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C4.4 INDUSTRIAL ENGINES - Safety

1. 86 Every 250 Service Hours Cooling System Coolant Sample Level 1 ODI eta eae eit site ea aii ua 69 Engine Oil Sample Obtain n 78 Initial 500 Service Hours Engine Valve Lash Inspect Adjust e ee 81 Every 500 Service Hours V Belts Inspect Adjust Replace ce 93 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check n se 63 Cooling System Supplemental Coolant Additive SCA Test Add 00 ececcccecceeeeeeeseeeeeseeeeeseeeeennees 70 Crankcase Breather Canister Replace 71 Engine Air Cleaner Element Dual Element Clean Replace ninni tea rei e 73 Engine Air Cleaner Element Single Element Inspect Replace ceeeceeceeeeeeeeeeeteeesenteeaeees 75 Engine Air Cleaner Element Single Element Replace aer A rE een a ES 76 Engine Oil and Filter Change n se 79 Fuel System Primary Filter Water Separator Element Replace ccccccceeeeeeeeeeeeseeneees 83 Fuel System Secondary Filter Replace 85 Radiator Clean cccceceeeeeeeeeeeeceeceeeeeeeeeeeeeeteees 91 Every 1000 Service Hours Engine Valve Lash Inspect Adjust 0 81 Every 2000 Service Hours Aftercooler Core Inspect ceceeeeeeeteeeeeeeeees 61 Starting Motor Inspect seeen 92 Turbocharger Inspect eee eeetteeeeeeeenteeeeeeeaes 92 Water Pump Inspect cceeeeeeeeeeeeseecteeeeeeeeees
2. 3 Install new air cleaner element 1 to the air inlet and tighten clamp 2 Refer to Torque Specifications SENR3130 for the correct torque 102335405 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 in a remote location SEBU8180 77 Maintenance Section Engine Air Precleaner Check Clean Illustration 40 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 e Check for ease of resetting The service indicator should reset in less than three push
3. 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 Torque Specifications SENR3130 for more information on the correct torques Cooling Systems with Heavy 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 Torque Specifications SENR3130 for more information on the correct torques NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast
4. 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 recommended maximum SEBU8180 71 Maintenance Section Cooling System Water Temperature Regulator Replace 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 Special Publication SEBU6251 Caterpillar Commercial Diesel Engines Fluids Recommendations 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 temp
5. ON position COU Illustration 48 g01191752 Typical example 2 Operate the fuel priming pump 1 Count the number of operations of the fuel priming pump After 100 depressions of the fuel priming pump stop 3 The engine fuel system should now be primed and the engine should now be able to start 4 Operate the engine starter and crank the engine After the engine has started operate the engine at low idle for a minimum of five minutes immediately after air has been removed from the fuel system Note Operating the engine for this period of time will help ensure that the fuel system is free of air Note Do not loosen the high pressure fuel line in order to purge air from the fuel system This procedure is not required SEBU8180 83 Maintenance Section Fuel System Primary Filter Water Separator Element Replace Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system
6. 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 Lifters 90 Maintenance Section Overhaul Considerations SEBU8180 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 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 14 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer Table 14 Hydrosolv Liquid Cleaners Part PERS Number Description Size 1U 5490 Hydrosolv4165 19 L 5 US gal 1U 5492 Hydrosolv100 19 L 5 US gallon 4 Use steam to clean the oil cooler core This removes any remaining resid
7. 95 Every 2000 Service Hours or 1 Year Alternator Inspect ccecceceeeeeeeeeeeeteenteaeees 62 Engine Mounts Inspect ieee 77 Every Year Cooling System Coolant Sample Level 2 Obtain inven eee inl ee E eerieedaells 69 Every 3000 Service Hours Alternator Belt Inspect Adjust Replace 62 Every 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 64 Cooling System Water Temperature Regulator Replace r a aa a E a ER 71 Every 4000 Service Hours Aftercooler Core Clean Test annn 61 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 67 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 66 Overhaul Overhaul Considerations ccccceseecceeeeeeeeeeees 88 SEBU8180 61 Maintenance Section Aftercooler Core Clean Test 101546702 Aftercooler Core Clean Test SMCS Code 1064 070 1064 081 1 Remove the core Refer to the Service Manual for the procedure 2 Turn the aftercooler core upside down in order to remove debris NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 3 Back flush the core with cleaner Caterpillar recommends the use of Hydrosolv liquid cleaner Table 12
8. Cat ELC This includes the following types of coolants Table 13 Recommended Interval Type of Coolant Level 1 Level 2 Cat DEAC rane Yearly tv2 Cat ELC Optional Yearly 1 This is the recommended interval for coolant samples for all conventional heavy duty coolant antifreeze This is also the recommended interval for coolant samples of commercial coolants that meet the Cat EC 1 specification for engine coolant 2 The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified e Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat DEAC Diesel Engine Antifreeze Coolant e Commercial heavy duty coolant antifreeze NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenl
9. Code 1064 040 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 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 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 62 SEBU8180 Maintenance Section Alternator Inspect After cleaning start the engine
10. Fill NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 1 Fill the cooling system with Extended Life Coolant ELC Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations 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 rpm 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 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
11. accelerated wear to engine components 5 Install the oil filter Tighten the oil filter to 12 N m 8 8 Ib ft Do not overtighten the oil filter Note Some oil filters may be installed horizontally Refer to illustration 46 This type of oil filter assembly can be drained before the oil is removed The torque for the drain plug 4 is 12 N m 8 lb ft If necessary install a new O ring seal 5 Start at 1 in order to remove the oil filter and install the oil filter Fill the Oil Pan 1 Remove the oil filler cap Refer to this Operation and Maintenance Manual Fluid Recommendations for more information on suitable oils Fill the oil pan with the correct amount of new engine lubricating oil Refer to this Operation and Maintenance Manual Refill Capacities for more information on refill capacities NOTICE If equipped with an auxilliary oil filter system or a re mote filter system follow the OEM or the filter manu facture s remonmendations Under filling or over filling the crankcase with oil can cause engine damage 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 oil pan for a minimum of ten minutes Illustration 47 g01165836 Typical example
12. and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and Assembly Manual Fuel Injection Lines Install If you inspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information Electric Fuel Priming Pump 1 Ensure that the fuel system is in working order Check that the fuel supply valve if equipped is in the ON position NOTICE The electric fuel priming pump will operate for 90 sec onds If necessary the electric fuel priming pump can be stopped during the 90 seconds of operation by op eration of the switch 2 Turn the keyswitch to the RUN position Operate the switch for the electric priming pump After 90 seconds of the electric fuel priming pump operation the fuel system will be primed and the electric fuel priming pump will turn off 3 The engine should now be able to start 4 Operate the engine starter and crank the engine After the engine has started operate the engine at low idle for a minimum of five minutes immediately after air has been removed from the fuel system Note Operating the engine for this period of time will help ensure that the fuel system is free of air Note Do not loosen the high pressure fuel line in order to purge air from the fuel system This procedure is no
13. lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 12 Hydrosolv Liquid Cleaners Part Per Number Description Size 1U 5490 Hydrosolv 4165 174 6854 Hydrosolv 100 19 L 5 US gallon 19 L 5 US gallon 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information 4 Steam clean the core in order to remove any residue Flush the fins of the aftercooler core Remove any other trapped debris 5 Wash the core with hot soapy water Rinse the core thoroughly with clean water 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 6 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the core in order to ensure cleanliness Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 8 Install the core Refer to the Service Manual for the procedure For more information on cleaning the core consult your Caterpillar dealer i01468985 Aftercooler Core Inspect SMCS
14. may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death Refer to the Operation and Maintenance Manual General Hazard Information and High Pressure Fuel Lines before adjustments and repairs are performed Note Refer to Systems Operation Testing and Adjusting Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training 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 If air enters the fuel system the air must be purged from the fuel system before the engine can be started Air can enter the fuel system when the following events occur e The fuel tank is empty or the fuel tank has been partially drained e The low pressure fuel lines are disconnected e A leak exists in the low pressure fuel system e The fuel filter has been replaced Hand Fuel Priming Pump Use the following procedures in order to remove air from the fuel system 1 Ensure that the fuel system is in working order Check that the fuel supply valve if equipped is in the
15. must be observed during ALL work on the fuel system NOTICE Ensure that the engine is stopped before any servicing or repair is performed 84 SEBU8180 Maintenance Section Fuel System Primary Filter Water Separator Element Replace After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install 1 Turn the fuel supply valve if equipped to the OFF position before performing this maintenance 2 Place a suitable container under the water separator in order to catch any fuel that might spill Clean up any spilled fuel Clean the outside of the water separator N 5 Illustration 50 g01259366 Typical example 9 Install the new canister Do not use a tool in order to install the canister Tighten the canister by hand 10 Install the new O ring seal 5 onto the setscrew jan 2 Install the new O ring seal 6 into the glass bowl P eae 11 Align the glass bowl to the canister Ensure that 3 the sensor if equipped is in th
16. of the hoses will cause 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 Refer to the OEM information for further information on removing and replacing fuel hoses if equipped The following text describes a typical method of replacing coolant hoses Refer to the OEM information for further information on the coolant system and the hoses for the coolant system 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 Allow the engine to cool 88 Maintenance Section Overhaul Considerations SEBU8180 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 ho
17. order to connect the battery connect the positive connection before the negative connector 102242514 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 The engine overheats frequently Foaming is observed The oil has entered the cooling system and the coolant is contaminated 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 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 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 equ
18. 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 SEBU8180 89 Maintenance Section Overhaul Considerations 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 If an overhaul is performed without overhaul service from your Caterpillar dealer be aware of the following maintenance recommendations Rebuild or Exchange Cylinder Head Assembly 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 e
19. the turbocharger to slobber 3 Inspect the bore of the housing of the turbine outlet for corrosion 4 Fasten the air intake pipe and the exhaust outlet pipe to the turbocharger housing 102517672 V Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspection Illustration 53 g01249073 Arrangement for the V belts To maximize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged 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 belt is stretched The additional load on the new belt could cause the new belt to break If the belts are too loose vibration causes unnecessary wear on the belts and pulleys Loose belts may slip enough to cause overheating To accurately check the belt tension install 144 0235 Belt Tension Gauge 94 Maintenance Section Walk Around Inspection SEBU8180 Illustration 54 g0 1003936 Typical example 1 Gauge Fit the gauge 1 at the center of the longest free length and check the tension The correct tension is 400 N 90 Ib If the tension of the belt is below 250 N 56 Ib adjust the belt to 400 N 90 Ib If twin belts are installed check and adjust the tension on both belts k 2 Adjustment Illustration 55 g010
20. 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 102503968 Crankcase Breather Canister Replace SMCS Code 1317 510 NOTICE Ensure that the engine is stopped before any servicing or repair is performed Note This breather assembly is not installed on all engines 1 Place a container under the canister 1 2 Clean the outside of the canister Remove the canister with a 1U 8760 Chain Wrench 72 Maintenance Section Driven Equipment Check SEBU8180 Illustration 33 g01259960 Typical example 3 Lubricate the O ring seal 2 on the new canister 3 with clean engine lubricating oil Install the new canister Tighten the canister to 12 N m 8 lb ft Do not overtighten the canister 4 Remove the container Dispose of the old canister and any split oil in a safe place 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 equi
21. 03939 1 Loosen The alternator pivot bolt 2 and the bolt 3 2 Move the alternator in order to increase or decrease the belt tension Tighten the alternator pivot bolt and the link bolt to 22 N m 16 Ib ft 1 Replace Refer to Disassembly and Assembly manual for more information 102517579 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 correct 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 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 is a fire hazard Remove the accumulated grease and oil Re fer to thi
22. 13 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 when the engine is in operation 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 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water e A mixture of 0 1 L 0 11 qt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to n
23. 4 Remove the engine oil level gauge in order to check the oil level Maintain the oil level between the MIN and MAX marks on the engine oil level gauge 102519453 Engine Valve Lash Inspect Adjust SMCS Code 1102 025 This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life 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 adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life 82 Maintenance Section Fuel System Prime SEBU8180 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 102387482 Fuel System Prime SMCS Code 1258 548 Contact with high pressure fuel
24. 60 Chain Wrench in order to remove the canister 1 from the engine and dispose of the canister in a safe place 3 Install the new canister Do not use a tool in order to install the canister Tighten the canister by hand 4 Remove the container and dispose of the fuel ina safe place If equipped open the fuel supply valve 5 Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime for more information 102348492 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Dispose of all fluids according to local regulations and mandates Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Water can be introduced into the fuel tank when the fuel tank is being filled 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
25. 8T 5296 Coolant Conditioner Test Kit Refer to the Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations for more information S O S Coolant Analysis S 0 S coolant samples can be analyzed at your Caterpillar dealer S O S Coolant Analysis is a program that is based on periodic samples 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 Level 2 This level coolant analysis is recommended when the engine is overhauled Refer to this Operations and Maintenance Manual Overhaul Considerations for further information 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
26. 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 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 Torque Specifications SENR3130 for more information on the correct torques Fill NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 1 Fill the cooling system with coolant antifreeze Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section for more information on co
27. C4 4 INDUSTRIAL ENGINES Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU8180 00 01 2007 Caterpillar CATERPILLAR All Rights Reserved 60 Maintenance Section Maintenance Interval Schedule SEBU8180 102501524 Maintenance Interval Schedule SMCS Code 1000 7500 When Required Battery REPIACE ceiien 63 Battery or Battery Cable Disconnect 64 Engine CICAMN o iie a a T E 72 Engine Air Cleaner Element Dual Element Clean Replace 0 cccccceceeeeeeeeeeeeeeeeeeeeeeteeeeees 73 Engine Air Cleaner Element Single Element Inspect Replace eccceecceeceeeeeeeeeeeteeeeeneeeaees 75 Fuel System Prime cccceeeceeeeeeeeseeeeeeeeeeeenneeees 82 Severe Service Application Check 91 Daily Alternator Belt Inspect Adjust Replace 62 Cooling System Coolant Level Check 68 Driven Equipment Check cccceeeeeteeeeee 72 Engine Air Cleaner Service Indicator Inspect 76 Engine Air Precleaner Check Clean 77 Engine Oil Level Check eeceeeeceeeeeeeeeeetneees 78 Fuel System Primary Filter Water Separator Be a aa E 85 Hoses and Clamps Inspect Replace 87 V Belts Inspect Adjust Replace e 93 Walk Around Inspection cccceeeeeeeeeeeeeereeeees 94 Every 50 Service Hours or Weekly Fuel Tank Water and Sediment Drain
28. The older belts are stretched The additional load on the new belt could cause the belt to break High Pressure Fuel Lines Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install If you inspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information Visually inspect the high pressure fuel lines for damage or signs of fuel leakage Replace any damaged high pressure fuel lines or high pressure fuel lines that have leaked Ensure that all clips on the high pressure fuel lines are in place and that the clips are not loose e Inspect the rest of the fuel system for leaks Look for loose fuel line clamps Drain the water and the sediment fro
29. 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 NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air cleaner element e Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element e The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected e The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and
30. ance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant 70 Maintenance Section SEBU8180 Cooling System Supplemental Coolant Additive SCA Test Add Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6251 Caterpillar Commercial Diesel Engines Fluids Recommendations or consult your Caterpillar dealer 102456600 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 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 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 this Operation and Maintenance Manual Refill Capacities and Recommendations for more information Water and SCA NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration Test the concentration of the SCA with the
31. and accelerate the 102491869 engine to high idle rpm 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 The FT1984 Aftercooler Testing Group is used to perform leak tests on the aftercooler Refer to the Systems Operation Testing and Adjusting Aftercooler Test and the Special Instruction SEHS8622 for the proper testing procedure 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 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 readi
32. ble by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Dealer Service Tools 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 Torque Specifications SENR3130 for more information on the correct torques NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 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 temperature reaches 49 to 66 C 120 to 150 F SEBU8180 67 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 Torque Specifications SENR3130 for more information on the correct torques
33. closure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury _ Switch the engine to the OFF position Remove all electrical loads N Turn off any battery chargers Disconnect any battery chargers oo The NEGATIVE cable connects the NEGATIVE battery terminal to the NEGATIVE terminal on the starting motor Disconnect the cable from the NEGATIVE battery terminal D The POSITIVE cable connects the POSITIVE battery terminal to the POSITIVE terminal on the starting motor Disconnect the cable from the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Dispose of 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 engine start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Connect the NEGATIVE cable to the NEGATIVE battery terminal 1023457
34. correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 102482066 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1395 081 Cat ELC Extended Life Coolant does not require the frequent additions of any supplemental cooling additives which are associated with the present conventional coolants The Cat ELC Extender only needs to be added once NOTICE Use only Cat Extended Life Coolant ELC Extender with Cat ELC Do NOT use conventional supplemental coolant addi tive SCA with Cat ELC Mixing Cat ELC with conven tional coolants and or conventional SCA reduces the Cat ELC service life Check the cooling system only when the engine is stopped and cool Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes 68 Maintenance Section Cooling System Coolan
35. d be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean primary air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean primary air cleaner elements e Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 35 g00281692 Note When the primary air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air cleaner element Dirt could be fo
36. d sampling bottle includes the parts that are needed for obtaining oil samples Instructions are also provided SEBU8180 79 Maintenance Section Engine Oil and Filter Change NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers 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 102504532 Engine Oil and Filter Change SMCS Code 1318 510 1348 044 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids D
37. e correct position 1 Install the setscrew 2 Tighten the setscrew to a A torque of 5 N m 44 Ib in 2 12 If equipped install the wiring harness to the sensor Illustration 49 Gee ae 13 Remove the container and dispose of the fuel in Typical example a safe place 3 Install a suitable tube onto the drain 1 Open the 14 The secondary filter must be replaced at the same drain 1 Allow the fluid to drain into the container time as the primary filter Refer to the Operation Remove the tube and Maintenance Manual Fuel System Filter Replace 4 Tighten the drain 1 by hand pressure only 5 If equipped remove the wiring harness from the sensor on the bottom of the glass bowl 6 Hold the glass bowl 3 and remove the screw 2 Remove the glass bowl 3 from the canister 4 7 Use a 1U 8760 Chain Wrench in order to remove the canister 4 Discard the old seals 5 and 6 and the canister in a safe place 8 Clean the glass bowl 3 SEBU8180 85 Maintenance Section Fuel System Primary Filter Water Separator Drain 102387484 Fuel System Primary Filter Water Separator Drain SMCS Code 1260 543 1263 543 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 NOTICE Ensure that the engine is stopped before an
38. em 100151038 Severe Service Application Check SMCS Code 1000 535 Severe service is an application of an engine that exceeds current published standards for that engine Caterpillar maintains standards for the following engine parameters Performance power range speed range and fuel consumption Fuel quality Altitude range Maintenance intervals Oil selection and maintenance Coolant selection and maintenance Environmental qualities Installation Refer to the standards for the engine or consult with your Caterpillar dealer in order to determine if the engine is operating within the defined parameters Severe service operation can accelerate component wear Engines that operate under severe conditions may need more frequent maintenance intervals in order to ensure maximum reliability and retention of full service life Due to individual applications it is not possible to identify all of the factors which can contribute to severe service operation Consult your Caterpillar dealer for the unique maintenance that is necessary for the engine The operating environment improper operating procedures and improper maintenance procedures can be factors which contribute to severe service conditions 92 Maintenance Section Starting Motor Inspect SEBU8180 Environmental Factors Ambient temperatures The engine may be exposed to extended operation in extremely cold environments or hot environm
39. ents Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures Extremely hot inlet air reduces engine performance Air Quality The engine may be exposed to extended operation in an environment that is dirty or dusty unless the equipment is cleaned regularly Mud dirt and dust can encase components Maintenance can be very difficult The buildup can contain corrosive chemicals Buildup Compounds elements corrosive chemicals and salt can damage some components Altitude Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application Necessary adjustments should be made Improper Operating Procedures e Extended operation at low idle e Frequent hot shutdowns e Operating at excessive loads e Operating at excessive speeds e Operating outside the intended application Improper Maintenance Procedures e Extending the maintenance intervals e Failure to use recommended fuel lubricants and coolant antifreeze 102348493 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar 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 correct operation Check the electrical connections and clean the electrical connections Refer to the Systems Operation Testing and Adjust
40. er element that passes inspection will not be used the primary air cleaner element can be stored for future use Illustration 37 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air cleaner elements in Volatile Corrosion Inhibited VCI paper Place the primary air cleaner element into a box for storage For identification mark the outside of the box and mark the primary air cleaner element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location 101432811 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 NOTICE Never service the air cleaner element with t
41. erature 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 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
42. es e Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch 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 restricted The service indicator may need to be replaced frequently in environments that are severely dusty 100720883 Engine Air Precleaner Check Clean SMCS Code 1055 070 1055 535 On el lt Typical engine precleaner 1 Wing nut 2 Cover 3 Body Illustration 41 g00287039 Remove wing nut 1 and cover 2 Check for an accumulation of dirt and debris in body 3 Clean the body if necessary After cleaning the precleaner install cover 2 and wing nut 1 Note When the engine is operated in dusty applications more frequent cleaning is required 102456872 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 e Deterioration of the engine mounts Any engine mount that shows deterioration should be replaced Refer to Special Publication SENR3130 Torque Specifications for the recommended torques Refer to
43. f the engine is equipped with a shallow oil pan 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 If necessary replace the O ring seal Tighten the drain plug to 34 N m 25 lb ft 80 Maintenance Section Engine Oil and Filter Change SEBU8180 Replace the Oil Filter NOTICE Caterpillar oil filters are manufactured to Caterpillar specifications Use of an oil filter that is not recom mended by Caterpillar could result in severe 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 rec ommended by Caterpillar 1 Remove the oil filter with a 1U 8760 Chain Wrench Note Some oil filters may be installed horizontally This type of oil filter can be drained before the filter is removed The torque for this drain plug is 12 N m 8 Ib ft Note The following actions can be carried out as part of the preventive maintenance program Illustration 44 g00588944 Element with debris 2 Cut the oil filter open with a 175 7546 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 the nonferrous metals that are
44. 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 45 g01187802 Typical example 3 Clean the sealing surface of the oil filter head 2 Ensure that the union is secure in the filter head 4 Apply clean engine oil to the O ring seal 3 for the new oil filter Note Some oil filters may be installed horizontally Refer to the illustration This type of oil filter assembly can be drained before the filter is removed The torque for this drain plug 4 is 12 N m 8 lb ft If necessary install a new O ring seal 5 Start at step 1 in order to remove the oil filter and install the oil filter SEBU8180 81 Maintenance Section Engine Valve Lash Inspect Adjust Illustration 46 g01169166 Typical example 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
45. h 5 Remove the tape for the turbocharger air inlet Install the secondary air cleaner element Install a primary air cleaner element that is new or cleaned 6 Install the air cleaner cover 7 Reset the air cleaner service indicator 74 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace SEBU8180 Cleaning the Primary Air Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected When the primary air cleaner element is cleaned check for rips or tears in the filter material The primary air cleaner element shoul
46. hanging fuel filters or water separator elements Clean up fuel spills immediately Note Refer to Testing and Adjusting Manual Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system NOTICE Ensure that the engine is stopped before any servicing or repair is performed 86 Maintenance Section Fuel Tank Water and Sediment Drain SEBU8180 After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install 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 1 Ensure that the fuel supply valve if equipped is in the OFF position Place a suitable container under the fuel filter in order to catch any fuel that might spill Clean up any spilled fuel Illustration 52 g01249050 Typical example 2 Clean the outside of the fuel filter Use 1U 87
47. hat 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 Ib 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 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 Costly unplanned downtime can be avoided Many original parts can be reused according to the standards for reusable parts The engine s service life can be extended without the risk of a major catastrophe due to engine failure 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
48. he engine running since this will allow dirt to enter the engine 76 Maintenance Section Engine Air Cleaner Element Single Element Replace SEBU8180 Illustration 38 g00310664 1 Air cleaner cover 2 Air filter element 3 Air inlet 1 Remove air cleaner cover 1 and remove air filter element 2 2 Cover air inlet 3 with tape or a clean cloth so that debris cannot enter the air inlet 3 Clean the inside of air cleaner cover 1 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 air filter element 2 7 Install air cleaner cover 1 8 Reset the air cleaner service indicator 102242500 Engine Air Cleaner Element Single Element Replace SMCS Code 1051 1054 510 NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine ol oi o 0 0 0 0 0 0 02020202000 0 0 0 0 0 0 00 0 0 0 0 02020920900 0000000 0 0 0 0 0 q Q 0 Illustration 39 g00109823 1 Air cleaner element 2 Clamp 1 Loosen clamp 2 which fastens air cleaner element 1 to the air inlet Remove the dirty air cleaner element and clamp 2 Install clamp 2 on new air cleaner element 1
49. ing Manual Electric Starting System Test for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance 102326109 Turbocharger Inspect SMCS Code 1052 040 A regular visual inspection of the turbocharger is recommended Any fumes from the crankcase are filtered through the air inlet system Therefore by products 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 NOTICE Turbocharger bearing failures can cause large quanti ties of oil to enter the air intake and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of oil into a turbocharger under extend ed low idle operation should not cause problems as long as a turbocharger bearing failure has not oc cured 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 renewed A visual inspection of the turbocharger can minimize un
50. ing 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 0 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 SEBU8180 91 Maintenance Section Radiator Clean e Identification of contaminants e Identification of built up impurities corrosion and scale S 0 S Coolant Analysis Level 2 provides a report of the results of both the analysis and the maintenance recommendations For more information about coolant analysis see your Caterpillar dealer 101604510 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 Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tec
51. ipped 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 Dealer Service Tools Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL SEBU8180 65 Maintenance Section Cooling System Coolant DEAC Change 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 Torque Specifications SENR3130 for more information on the correct torques NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 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
52. ispose of all fluids according to local regulations and mandates NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Do not drain the engine lubricating oil when the engine is cold As the engine lubricating oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with draining cold oil Drain the oil pan with the engine stopped Drain the oil pan 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 Lubricating Oil Note Ensure that the vessel that will be used is large enough to collect the waste oil After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine oil pan A ea Illustration 43 g01187801 Typical example If 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 If the engine is not equipped with a drain valve remove the oil drain plug 1 in order to allow the oil to drain I
53. m the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Check for any loose tie wraps or missing tie wraps Inspect the 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 that are cracked Replace any gauge that can not be calibrated 102517764 Water Pump Inspect SMCS Code 1361 040 1361 A failed water pump may 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 Illustration 56 g01249453 1 Weep hole 96 Maintenance Section Water Pump Inspect SEBU8180 Note The water pump seal is lubricated by the coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and parts contract Visually inspect the water pump for leaks The water pump is not a serviceable item In order to install a new water pump refer to the Disassembly and Assembly Manual Water Pump Remove and Install or contact
54. nance 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 S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels Obtain the Sample and the Analysis 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 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The flui
55. ng 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 A battery with a low charge will freeze more easily than a battery with a full charge Alternator Belt Inspect Adjust Replace Poly V Belt SMCS Code 1357 036 1357 510 Inspection To maximize the engine performance inspect the belt 1 for wear and for cracking Replace the belt if the belt is worn or damaged e If the belt 1 has more than four cracks per 25 4000 mm 1 inch the belt must be replaced e Check the belt of cracks splits glazing grease and splitting Illustration 30 g01251375 Typical example Adjustment This type of belt has an automatic belt tensioner Replace Refer to Disassembly and Assembly manual Alternator Belt Remove and Install SEBU8180 63 Maintenance Section Battery Replace 102322315 Battery Replace SMCS Code 1401 510 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 en
56. oling system specifications Do not install the cooling system filler cap 66 Maintenance Section Cooling System Coolant ELC Change SEBU8180 2 Start and run the engine at low idle Increase the engine rpm to 1500 rpm 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 pressure 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 the correct operating temperature 102242512 Cooling System Coolant ELC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling
57. or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings The secondary air cleaner element is not serviceable or washable The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element When the engine is operating in environments that are dusty or dirty air cleaner elements may require more frequent replacement Illustration 34 g00736431 1 Cover 2 Primary air cleaner element 3 Secondary air cleaner element 4 Turbocharger air inlet 1 Remove the cover Remove the primary air cleaner element 2 The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element Note Refer to Cleaning the Primary Air Cleaner Elements 3 Cover the turbocharger air inlet with tape in order to keep dirt out 4 Clean the inside of the air cleaner cover and body with a clean dry clot
58. ot fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM 64 Maintenance Section Battery or Battery Cable Disconnect SEBU8180 102323088 Battery or Battery Cable Disconnect SMCS Code 1402 029 The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 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 Ensure that the cable cannot contact the terminal When four 12 volt batteries are involved two negative connection must be disconnected 3 Remove the positive connection 4 Clean all disconnected connection and battery terminals 5 Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit correctly Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly 6 Tape the cable connections in order to help prevent accidental starting 7 Proceed with necessary system repairs 8 In
59. pment which is recommended by the OEM 102345750 Engine Clean SMCS Code 1000 070 Personal injury or death can result from high volt age Moisture can create paths of electrical conductiv ity Make sure that the electrical system is OFF Lock out the starting controls and tag the controls DO NOT OPERATE 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 Note Caution must be used in order to prevent electrical components from being damaged by excessive water when the engine is cleaned Pressure washers and steam cleaners should not be directed at any electrical connectors or the junction of cables into the rear of the connectors Avoid electrical components such as the alternator the starter and the ECM Protect the fuel injection pump from fluids in order to wash the engine SEBU8180 73 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace 101553486 Engine Air Cleaner Element Dual Element Clean Replace SMCS Code 1054 037 1054 510 NOTICE Never run the engine without an
60. rced further into the pleats Note Refer to Inspecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements SEBU8180 75 Maintenance Section Engine Air Cleaner Element Single Element Inspect Replace Inspecting the Primary Air Cleaner Elements Illustration 36 g00281693 Inspect the clean dry primary air cleaner element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element for tears and or holes Inspect the primary air cleaner element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air cleaner element to a new primary air cleaner element that has the same part number Do not use a primary air cleaner element that has any tears and or holes in the filter material Do not use a primary air cleaner element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements Storing Primary Air Cleaner Elements If a primary air clean
61. s Operation and Maintenance Manual En gine Clean for more information e Ensure that the cooling system hoses are correctly clamped and that the cooling system hoses are 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 the 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 Remove the water pump Refer to Disassembly and Assembly Water Pump Remove and Install For more information consult your Caterpillar dealer SEBU8180 95 Maintenance Section Water Pump Inspect Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the rocker cover Inspect the piping for the air intake system and the elbows for cracks and for loose clamps Ensure that hoses and tubes are not contacting other hoses tubes wiring harnesses etc Ensure that the areas around the rotating parts are clear Inspect the alternator belts and any accessory drive belts for cracks breaks or other damage e Inspect the wiring harness for damage Belts for multiple 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
62. scheduled downtime A visual inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Removal and Installation Note The turbochargers that are supplied are nonserviceable SEBU8180 93 Maintenance Section V Belts Inspect Adjust Replace For options regarding the removal installation and replacement consult your Carerpillar dealer or your Carerpillar distributor Refer to the Disassembly and Assembly Manual Turbocharger Remove and Turbocharger Install for further information Inspecting NOTICE The compressor housing for the turbocharger must not be removed from the turbocharger for cleaning The actuator linkage is connected to the compressor housing If the actuator linkage is moved or disturbed the engine may not comply with emmissions legisla tion 1 Remove the pipe from the turbocharger exhaust outlet and remove the air intake pipe to the turbocharger Visually inspect the piping for the presence of oil Clean the interior of the pipes in order to prevent dirt from entering during reassembly 2 Check for the presence of oil If oil is leaking from the back side of the compressor 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 intake air clogged air filters which causes
63. se 6 Replace the old hose with a new hose 7 Install the hose clamps with a torque wrench Note For the correct coolant see this Operation and Maintenance Manual Fluid Recommendations 8 Refill the cooling system Refer to the OEM information for further information on refilling the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler cap s seals Replace the cooling system filler cap if the seals are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks 101515272 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 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 t
64. 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 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 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 accepta
65. t Level Check SEBU8180 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 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 Cat ELC Extender 3 Add Cat ELC Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations article for more information 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the 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 Illustration 31 g00285520 Cooling system filler cap Press
66. t required Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install If you inspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information 102517138 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ 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 Note Refer to Testing and Adjusting Manual Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that
67. the OEM recommendations for more information 78 SEBU8180 Maintenance Section Engine Oil Level Check 102335785 101935337 Engine Oil Level Check SMCS Code 1348 535 FLV Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin lt i Illustration 42 g01165836 Y Min mark X Max mark NOTICE Perform this maintenance with the engine stopped Note Ensure that the engine is either level or that the engine is in the normal operating position in order to obtain a true level indication Note After the engine has been switched OFF wait for ten minutes in order to allow the engine oil to drain to the oil pan before checking the oil level 1 Maintain the oil level between the ADD mark Y and the FULL mark X on the engine oil dipstick Do not fill the crankcase above the 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 mainte
68. 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 102518232 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death If you inspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information 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 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 harden Hardening
69. tive 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 rpm 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 refer to Special Publication SEBD0518 Know Your Cooling Syst
70. ue 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 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 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 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 be
71. urized 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 32 g00103639 Typical filler cap gaskets 3 Clean the cooling system filler cap and check the condition 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 SEBU8180 69 Maintenance Section Cooling System Coolant Sample Level 1 Obtain 102326688 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Note Obtaining a Coolant Sample Level 1 is optional if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of
72. 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 Allow five minutes after the fuel tank has been filled before draining water and sediment from the fuel tank Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow SEBU8180 87 Maintenance Section Hoses and Clamps Inspect Replace 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 at the following intervals e Weekly e Service intervals e Refill of the tank This will help 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
73. xpressed 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 and Crankshaft Seals The following components may not last until the second overhaul e Thrust bearings e Main bearings e Rod bearings e Crankshaft seals Caterpillar Inc recommends the installation 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
74. y servicing or repair is performed After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and Assembly Manual Fuel Injection Lines Install NOTICE The water separator can be under suction during nor mal engine operation Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system 1 Place a suitable container under the water separator in order to catch any fuel that might spill Clean up any spilled fuel Reames fetes ge ee ered aL Lii Illustration 51 g01191846 Typical example 2 Install a suitable tube onto the drain 1 Open the drain 1 Allow the fluid to drain into the container 3 Tighten the drain 1 by hand pressure only Remove the tube and dispose of the drained fluid in a safe place 102517255 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE 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 c
75. y spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant Complete the information on the label for the sampling bottle before you begin to take the samples Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations or consult your Caterpillar dealer 101987714 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Refer to Operation and Mainten
76. your Caterpillar dealer

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