information on the procedures for
24. ARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 8T 9190 Fluid Sampling Bottle Group is recommended for use with the sampling valve The bottle group includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Do not use the same vacuum sampling pump for ex tracting oil samples that is used for extracting coolant samples A small residue of either type sample may remain in the pump and may cause a false positive analysis for
25. Cooling System Maintenance topic Maintenance Section S 0 S Coolant Analysis S O S coolant samples can be analyzed at your Caterpillar dealer S O S Coolant Analysis is a program that is based on periodic samples 70 Maintenance Section Cooling System Water Temperature Regulator Replace Level 1 Level 1 is a basic analysis of the coolant The following items are tested e Glycol Concentration e Concentration of SCA e pH e Conductivity The results are reported and recommendations are made according to the results Consult your Caterpillar dealer for information on the benefits of managing your equipment with an S O S Coolant Analysis Add the SCA If Necessary NOTICE Do not exceed the recommended amount of sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temper ature components Excessive supplemental coolant additive concentration could also result in radiator tube blockage overheating and or accelerated water pump seal wear Never use both liquid supplemental coolant additive and the spin on element if equipped at the same time The use of those additives together could result in supplemental coolant additive concen tration exceeding the recomme
26. DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM grease i00095575 Battery or Battery Cable Disconnect SMCS Code 1402 029 1 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 2 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 3 Tape the leads in order to help prevent accidental starting 4 Proceed with necessary system repairs Reverse the steps in order to reconnect all of the cables 101039758 Battery Charger Check SMCS Code 1401 535 Checking Before Start Up Check the battery charger for proper operation If the batteries are properly charged the needle of the ammeter will register near O zero The battery charger must not produce excessive current during start up Alternatively the charger must be automatically disconnected for start up If the engine has an alternator the charger must be automatically disconnected during start up and during engine operation Charging the Battery A WARNING Never disconnect any charging unit circuit or bat tery circuit cabl
27. NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine g00310663 Illustration 34 E Illustration 35 g00310664 1 Remove the air cleaner cover 1 and remove the element 2 2 Seal the air inlet 3 so that debris cannot enter the air inlet Tape or a clean cloth can be used to cover the opening 3 Clean the inside of the air cleaner cover Clean the body that holds the air cleaner element 4 Inspect the replacement element for the following items damage dirt and debris 5 Remove the seal from the opening of the air inlet 6 Install a clean undamaged element 7 Install the air cleaner cover 1 8 Reset the service indicator 101175055 Engine Air Cleaner Service Indicator Inspect SMCS Code 7452 040 Some engines may be equipped with a different service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendations in order to service the air cleaner service indicator The service indicator may be mounted on the air cleaner element or
28. S Coolant Analysis Level 2 provides a report of the results of both the analysis and the maintenance recommendations 86 Maintenance Section Power Take Off Clutch Check Adjust Lubricate For more information about coolant analysis see your Caterpillar dealer 100339617 Power Take Off Clutch Check Adjust Lubricate SMCS Code 3055 036 3055 086 NOTICE New power take offs should have the clutch adjust ment checked before being placed into service The clutch adjustment should be checked again after the first ten hours of operation New clutch plates have a wear in period and the clutch may require several adjustments until the new plates are worn in Illustration 44 g00108044 1 Typical instruction plate for the clutch 2 Typical serial number plate for the clutch The clutch adjustment should be checked regularly after wear in Heavy duty applications which have engagements that are frequent and relatively long periods of clutch slippage require more frequent adjustment than light duty applications The operating torque should be measured in order to determine if a clutch adjustment is required Refer to the OEM information and instruction plate 1 for instructions on the following items lubrication adjustment and other service recommendations Perform the maintenance that is specified on the instruction plate A WARNING Do not operate the engine with the Instruction Plate cover remo
29. al 101206348 Battery Electrolyte Level Check SMCS Code 1401 535 When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing If batteries are properly charged ammeter reading should be very near zero A WARNING All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 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 2 Check the condition of the electrolyte with the 1U 7298 Coolant Battery Tester C or the 1U 7297 Coolant Battery Tester F 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 L 0 11 qt of baking soda and 1L 1 qt of clean water e A mixture of 0 1 L 0 11 qt of ammonia and 1L 1 qt of clean water Thoroughly rinse the battery case with clean water 64 Maintenance Section Battery or Battery Cable Disconnect Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny
30. allation of new parts at each overhaul period Inspect these parts while the engine is disassembled for an overhaul Inspect the crankshaft for any of the following conditions e Deflection e Damage to the journals e 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 e Rod bearing e Main bearings Inspect the camshaft for damage to the journals and to the lobes Note If the camshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the camshaft Inspect the following components for signs of wear or for signs of scuffing e Camshaft bearings e Camshaft followers Caterpillar Inc recommends replacing the crankshaft vibration damper Oil Cooler Core During an overhaul Caterpillar Inc recommends the removal of the oil cooler core Clean the oil cooler core Then pressure test the oil cooler core NOTICE Do not use caustic cleaners to clean the core Caustic cleaners can attack the internal metals of the core and cause leakage Note Use this cleaning procedure to clean the oil cooler core 1 Remove the oil cooler core 2 Remove any debris from the oil cooler core To remove debris from the oil cooler core turn the oil cooler core onto one end 3 Flush the oil cooler core internally with cleaner in order
31. amaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extreme 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 help to prevent loose hose clamps Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Replace the Hoses and the Clamps A WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop
32. anual Refill Capacities in the Maintenance Section for the capacity of the cooling system for your engine Refer to the Operation and Maintenance Manual Cooling System Specifications information for the Caterpillar ELC Extender additions 4 Clean the cooling system filler cap Inspect the cooling system filler cap gaskets Replace the cooling system filler cap if the cooling system filler cap gaskets are damaged Install the cooling system filler cap 101197583 Cooling System Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and cool 69 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add N AT g00285520 Illustration 32 Cooling system filler cap A WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly in order to relieve pressure 2 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe If the engine is equipped with a sight glass maintain the coolant level to the proper level in the sight glass Illustration 33 g00103639 Typical filler cap gaskets 3 Clean the cooling system filler cap and check the cond
33. ar of the air compressor pressure relief valve when compressed air is released All personnel should also stay clear of the air compressor when the engine is operating and the air compressor is exposed Refer to the Service Manual or refer to the OEM specifications in order to find information concerning the air compressor Consult your Caterpillar dealer for assistance Air Starting Motor Lubricator Oil Level Check If Equipped 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 Illustration 30 g00381232 1 Air valve 2 Lubricator bowl 3 Adjustment knob 1 The vanes of the air starting motor are lubricated with a fine mist of oil from the air starting motor lubricator Check the level of oil in lubricator bowl 2 If the oil level is less than 1 2 add oil to the lubricator bowl 2 Ensure that the air supply to the lubricator is OFF 3 Remove the plug Pour oil into lubricator bowl 2 Use 10W oil for temperatures that are greater than O C 32 F Use air tool oil for temperatures that are below 0 C 82 F 4 Install the plug 61 Maintenance Section Air Starting Motor Lubricator Oil Level Check Oiler Feed Adjustment If necessary adjust the lubricator in order to release approximately two drops
34. ation Inspect the damper for evidence of fluid leaks If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous smooth and difficult to remove from surfaces If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace the crankshaft seals Inspect the damper and repair or replace the damper for any of the following reasons e The damper is dented cracked or leaking e The paint on the damper is discolored from heat e The engine has had a failure because of a broken crankshaft e Analysis of the oil has revealed that the front main bearing is badly worn e There is a large amount of gear train wear that is not caused by a lack of oil Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement 100174798 Driven Equipment Check SMCS Code 3279 535 Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment e Inspection e Adjustment e Lubrication e Other maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM 72 Maintenance Section Engine Clean 101239442 Engine Clean SMCS Code 1000 070 A WARNING Personal injury or death can result from high volt age Moisture can create paths of electrical
35. conductiv ity Make sure that the electrical system is OFF Lock out the starting controls and tag the controls DO NOT OPERATE NOTICE Water and or condensation can cause damage to electrical components Protect all electrical compo nents from exposure to water NOTICE Accumulated grease and oil on an engine is a fire haz ard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumulates on the engine Periodic cleaning of the engine is recommended Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits e Easy detection of fluid leaks e Maximum heat transfer characteristics e Ease of maintenance 101173387 Engine Air Cleaner Element Single Element Inspect Replace SMCS Code 1054 040 1054 510 Perform the Operation and Maintenance Manual Engine Air Cleaner Service Indicator Inspect procedure and perform the Operation and Maintenance Manual Engine Air Precleaner Check Clean procedure if equipped before performing the following procedure NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet
36. e engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine crankcase oil e f the engine is equipped with a drain valve turn the drain valve knob counterclockwise in order to drain the oil After the oil has drained turn the drain valve knob clockwise in order to close the drain valve e f the engine is not equipped with a drain valve remove the oil drain plug in order to allow the oil to drain If the engine is equipped with a shallow sump remove the bottom oil drain plugs from both ends of the oil pan After the oil has drained the oil drain plugs should be cleaned and installed 76 Maintenance Section Engine Oil and Filter Change Replace the Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 1 Remove the oil filter with a 1U 8760 Chain Wrench 2 Cut the oil filter open with a 40 5084 Oil Filter Cutter Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and th
37. e from the battery when the charg ing unit is operated A spark can cause an explo sion from the flammable vapor mixture of hydro gen and oxygen that is released from the elec trolyte through the battery outlets Injury to per sonnel can be the result Perform the following procedure to charge the battery 1 Ensure that the charger is turned OFF 2 Adjust the voltage of the charger in order to match the voltage of the battery 3 Connect the POSITIVE lead of the charger to the POSITIVE battery terminal Connect the NEGATIVE lead of the charger to the NEGATIVE battery terminal 4 Turn ON the battery charger 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 e The battery is very warm to the touch e A strong odor of acid is present e The battery emits smoke or a dense vapor gas Perform one of the following procedures if the battery shows symptoms of overcharging e Reduce the rate of charging by a significant amount Complete the charging at the reduced rate e Turn OFF the charger Table 34 describes the effects of overcharging on different types of batteries Table 34 Effects of Overcharging Batteries Type of Battery Effect Caterpillar
38. e nonferrous metals that are found in the oil filter element Ferrous metals may indicate wear on the steel and cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts brass parts or bronze parts of the engine Parts that may be affected include the following items main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter Illustration 39 g00103713 Typical filter mounting base and filter gasket 3 Clean the sealing surface of the filter mounting base Ensure that all of the old oil filter gasket is removed 4 Apply clean engine oil to the new oil filter gasket NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 5 Install the oil filter Tighten the oil filter until the oil filter gasket contacts the base Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Fill the Engine Crankcase 1 Remove the oil filler cap Refer to the Operation and Maintenance Manual for more information on lubricant specifications Fill the crankca
39. fer to the Service Manual or consult your Caterpillar dealer if any repair is needed or any replacement is needed 89 Maintenance Section Water Pump Inspect
40. g system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze Refer to the Operation and Maintenance Manual Cooling System Specifications topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rom to 1500 rom Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged perform a press
41. ge 4 Open the vent valve if equipped on the fuel injection pump s housing 5 Operate the priming pump until the flow of fuel from the vent valve is continuous and the flow of fuel is free of air bubbles If the engine does not have a fuel priming pump crank the engine Crank the engine until the fuel flows freely and until the fuel is free of air bubbles 6 Close the vent valve Then push in the plunger Hand tighten the plunger 7 Crank the engine If the engine starts and if the engine runs rough run the engine at low idle Continue running the engine until the engine runs smoothly Note If the engine will not start more priming is necessary If the engine continues to run rough more priming is necessary as well NOTICE Do not let the tops of fuel nozzles turn when the fuel line nuts are loosened or tightened The nozzles will be damaged if the top of the nozzle turns in the body The engine will be damaged if a defective fuel injec tion nozzle is used because the shape of fuel spray pattern that comes out of the nozzles will not be cor rect g00290109 Illustration 42 8 Loosen the fuel line nuts at the valve cover base Loosen these line nuts one at a time 9 Operate the priming pump until the flow of fuel from the fuel line is continuous and the flow of fuel is free of air bubbles 10 Push in the plunger and hand tighten the plunger If the engine does not have a fuel priming pump c
42. hot exhaust components Tighten each nut before loosening the next nut 3 A defective fuel injection nozzle may be identified when a fuel line nut is loosened and the following conditions are present e The exhaust smoke is partially eliminated or the exhaust smoke is completely eliminated e Engine performance is not affected A fuel injection nozzle that is suspected of being defective should be removed A new fuel injection nozzle should be installed in the cylinder in order to determine if the removed fuel injection nozzle is defective Removal and Installation of the Fuel Injection Nozzles For the removal and the installation of fuel injection nozzles special tooling is required Refer to the Service Manual for more information Consult your Caterpillar dealer for assistance 79 Maintenance Section Fuel Ratio Control Inspect Adjust 100908934 Fuel Ratio Control Inspect Adjust SMCS Code 1278 025 1278 040 Slow engine response and low power may indicate a need for adjustment or repair of the fuel ratio control Refer to the Service Manual or your Caterpillar dealer for the complete adjustment procedure on the fuel ratio control 100891826 Fuel System Prime SMCS Code 1258 548 A WARNING Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel
43. is being made on the proper time for an engine overhaul e The need for preventive maintenance e The quality of the fuel that is being used e The operating conditions e The results of the S O S analysis Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases The oil consumption rate brake specific oil consumption is measured in grams per kW h lb per bhp The brake specific oil consumption BSOC depends on the engine load Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine 83 Maintenance Section Overhaul Considerations When an engine s oil consumption has risen to three times the original oil consumption rate due to normal wear an engine overhaul should be scheduled There may be a corresponding increase in blowby and a slight increase in fuel consumption Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons e Costly unplanned downtime can
44. ition of the filler cap gaskets Replace the cooling system filler cap if the filler cap gaskets are damaged Reinstall the cooling system filler cap 4 Inspect the cooling system for leaks 100992487 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 A WARNING Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and the eyes Do not drink cooling system coolant additive Note Test the concentration of the Supplemental Coolant Additive SCA or test the SCA concentration as part of an S O S Coolant Analysis Test for SCA Concentration Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Use the 8T 5296 Coolant Conditioner Test Kit or use the 4C 9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA Refer to the Operation and Maintenance Manual for more information on conventional coolant antifreeze cooling system maintenance Water and SCA NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Refer to the Operation and Maintenance Manual Water Supplemental Coolant Additive SCA topic Maintenance Section Refer to the Operation and Maintenance Manual Conventional Coolant Antifreeze
45. justments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life A WARNING Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this maintenance is performed Refer to the Service Manual for more information 100937014 Engine Valve Rotators Inspect SMCS Code 1109 040 A WARNING When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to help prevent being burned by hot oil or spray NOTICE A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life If a damaged rotator is not replaced valve face guttering could result and cause pieces of the valve to fall into the cylinder This can cause piston and cylinder head damage Valve rotators cause the valves to rotate when the engine runs This helps to prevent deposits from building up on the valves and the valve seats Perform the following steps after the valve lash is set but before the valve
46. ltered and could be contami nated Contaminated fuel will cause accelerated wear to fuel system parts 7 Install the element 2 and the filter case 3 Tighten the bolt 1 to a torque of 24 4 Nm 18 3 lb ft 81 Maintenance Section Fuel Tank Water and Sediment Drain 100073301 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive fuel system wear Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Check the fuel daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure Fill the fuel tank after operating the engine in order to drive out moist air This will help
47. nance Section for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 66 Maintenance Section Cooling System Coolant DEAC Change 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the cooling system filler cap 4 Start and run the engine at low idle for a minimum of 30 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques Cooling Systems with Heav
48. nded maximum A WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Slowly loosen the cooling system filler cap in order to relieve the pressure Remove the cooling system filler cap Note Always discard drained fluids according to local regulations 2 If necessary drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA 3 Add the proper amount of SCA Refer to the Operation and Maintenance Manual for more information on SCA requirements 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets are damaged replace the old cooling system filler cap with a new cooling system filler cap Install the cooling system filler cap 100912898 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails in the
49. or electri cal components can cause a fire NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component Fuel injection nozzles are subject to tip wear Tip wear is a result of fuel contamination Tip wear can cause the following problems e Increased fuel consumption e Black smoke e Misfire e Rough running Fuel Injection nozzles should be cleaned inspected tested and replaced if necessary Refer to Special Instruction SEHS7292 for using the 8S 2245 Injection Cleaning Tool Group Consult your Caterpillar dealer about cleaning the fuel injection nozzle and testing the fuel injection nozzle NOTICE Never wire brush or scrape a fuel injection nozzle Wire brushing or scraping a fuel injection nozzle will damage the finely machine orifice Proper tools for cleaning and testing the fuel injection nozzles can be obtained from Caterpillar dealers The following items are symptoms of a malfunction of the fuel injection nozzle e Abnormal engine operation e Smoke emission e Engine knock Each fuel injection nozzle must be isolated one at a time in order to determine the malfunctioning fuel injection nozzle 1 Start the engine 2 Loosen each fuel line nut one at a time at the fuel injection pump A cloth or similar material must be used in order to prevent fuel from spraying on the
50. otective cloth ing and protective shoes Pressurized air could cause debris to be blown and result in personal injury 1 Open the drain valve that is on the bottom of the air tank Allow the moisture and sediment to drain 2 Close the drain valve 3 Check the air supply pressure The air starting motor requires a minimum of 620 kPa 90 psi of air pressure to operate properly The maximum air pressure must not exceed 1550 kPa 225 psi The normal air pressure will be 758 to 965 kPa 110 to 140 psi 100072207 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 Refer to the Service Manual Check the alternator and the battery charger for proper operation If the batteries are properly charged the ammeter reading should be very near zero All batteries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine The battery will not crank the engine even if the engine is warm When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge
51. ple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break e Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system e Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the engine to frame ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check the condition of the gauges Replace any gauges which are cracked or can not be calibrated 101057943 Water Pump Inspect SMCS Code 1361 040 1361 A failed water pump might cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure e Other potential damage to the engine Visually inspect the water pump for leaks If any leaking is observed replace the water pump seal or the water pump assembly Refer to the Service Manual for the disassembly and assembly procedure Note Re
52. r to slobber 4 Use a dial indicator to check the end clearance on the shaft If the measured end play is greater than the Service Manual specifications the turbocharger should be repaired or replaced An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications 5 Inspect the bore of the turbine housing for corrosion 6 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 7 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 100632301 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination
53. rank the engine 11 Tighten each fuel line nut before you loosen the next fuel line nut Tighten the fuel line nuts to a torque of 40 7 N m 30 5 lb ft Continue this procedure until all of the fuel lines have been cleared of any air Before you start the engine make sure that the fuel line nuts are properly tightened Also make sure that the priming is locked 100951418 Fuel System Primary Filter Clean Replace SMCS Code 1260 070 1260 510 A WARNING Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately 1 Stop the engine 2 Turn the start switch to the OFF position Disconnect the battery 3 Shut off the fuel tank supply valve to the engine 4 If the primary fuel filter is equipped with a drain valve open the drain valve in order to drain any fuel from the filter case Close the drain valve NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately Illustration 43 g00485293 1 Bolt 2 Element 3 Case 5 Loosen the bolt 1 that is on the filter housing Remove the filter case 3 6 Remove the element 2 and wash the element in clean nonflammable solvent NOTICE Do not fill the fuel filters with fuel before installing them The fuel would not be fi
54. rmed without overhaul service from your Caterpillar dealer be aware of the following maintenance recommendations Rebuild or Exchange Cylinder Head Assembly Cylinder Packs Oil Pump and Fuel Transfer Pump These components should be inspected according to the instructions that are found in various Caterpillar reusability publications The Special Publication SEBF8029 lists the reusability publications that are needed for inspecting the engine parts If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline the parts should be reused Parts that are not within the established inspection specifications should be dealt with in one of the following manners e Salvaging e Repairing e Replacing Using out of spec parts can result in the following problems e Unscheduled downtime e Costly repairs e Damage to other engine parts e Reduced engine efficiency e Increased fuel consumption Reduced engine efficiency and increased fuel consumption translates into higher operating costs Therefore Caterpillar Inc recommends repairing out of spec parts or replacing out of spec parts Inspection and or Replacement Crankshaft Bearings Valve Rotators and Crankshaft Seals The following components may not last until the second overhaul e Thrust bearings e Main bearings e Rod bearings e Valve rotators e Crankshaft seals Caterpillar Inc recommends the inst
55. rotective devices will ensure that the alarms and shutoffs activate at the setpoints Ensure that the engine protective devices are functioning properly NOTICE During testing abnormal operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately Engine Valve Lash Inspect Adjust SMCS Code 1102 025 The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life 77 Maintenance Section Engine Protective Devices Check NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust ment procedure Operation of Caterpillar engines with improper valve ad
56. ry Charger Check 0 ccceeeseeeeeeeeseeeees 64 Every 1000 Service Hours Engine Protective Devices Check ce0 77 Fuel Control Linkage Check Lubricate 78 Every 9500 L 2500 US gal of Fuel or 250 Service Hours or Yearly Aftercooler Core Clean Test cccccceeeeseeees 60 Alternator Belt Inspect Adjust Replace 62 Battery Electrolyte Level Check cceeseees 63 Cooling System Supplemental Coolant Additive SCA Test Add i steccicdieczssttsaresteetiansbicteiceadcitss 69 Engine Crankcase Breather Clean 008 73 Engine Oil Sample Obtain cesses 74 Engine Oil and Filter Change cccseeeees 75 Fan Drive Bearing Lubricate ceeeeeeeeee 78 Fuel System Primary Filter Clean Replace 80 Fuel Tank Water and Sediment Drain 81 Hoses and Clamps Inspect Replace 82 59 Maintenance Section Maintenance Interval Schedule Radiator Clean w ccccececcccceeeececcseesseaeeeceeseeaeaaees 86 Every 114 000 L 30 000 US gal of Fuel or 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 65 Cooling System Coolant Extender ELC Add 68 Cooling System Water Temperature Regulator Replace naia a e OG re eras 70 Crankshaft Vibration Damper Inspect 71 Engine Mounts Inspect siseses 74 Engine Valve Lash Inspect Adjust
57. s of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water After cleaning start the engine and accelerate the engine to high idle rom This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary For more detailed information on cleaning and inspection see Special Publication SEBD0518 Know Your Cooling System 100651416 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar Inc recommends a scheduled inspection of the starting motor If the starting motor fails the engine may not start in an emergency situation Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance 100912946 Turbocharger Inspect SMCS Code 1052 040 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Any fumes from the crankcase are filtered through the air inlet system Therefore by products
58. se with the proper amount of oil Refer to the Operation and Maintenance Manual for more information on refill capacities NOTICE If equipped with an auxiliary oil filter system or a re mote oil filter system follow the OEM or filter manu facturer s recommendations Under filling or overfilling the crankcase with oil can cause engine damage NOTICE To prevent crankshaft bearing damage crank the en gine with the fuel OFF This will fill the oil filters before starting the engine Do not crank the engine for more than 30 seconds 2 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 3 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL marks on the oil level gauge 100626013 Engine Protective Devices Check SMCS Code 7400 535 Alarms and shutoffs must function properly Alarms provide timely warning to the operator Shutoffs help to prevent damage to the engine It is impossible to determine if the engine protective devices are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices A calibration check of the engine p
59. the engine Allow the engine to cool 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suitable clean container The coolant can be reused 3 Drain the coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose Note For torques on hose clamps see this Operation and Maintenance Manual Torque Specifications Maintenance Section 7 Install the hose clamps with a torque wrench Note For the proper coolant to use see this Operation and Maintenance Manual Coolant Recommendations Maintenance Section 8 Refill the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler cap s gaskets Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks 101037896 Overhaul Considerations SMCS Code 7595 043 Reduced hours of operation at full load will result in a lower average power demand A decreased average power demand should increase both the engine service life and the overhaul interval The need for an overhaul is generally indicated by increased fuel consumption and by reduced power The following factors are important when a decision
60. the following topics belt removal and belt installation i01179608 Battery Replace SMCS Code 1401 510 A WARNING Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite This can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced 1 Turn the key start switch to the OFF position Remove the key and all electrical loads 2 Turn OFF the battery charger Disconnect the charger 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the ground plane Disconnect the cable from the NEGATIVE battery terminal 4 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 5 Remove the used battery 6 Install the new battery Note Before the cables are connected ensure that the key start switch is OFF 63 Maintenance Section Battery Replace 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Connect the cable from the ground plane to the NEGATIVE battery termin
61. tions clamps and seals Make repairs if necessary For more detailed information on cleaning and inspection see Special Publication SEBD0518 Know Your Cooling System 101183385 Air Compressor Inspect SMCS Code 1803 040 A WARNING Do not disconnect the air line from the air com pressor governor without purging the air brake and the auxiliary air systems Failure to purge the air brake and the auxiliary air systems before re moving the air compressor and or the air lines could cause personal injury Me it Tio p Illustration 29 g00633741 1 Air compressor pressure relief valve A WARNING If the air compressor pressure relief valve that is mounted in the air compressor cylinder head is bypassing compressed air there is a malfunction in the air system possibly ice blockage Under these conditions your engine may have insuffi cient air for normal brake operation Do not operate the engine until the reason for the air bypass is identified and corrected Failure to heed this warning could lead to property damage personal injury or death to the operator or by standers The function of the air compressor pressure relief valve is to bypass air when there is a malfunction in the air compressor system The air compressor pressure relief valve releases air at 1723 kPa 250 psi It is very important that all personnel stand cle
62. ture reaches 49 to 66 C 120 to 150 F 68 Maintenance Section Cooling System Coolant Extender ELC Add 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with Extended Life Coolant ELC Refer to the Operation and Maintenance Manual Cooling System Specifications topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rom to high idle Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass if equipped
63. ure test A 9S 8140 Pressurizing Pump is used to perform the pressure test The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 101206445 Cooling System Coolant ELC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is needed when the ELC is drained and replaced Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain A WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 67 Maintenance Section
64. ut 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 Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both sides of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water After cleaning start the engine and accelerate the engine to high idle rom This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Note If parts of the aftercooler system are repaired or replaced a leak test is highly recommended Inspect these items for good condition welds mounting brackets air lines connec
65. ved from the clutch Personal injury may result If the clutch is damaged to the point of burst fail ure expelled pieces can cause personal injury to anyone in the immediate area Proper safeguards must be followed to help prevent accidents 101206548 Radiator Clean SMCS Code 1353 070 Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the radiator for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the radiator if necessary A WARNING 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 Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both side
66. y Deposits or Plugging Note For the following procedure to be effective there must be some active flow through the cooling system components 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the cooling system filler cap 4 Start and run the engine at low idle for a minimum of 90 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the coolin

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