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C11 and C13 Industrial Engines-Maintenance - Safety

1. J St HII g00485291 Illustration 34 1 Bolts 2 Hose clamp 3 Breather cover NOTICE Perform this maintenance with the engine stopped If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage 1 Loosen hose clamp 2 and remove the hose from breather cover 3 2 Loosen four bolts 1 for the breather cover and remove breather cover 3 3 Remove the breather element and wash the breather element in solvent that is clean and nonflammable Allow the breather element to dry 4 Install a breather element that is clean and dry Install breather cover 3 and install bolts 1 Refer to the Specifications SENR3130 in order to locate the proper torques 5 Install the hose Install hose clamp 2 Refer to the Specifications SENR3130 in order to locate the proper torques SEBU7901 01 71 Maintenance Section Engine Mounts Inspect 102139969 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 the Specificat
2. 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 102107152 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 Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase with the engine stopped Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil Drain the Engine Oil After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine crankcase oil e If the engine is equipped with a drain valve turn the drain valve knob counterclockwise in order to drain the oil After the o
3. 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 fluid sampling bottle includes the parts that are needed for obtaining oil samples Instructions are also provided 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
4. 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 62 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SEBU7901 01 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 evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e 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 l
5. 54 Maintenance Section Battery Replace SEBU7901 01 101878164 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 enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced 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 starter 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 Return used batteries to an appropriate recycli
6. NOTICE To prevent crankshaft bearing damage crank the en gine with the fuel OFF This will fill the oil filters before starting the engine Do not crank the engine for more than 30 seconds 2 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 74 Maintenance Section Engine Protective Devices Check SEBU7901 01 3 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL marks on the oil level gauge 100626013 Engine Protective Devices Check SMCS Code 7400 535 Alarms and shutoffs must function properly Alarms provide timely warning to the operator Shutoffs help to prevent damage to the engine It is impossible to determine if the engine protective devices are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints Ensure that the engine protective devices are functioning properly NOTICE During testing abnormal operating conditions must be simulated The tests must be performed correc
7. 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 not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM SEBU7901 01 55 Maintenance Section Battery or Battery Cable Disconnect 101492654 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 at the battery that goes to the start switch Ensure that the cable cannot contact the terminal When four 12 volt batteries are involved the negative side of two batteries must be disconnected 3 Tape the leads in order to help prevent accidental starting 4 Proceed with necessary system repairs Reverse the ste
8. Every 114 000 L 30 000 US gal of Fuel or 3000 Service Hours Aftercooler Core Clean Test 0 ccccccceeeeeeees 53 Every 170 400 L 45 000 US gal of Fuel or 3000 Service Hours Crankshaft Vibration Damper Inspect 64 Electronic Unit Injector Inspect Adjust 65 Engine Cleg aaee EES EEEE 66 Engine Mounts Inspect 0 0 0 eeeeeeeeeeeeeeeeeeeenneeees 71 Engine Speed Timing Sensors Check Clean Calibrate e ainiin ii die 74 Engine Valve Lash Inspect Adjust cee 75 Engine Valve Rotators Inspect eeen 76 Fan Drive Bearing Lubricate 0 0 0 eeeeeeeees 76 Every 380 000 L 100 000 US gal of Fuel or 10 000 Service Hours Overhaul Considerations 0 ccccccccceeeeeeesseeeeeeeaes 82 Overhaul Fan Drive Bearing Replace 76 SEBU7901 01 53 Maintenance Section Aftercooler Core Clean Test 101188617 Aftercooler Core Clean Test Air To Air Aftercooler SMCS Code 1064 070 1064 081 Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the cooling air side of the aftercooler for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the cooling air side of the aftercooler if necessary For air to air aftercoolers use the same methods that are used for cleaning the outside of radiators Personal injury can result from air pressure Personal injury ca
9. Inspect SMCS Code 1205 040 Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A damper that is damaged can cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine Visconic Damper The visconic damper has a weight that is located inside a fluid filled case The weight moves in the case in order to limit torsional vibration Inspect the damper for evidence of fluid leaks If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous smooth and difficult to remove from surfaces If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace the crankshaft seals Inspect the damper and repair or replace the damper for any of the following reasons The damper is dented cracked or leaking The paint on the damper is discolored from heat The engine has had a failure because of a broken crankshaft Analysis of the oil has revealed that the front main bearing is badly worn There is a large amount of gear train wear that is not caused by a lack of oil Refer to the Service Manual or consult your Caterpillar dealer for infor
10. VCI oil to function properly The VCI oil is easily cleaned from the engine when you remove the engine from storage The volatile vapors are removed by simply running the engine to operating temperature A mineral oil base is left behind after the volatile vapors are removed i01849001 Engine Valve Lash Inspect Adjust SMCS Code 1102 025 The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life 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 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
11. age to the cylinder block will be the result 102052170 Electronics Grounding Stud Inspect Clean Tighten SMCS Code 7423 040 7423 070 7423 079 The connection of battery cables to a battery and the disconnection of battery cables from a battery may cause an explosion which may result in injury or death The connection and the disconnection of other electrical equipment may also cause an explosion which may result in injury or death The procedures for the connection and the disconnec tion of battery cables and other electrical equip ment should only be performed in a nonexplosive atmosphere 66 Maintenance Section Engine Clean SEBU7901 01 ae 1 1 r IT y Illustration 28 g00765094 Electronics grounding stud side view Inspect the OEM harness for good connections Inspect the condition of the OEM harness The electronics grounding stud must have a wire ground to the battery Tighten the electronics grounding stud at every oil change Ground wires and straps should be combined at engine grounds All grounds should be tight and free of corrosion e Clean the electronics grounding stud and the terminals for the electronics ground strap with a clean cloth e f the connections are corroded clean the connections with a solution of baking soda and water
12. at low idle Increase the engine rpm to high idle Operate the engine at high idle for one minute in order to purge air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 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 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 NOTIC
13. combustion chamber lead to the following problems guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately 2 Remove oil filler cap 2 and add oil if necessary For the correct oil to use see this Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section Do not fill the crankcase above FULL mark X on the oil level gauge Clean the oil filler cap Install the oil filler cap 3 Record the amount of oil that is added For the next oil sample and analysis include the total amount of oil that has been added since the previous sample This will help to provide the most accurate oil analysis 72 Maintenance Section Engine Oil Sample Obtain SEBU7901 01 Engine Oil Sample Obtain SMCS Code 1000 008 1348 554 SM 7542 554 OC SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine 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
14. e Keep the electronics grounding stud and the strap clean and coated with MPGM grease or petroleum jelly i01646701 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 you clean the engine Avoid electrical components such as the alternator the starter and the ECM 101553486 Engine Air Cleaner Element Dual Element Clean Replace SMCS Code 1054 037 1054 510 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 cleane
15. has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used 102121526 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Inspect all hoses for leaks that are caused by the following conditions e Cracking e Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extreme temperature changes the hose will heat set Heat setting causes hos
16. 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 The following components should be inspected and adjusted when the valves are inspected and adjusted e Valve actuators e Injectors e Compression brakes Refer to the Service Manual for more information 76 Maintenance Section Engine Valve Rotators Inspect SEBU7901 01 101597115 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to help prevent being burned by hot oil or spray Engine valve rotators rotate the valves when the engine runs This helps to prevent deposits from building up on the valves and the valve seats Perform the following steps after the engine valve lash is set but before the valve covers are installed 1 Start the engine according to Operation and Maintenance Manual Engine Starting Operation Section for the procedure 2 Operate the engine at low idle 3 Observe the top surface of each valve rotator The valve rotators should turn slightly when the valves close NOTICE A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life If a damaged rotator is not replaced valve face guttering could result and cause pieces
17. 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 i01900118 Engine Air Cleaner Service Indicator Inspect If Equipped 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 housing or in a remote location Illustration 33 g00103777 Typical service indicator 70 Maintenance Section Engine Crankcase Breather Clean SEBU7901 01 Observe the service indicator The air cleaner el
18. sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Check the fuel daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow SEBU7901 01 81 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 during the following conditions e Weekly e Oil change e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank A 2 micron filter for the breather vent on the fuel tank is also recommended Refer to Special Publication SENR9620 Improving Fuel System Durability If a bulk storage tank
19. should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water Ensure that the cooling lines are properly clamped and that the cooling lines are tight Check for leaks Check the condition of all pipes e Inspect the water pumps for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to
20. specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper 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 the Specifications Manual for your particular engine for more specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 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 the engine and run the engine at low idle fora 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 Con
21. turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately SEBU7901 01 77 Maintenance Section Fuel System Prime NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 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 Note Refer to Operation and Maintenance Manual Fuel System Secondary Filter Replace for information on replacing the filter 1 Turn the ignition switch to the OFF position Illustration 40 g00975199 1 Fuel priming pump 2 Air purge screw 3 Priming valve If Equipped 2 Turn the priming valve 3 If Equipped to the Closed Prime position in order to prime the fuel system 3 Open air purge screw 2 for the fuel filter by three full turns Do not remove the air purge screw NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 4 Start the engine The engine should start and the engine should run smoothly Note You may use the fuel priming pump for the fuel filter IF EQUIPPED instead of starting the engine and running the engine 5 While the engine is running observe air purge
22. 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 one of the drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar 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 the Specifications Manual for your particular engine for more specific information on the proper torq
23. 2 045 1395 081 This maintenance procedure is required for conventional coolants such as DEAC and for mixtures of water and SCA This maintenance is NOT required for cooling systems that are filled with Extended Life Coolant Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and eyes Do not drink cooling system coolant additive Note Caterpillar recommends an S O S coolant analysis Level 1 Test the Concentration of the SCA Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Water and SCA NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Use the instructions that follow 1 Fill the syringe to the 1 0 ml mark with the coolant 2 Dispense the 1 0 mL coolant sample from the syringe into the empty mixing bottle SEBU7901 01 63 Maintenance Section Cooling System Water Temperature Regulator Replace 3 Add tap water to the mixing bottle in order to bring the level up to the 10 ml mark Place the cap on the bottle and shake the bottle 4 Add 2 to 3 drops of the NITRITE INDICATOR SOLUTION B to the mixing bottle Move the bottle in a cir
24. C11 and C13 INDUSTRIAL ENGINES Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU7901 01 01 2007 Caterpillar CATERPILLAR All Rights Reserved SEBU7901 01 51 Maintenance Section Maintenance Interval Schedule 102433183 Maintenance Interval Schedule SMCS Code 1000 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Use fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed When Required Battery Replace o oo ee eeeeeeeeeeeeeeeeeeneeeeeeeeneaeees 54 Battery or Battery Cable Disconnect 55 Engine Air Cleaner Element Dual Element Clean Replace 2 cccccceeeeeee
25. Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance 101539769 Turbocharger Inspect SMCS Code 1052 040 1052 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Any fumes from the crankcase are filtered through the air inlet system Therefore by products 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 quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at
26. E 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 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 regulat
27. Months Engine Protective Devices Check iesen 74 Every 2000 Service Hours or 1 Year Alternator Inspect c cccecceceeeeeeeeeeeeneenaeees 53 Every Year Cooling System Coolant Sample Level 2 Obtains ise are a ita ee esol Sees 62 Every 3000 Service Hours or 3 Years Cooling System Coolant DEAC Change 56 Cooling System Coolant Extender ELC Add 60 Cooling System Water Temperature Regulator R place tiina i edad neta ai neuen 63 Every 8000 Service Hours or 3 Years Driven Equipment Check cecceeeeeeeteeeeeees 64 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 58 Every 14 400 L 3750 US gal of Fuel or 250 Service Hours or 1 Year Battery Electrolyte Level Check n 54 Electronics Grounding Stud Inspect Clean AEE nE 222 ose E E SEE E T 65 Engine Crankcase Breather Clean aaen 70 Engine Oil Sample Obtain a se 72 Fuel System Primary Filter Water Separator Element Replace cess essccscceeeeeeeeeeeesennenaeees 78 Fuel System Secondary Filter Replace 79 Hoses and Clamps Inspect Replace 81 Radiator ClOAn vecccescsizetenectasstnetacseyenteatetadseenasaeete 85 Every 28 500 L 7500 US gal of Fuel or 500 Service Hours or 1 Year Deep Sump Engine Oil and Filter Change n se 72 52 Maintenance Section Maintenance Interval Schedule SEBU7901 01
28. Reinstall the belt guard If new drive belts are installed check the drive belt tension again after 30 minutes of engine operation at the rated rpm Adjustment of the Fan Drive Belt 1 Remove the belt guard 2 Loosen the mounting bolt for the pulley 3 Loosen the adjusting nut for the pulley 4 Move the pulley in order to adjust the belt tension 5 Tighten the adjusting nut 6 Tighten the mounting bolt 56 Maintenance Section Cooling System Coolant DEAC Change SEBU7901 01 7 Reinstall the belt guard If new drive belts are installed check the drive belt tension again after 30 minutes of engine operation at the rated rpm 102070334 Cooling System Coolant DEAC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming of the coolant e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated NOTICE Use of commercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines 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
29. SEBU7901 01 Environmental Factors Ambient temperatures The engine may be exposed to extended operation in extremely cold environments or hot environments 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 100651416 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar Inc recommends a scheduled inspection of the starting motor If the starting motor fails the engine may not start in an emergency situation
30. aracteristics Reduced heat transfer could cause cracking of the cylinder head and other high temperature components Excessive supplemental coolant additive concentra tion could also result in blockage of the heat exchang er overheating and or accelerated wear of the water pump seal Do not exceed the recommended amount of supple mental coolant additive concentration 3 Add the proper amount of SCA For the proper amount of SCA refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic The proper concentration of SCA depends on the type of coolant that is used For the proper concentration of SCA refer to Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations 4 Clean the cooling system filler cap Install the cooling system filler cap 100912898 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head o
31. cap s gaskets Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks 102486400 Jacket Water Heater Check SMCS Code 1383 535 Jacket water heaters help to improve startability in ambient temperatures that are below 21 C 70 F All installations that require automatic starting should have jacket water heaters Check the operation of the jacket water heater For an ambient temperature of 0 C 32 F the heater should maintain the jacket water coolant temperature at approximately 32 C 90 F 101848653 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 us
32. changed at 50 to 70 kPa 15 to 20 inches Hg Replace the Element Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire 1 Close the main fuel supply valve ee Illustration 43 g00104012 Element 1 Bowl 2 and Drain 3 2 Remove element 1 from the element mounting base while bowl 2 is attached 3 Dispose of the contents of the filter Remove bowl 2 from element 1 The bowl is reusable Do not discard the bowl Dispose of the used element 4 Remove the O ring from the gland of the bowl Clean the following components e Bowl e O ring e Mounting base Inspect the O ring for damage and for deterioration Replace the O ring if necessary 5 Lubricate the O ring with clean diesel fuel 6 Install bowl 2 on a new element Tighten the bowl by hand Do not use tools in order to tighten the bowl NOTICE The primary filter water separator may be prefilled with fuel to avoid rough running stalling of the engine due to air Do not fill the secondary filter with fuel before installation The fuel would not be filtered and could be contaminated Contaminated fuel will cause accel erated wear to fuel system parts 7 Lubricate the top seal of element 1 with clean diesel fuel The element may be filled with fuel at this time Install the new element on the mounting base Tighten the element by hand NOTICE The water separator is under su
33. 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 30 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 forced further into the pleats Note Refer to Inspecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a go
34. ction during normal engine operation Ensure that the vent plug is tight ened securely to help prevent air from entering the fu el system 8 Open the main fuel supply valve 9 Start the engine and check for leaks Run the engine for one minute Stop the engine and check for leaks again Detecting leaks is difficult while the engine is running The primary filter water separator is under suction A leak will allow air to enter the fuel The air in the fuel can cause low power due to aeration of the fuel If air enters the fuel check the components for overtightening or undertightening i01776046 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 changing fuel filters or water separator elements Clean up fuel spills immediately 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 any dis connected fuel system components 80 Maintenance Section Fuel Tank Water and Sediment Drain SEBU7901 01 NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 1 Stop the engine Turn the ignition switch to the OFF position or disconnect the battery Refer to the Operation and Maintenanc
35. cular motion in order to mix the solution 5 Add 1 drop of NITRITE TEST SOLUTION A to the mixing bottle Move the bottle in a circular motion in order to mix the solution 6 Repeat 5 until the solution changes color from red to light gray green or blue Record the number of drops of NITRITE TEST SOLUTION A that were required to cause the color change 7 Use Table 13 to interpret the results Table 13 Number of Concentration Maintenance Drops of SCA Required Less than 25 Less than the Add SCA recommended Retest the concentration of coolant SCA 25 to 30 The None recommended concentration of SCA More than 30 More than the Remove the recommended coolant concentration of Replace with SCA water only Retest the coolant Add the SCA If Necessary Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly Note Always dispose of fluids according to local regulations 2 If necessary drain some coolant in order to allow space for the addition of the SCA NOTICE Excessive supplemental coolant additive concentra tion can form deposits on the higher temperature sur faces of the cooling system reducing the engine s heat transfer ch
36. e if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual for your particular engine for more specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper torques Fill Engines that are Equipped with a Coolant Recovery Tank NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with Extended Life Coolant ELC Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start the engine and operate the engine at low idle Increase the engine rpm to high idle Operate the engine at high idle for one minute in order to purge air from the cavities of the engine block Stop the engine 3 Pour more ELC into the cooling system until the cooling system is full 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 tha
37. e Manual Battery or Battery Cable Disconnect topic Maintenance Section for more information Shut off the fuel supply valve if equipped 2 It may be necessary to relieve residual fuel pressure from the fuel system before the fuel filter is removed Wait for one to five minutes until the fuel pressure has lowered Use a suitable container in order to catch any fuel that may spill 3 Remove the used fuel filter and discard the used fuel filter 4 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 5 Apply clean diesel fuel to the new fuel filter gasket NOTICE Do not fill the secondary fuel filter with fuel before in stalling The fuel would not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts NOTICE In order to maximize fuel system life and prevent pre mature wear out from abrasive particles in the fuel a two micron high efficiency fuel filter is required for all Caterpillar Electronic Unit Injectors Caterpillar High Efficiency Fuel Filters meet these requirements Con sult your Caterpillar dealer for the proper part num bers 6 Install the new fuel filter Spin the fuel filter onto the fuel filter base until the gasket contacts the base Use the rotation index marks on the filters as a guide for proper tightening Tighten the filter according to the instructions that are on the fuel f
38. e 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 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 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 82 Maintenance Section Jacket Water Heater Check SEBU7901 01 5 Disconnect the old hose 6 Replace the old hose with a new hose 7 Install the hose clamps with a torque wrench Note Refer to the Specifications SENR3130 Torque Specifications in order to locate the proper torques 8 Refill the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler
39. e repaired If the engine block is repairable and or the crankshaft is repairable the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core This lower cost can be attributed to three aspects e Specially designed Caterpillar engine features SEBU7901 01 83 Maintenance Section Overhaul Considerations e Caterpillar dealer exchange components e Caterpillar Inc remanufactured exchange components Overhaul Recommendation To minimize downtime a scheduled engine overhaul by your Caterpillar dealer is recommended 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 Unit Fuel Injector Clean the fuel injector body and replace the O rings Replace the O rings and the gasket on the injector sleeve Clean the area around the injector seating in the injector sleeve Refer to the Service Manual for the complete procedure or consult with your Caterpillar dealer for assistance Rebuild or Exchange Cylinder Head Assembly Connecting Rods Pistons Cy
40. eals Make repairs if necessary For more detailed information on cleaning and inspection refer to Special Publication SEBD0518 Know Your Cooling System 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 86 Maintenance Section Starting Motor Inspect
41. ed 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 SEBU7901 01 59 Maintenance Section Cooling System Coolant ELC Change For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar 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 the Specifications Manual for your particular engine for more specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with clean water Install the cooling system filler cap 4 Start the engine and run the engine at low idle until the temperature reaches 49 to 66 C 120 to 150 F 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 valv
42. ed to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases The oil consumption rate brake specific oil consumption is measured in grams per kW h 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 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 b
43. eeeceeeeeeeeeeeeeeteeeeees 66 Engine Storage Procedure Check n se T9 Fuel System Prime cccccceceeeeeeeeseeeeeeeeeeeeneeeees 76 Severe Service Application Check 0 0 0 85 Daily Cooling System Coolant Level Check 61 Engine Air Cleaner Service Indicator Inspect 69 Engine Oil Level Check eccceeeceeeeteeeeeeenneeees 71 Fuel System Primary Filter Water Separator Dram eana a r atid teeta 78 Power Take Off Clutch Check Adjust Lubricate 84 Walk Around Inspection 0 ccccceeeeeeeeeeeteeeeeees 87 Every Week Fuel Tank Water and Sediment Drain 80 Jacket Water Heater Check siseses 82 Every 250 Service Hours Cooling System Supplemental Coolant Additive SCA Test Add cccccceccecceeeeeeeeteseeeeeneaeees 62 Engine Oil and Filter Change n se 72 Fuel Tank Water and Sediment Drain 80 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 OD aU ooo EE ceed deve ieedenell uenededevevieendes 62 Every 500 Service Hours Belts Inspect Adjust Replace ee 55 Cooling System Coolant Sample Level 1 OBIA direita eE EEE ems tiaamecests det any 61 Starting Motor Inspect sses 86 Turbocharger Inspect eee ceeeeneeeeeeeeenteeeeeeeaas 86 Water Pump Inspect eeeeeeeeeeeeeeceeeeeeeeeees 88 Every 500 Service Hours or 6
44. 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 29 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 cloth 5 Remove the tape for the turbocharger air inlet Install the secondary air cleaner element Install a primary air cleaner element that is
45. ement 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 pushes e Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 101848984 Engine Crankcase Breather Clean SMCS Code 1317 070
46. f the following categories for oil change intervals in the Operation and Maintenance Manual Maintenance Interval Schedule have not been reached e Mileage e Operating hours e Fuel consumption If an engine is out of operation and if use of the engine is not planned special precautions should be made If the engine will be stored for more than three months a complete protection procedure is recommended For more detailed information on engine storage see Special Instruction SEHS9031 Storage Procedure For Caterpillar Products If the engine will not be started for several weeks the lubricating oil will drain from the cylinder walls and from the piston rings Rust can form on the cylinder liner surface Rust on the cylinder liner surface will cause increased engine wear and a reduction in engine service life Caterpillar recommends the use of volatile corrosion inhibitor VCI oil in order to prevent internal engine damage due to moisture during storage These inhibitors in the VCI oil act by evaporating inside the engine The inhibitors then condense over the inside surfaces of the engine The evaporation process and the condensing process offers full protection to surfaces that cannot be reached with preservatives 0 9 L 1 0 qt of 40 6792 VCI oil will treat 28 4 L 30 0 qt of engine oil This will give a 3 percent concentration of VCI oil The engine must be completely sealed when the engine is stored in order for the
47. he coolant level to the proper level in the sight glass Illustration 27 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 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 Cat ELC This includes the following types of coolants Table 12 Recommended Interval Type of Coolant Level 1 Level 2 Every 250 Cat DEAC Hours Yearly 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
48. hould 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 A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system A full water analysis can be obtained by consulting your local water utility company or an agricultural agent Private laboratories are also available for water analysis Caterpillar Inc recommends an S O S Coolant Analysis Level 2 S O S Coolant Analysis Level 2 An S O S Coolant Analysis Level 2 is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system An S O S Coolant Analysis Level 2 provides the following information e Complete S O S Coolant Analysis Level 2 e Visual inspection of properties e Identification of metal corrosion 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 consult your Caterpillar dealer 101506009 Power Take Off Clutch Check Adjust Lubricate SMCS Code 3055 036 3055 086 NOTICE New power take offs should have the clutch adjust ment checked before being placed into service The clutch adjustment should be checked again after the first
49. ids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles e 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 Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant 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 102417522 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 135
50. il has drained turn the drain valve knob clockwise in order to close the drain valve SEBU7901 01 73 Maintenance Section Engine Oil and Filter Change e If the engine is not equipped with a drain valve remove the oil drain plug in order to allow the oil to drain If the engine is equipped with a shallow sump remove the bottom oil drain plugs from both ends of the oil pan After the oil has drained the oil drain plugs should be cleaned and installed Replace the Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 1 Remove the oil filter with a 1U 8760 Chain Wrench 2 Cut the oil filter open with a 175 7546 Oil Filter Cutter Gp 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 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 Pa
51. illed fuel immediately 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 room Illustration 42 g00709596 1 Element 2 Bowl 3 Drain Bowl 2 should be monitored daily for signs of water If water is present drain the water from the bowl 1 Open drain 3 The drain is a self ventilated drain Catch the draining water in a suitable container Dispose of the water properly 2 Close drain 3 NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system 102053433 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ Water in the fuel can cause the engine to run rough Water in the fuel may cause a electronic unit injector to fail If the fuel has been contaminated with water the element should be changed before the regularly scheduled interval SEBU7901 01 79 Maintenance Section Fuel System Secondary Filter Replace The primary filter water separator also provides filtration in order to help extend the life of the secondary fuel filter The element should be changed regularly If a vacuum gauge is installed the primary filter water separator should be
52. ilter Do not overtighten the filter 7 Open the fuel supply valve The engine will need to be purged of air Refer to the Operation and Maintenance Manual Fuel System Prime topic Maintenance Section for more information 102436696 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 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 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 Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining
53. ions Manual SENR3130 Torque Specifications Refer to your Caterpillar dealer for more information 102073191 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 Illustration 35 g00622328 1 Oil level gauge 2 Oil filler cap a a ADD FULL 5 g00110310 Illustration 36 Y ADD mark X FULL mark NOTICE Perform this maintenance with the engine stopped 1 Maintain the oil level between ADD mark Y and FULL mark X on oil level gauge 1 Do not fill the crankcase above FULL mark X NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can enable the crankshaft to dip into the oil This will reduce the power that is de veloped and also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling of the pistons oil blow ing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will enable deposits to form on the pistons and in the combustion chamber De posits in the
54. ions 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 SEBU7901 01 61 Maintenance Section Cooling System Coolant Level Check 101197583 Cooling System Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and cool 4 Illustration 26 g00285520 Cooling system filler cap Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly in order to relieve pressure 2 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe If the engine is equipped with a sight glass maintain t
55. it Injector Inspect Adjust SMCS Code 1251 025 1251 040 1290 025 1290 040 Be sure the engine cannot be started while this maintenance is being performed To prevent pos sible 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 the unit injectors The electronic unit injectors use high voltage Dis connect the unit injector enable circuit connector in order to prevent personal injury Do not come in contact with the injector terminals while the en gine is running The operation of Caterpillar engines with improper adjustments of the electronic unit injector can reduce engine efficiency This reduced efficiency could result in excessive fuel usage and or shortened engine component life Only qualified service personnel should perform this maintenance Refer to the following topics for your engine for the correct procedure Refer to the Systems Operation Testing and Adjusting Electronic Unit Injector Test for the test procedure and Systems Operation Testing and Adjusting Electronic Unit Injector Adjust for the correct procedure for adjusting the injectors NOTICE The camshafts must be correctly timed with the crank shaft before an adjustment of the lash for the fuel in jector is made The timing pins must be removed from the camshafts before the crankshaft is turned or dam
56. linder Liners Turbocharger Cylinder Packs Oil Pump and Fuel Transfer Pump These components should be inspected according to the instructions that are found in various Caterpillar reusability publications The Special Publication SEBF8029 lists the reusability publications that are needed for inspecting the engine parts If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline the parts should be reused Parts that are not within the established inspection specifications should be dealt with in one of the following manners e Salvaging e Repairing e Replacing Parts that do not comply with the established inspection specifications 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 Piston Rings Crankshaft Bearings Valve Rotators and Crankshaft Seals The following components may not last until the second overhaul e Thrust bearings e Main bearings e Rod bearings e Valve rotators e Crankshaft seals Caterpillar Inc recommends the installation of new parts at each overhaul period Inspect these parts while
57. ling system for leaks and for proper operating temperature 102070355 Cooling System Coolant ELC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist The engine overheats frequently Foaming of the coolant The oil has entered the cooling system and the coolant is contaminated 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 us
58. mation about damper replacement 100934883 Driven Equipment Check SMCS Code 3279 535 Check the Alignment To minimize bearing problems and vibration of the engine crankshaft and the driven equipment the alignment between the engine and driven equipment must be properly maintained Check the alignment according to the instructions that are provided by the following manufacturers e Caterpillar e OEM of the drive coupling e OEM of the driven equipment Torque all of the fasteners to the proper specifications SEBU7901 01 65 Maintenance Section Electronic Unit Injector Inspect Adjust Inspect the Drive Coupling Inspect the drive coupling according to the instructions that are provided by the OEM of the coupling For the following service information see the literature that is provided by the OEM of the coupling e Lubrication requirements e Specifications for the end play e Reusability Guidelines e Replacement instructions Inspect the Rear Gear Train Inspect the crankshaft gear If excessive wear is found replace the crankshaft gear and the large cluster idler If any gear causes damage to other gears through failure replace the entire rear gear train For the correct parts see the Parts Manual for the engine For removal and replacement instructions see the Service Manual Disassembly and Assembly module Consult your Caterpillar dealer for assistance 102070777 Electronic Un
59. n result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both 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 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
60. new or cleaned 6 Install the air cleaner cover 7 Reset the air cleaner service indicator 68 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace SEBU7901 01 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 should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean primary air
61. ng 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 cable from the NEGATIVE terminal on the starter motor to the NEGATIVE battery terminal 102340858 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
62. no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartridge must be balanced due to high rpm Severe Service Applications can accelerate component wear Severe Service Applications require more frequent inspections of the cartridge Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine for the procedure and specifications SEBU7901 01 87 Maintenance Section Walk Around Inspection Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil Clean the interior of the pipes in order to prevent dirt from entering during reassembly 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel o
63. o purge the air from the cavities of the engine block Stop the engine 3 Add coolant to the cooling system until the cooling system is full 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 58 Maintenance Section Cooling System Coolant ELC Change SEBU7901 01 5 Loosen the cap for the coolant recovery tank slowly in order to relieve any pressure Remove the cap for the coolant recovery tank 6 Pour coolant into the coolant recovery tank until the coolant reaches the COLD FULL mark DO NOT fill the coolant recovery tank above the COLD FULL mark 7 Clean the cap for the coolant recovery tank Install the cap for the coolant recovery tank 8 Start the engine Inspect the cooling system for leaks and for proper operating temperature Engines that are Not Equipped with a Coolant Recovery Tank NOTICE Fill the cooling sy
64. od 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 SEBU7901 01 69 Maintenance Section Engine Air Cleaner Service Indicator Inspect Inspecting the Primary Air Cleaner Elements Illustration 31 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 cleaner element that passes inspection will not be used the primary air cleaner element can be stored for future use Illustration 32 g00281694 Do
65. of the valve to fall into the cylinder This can cause piston and cylinder head damage If a valve fails to rotate consult your Caterpillar dealer 102239650 Fan Drive Bearing Lubricate SMCS Code 1359 086 BD Some of the fan drives have grease fittings and some of the fan drives do not have grease fittings If there is no grease fitting periodic lubrication is not required The fan drive requires grease only if the fan drive is equipped with a zerk Illustration 39 g00746166 Typical location of the grease fitting if equipped that is for the fan drive bearing The pulley is shown with the belt guards that have been removed Lubricate the grease fitting that is on the fan drive bearing with Bearing Lubricant or the equivalent Inspect the fan drive pulley assembly for wear or for damage If the shaft is loose an inspection of the internal components should be performed Refer to the Service Manual for additional information 102053753 Fan Drive Bearing Replace SMCS Code 1359 510 BD 1 Remove Bearings Refer to Disassembly and Assembly Bearing Removal 2 Measure the bearing housings for roundness and for proper size 3 Replace the bearings 102075183 Fuel System Prime SMCS Code 1258 548 The Secondary Fuel Filter Has Been Replaced Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury
66. ps in order to reconnect all of the cables 102042962 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspection Inspect the alternator belt and the fan drive belts for wear and for cracking Replace the belts if the belts are not in good condition Check the belt tension according to the information in the Service Manual Specifications Slippage of loose belts can reduce the efficiency of the driven components Vibration of loose belts can cause unnecessary wear on the following components e Belts e Pulleys e Bearings If the belts are too tight unnecessary stress is placed on the components This reduces the service life of the components Replacement For applications that require multiple drive belts replace the drive belts in matched sets Replacing one drive belt of a matched set will cause the new drive belt to carry more load because the older drive belts are stretched The additional load on the new drive belt could cause the new drive belt to fail Alternator Belt Adjustment O O 2 1 ae SS e o ji o oH o o g00788814 Illustration 25 1 Remove the belt guard 2 Loosen mounting bolts 1 and adjusting bolt 2 3 Move the assembly in order to increase or decrease the belt tension 4 Tighten adjusting bolt 2 Tighten mounting bolts 1 5
67. r elements help to prevent air borne debris from entering the air inlet SEBU7901 01 67 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace 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 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
68. r piston seizure problems 64 Maintenance Section Crankshaft Vibration Damper Inspect SEBU7901 01 A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface Refer to the Service Manual for the replacement procedure of the water temperature regulator or consult your Caterpillar dealer Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 100934535 Crankshaft Vibration Damper
69. r the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber 4 Use a dial indicator to check the end clearance on the shaft If the measured end play is greater than the Service Manual specifications the turbocharger should be repaired or replaced An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications 5 Inspect the bore of the turbine housing for corrosion 6 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 7 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 101185304 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection
70. replace the water pump seal For the removal of water pumps and the installation of water pumps and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve cover 88 Maintenance Section Water Pump Inspect SEBU7901 01 Inspect the fuel system for leaks Look for loose fuel line clamps or for loose fuel line tie wraps Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Ensure that hoses and tubes are not contacting other hoses tubes wiring harnesses etc Inspect the alternator belt and the accessory drive belts for cracks breaks or other 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 The older belts are stretched The additional load on the new belt could cause the belt to break e Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the ECM to the cylinder head ground strap for a good connection and for good condition Di
71. rts 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 37 g00103713 Typical filter mounting base and filter gasket 3 Clean the sealing surface of the filter mounting base Ensure that all of the old oil filter gasket is removed 4 Apply clean engine oil to the new oil filter gasket NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 5 Install the oil filter Tighten the oil filter until the oil filter gasket contacts the base Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Fill the Engine Crankcase 1 Remove the oil filler cap Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations for more information NOTICE If equipped with an auxiliary oil filter system or a re mote oil filter system follow the OEM or filter manu facturer s recommendations Under filling or overfilling the crankcase with oil can cause engine damage
72. sconnect 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 e Check the condition of the gauges Replace any gauges that are cracked Replace any gauge that can not be calibrated 101057943 Water Pump Inspect SMCS Code 1361 040 1361 A failed water pump might cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure e Other potential damage to the engine Visually inspect the water pump for leaks If any leaking is observed replace the water pump seal or the water pump assembly Refer to the Service Manual for the disassembly and assembly procedure Note Refer to the Service Manual or consult your Caterpillar dealer if any repair is needed or any replacement is needed
73. screw 2 When a small drop of fuel appears at the threads of the air purge screw close and tighten air purge screw 2 Note There may be a noticeable change in the sound of the running engine when the air purge screw is tightened The change in the sound of the engine is normal Note Failure to tighten all fittings could result in serious fuel leaks 6 Clean any residual fuel from the engine components 7 After the engine has operated smoothly for 30 seconds turn the priming valve 3 to the Open Run position Note Shortened injector life may occur if the priming valve 3 is left in the Closed Prime position The Engine Has Been Run Out of Fuel NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 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 Turn the ignition switch to the OFF position 2 Fill the fuel tank s with clean diesel fuel Illustration 41 g00975199 1 Fuel priming pump 2 Air purge screw 3 Priming valve If Equipped 3 Turn the priming valve 3 If Equipped to the Closed Prime position in order to prime the fuel system 78 Maintenance Section Fuel System Primary Filter Water Separator Drain SEBU7901 01 4 Open air p
74. stem no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start the engine 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 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 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 coo
75. t is on the cooling system filler cap is not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Loosen the cap for the coolant recovery tank slowly in order to relieve any pressure Remove the cap for the coolant recovery tank 6 Pour Extended Life Coolant ELC into the coolant recovery tank until the coolant reaches the COLD FULL mark DO NOT fill the coolant recovery tank above the COLD FULL mark 7 Clean the cap for the coolant recovery tank Install the cap for the coolant recovery tank 8 Start the engine Inspect the cooling system for leaks and for proper operating temperature Engines that are NOT Equipped with a Coolant Recovery Tank NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with Extended Life Coolant ELC Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 60 Maintenance Section Cooling System Coolant Extender ELC Add SEBU7901 01 2 Start the engine and operate the engine
76. ten hours of operation New clutch plates have a wear in period and the clutch may require several adjustments until the new plates are worn in Illustration 44 g00781502 1 Instruction plate 2 Serial number plate Check the clutch adjustment regularly after wear in Heavy duty applications which have engagements that are frequent and relatively long periods of clutch slippage require more frequent adjustment than light duty applications The operating torque should be measured in order to determine if a clutch adjustment is required Refer to the OEM information and instruction plate 1 for instructions on lubrication adjustment and other recommendations for service Perform the maintenance that is specified on the instruction plate SEBU7901 01 85 Maintenance Section Radiator Clean Do not operate the engine with the Instruction Plate cover removed from the clutch Personal injury may result If the clutch is damaged to the point of burst fail ure expelled pieces can cause personal injury to anyone in the immediate area Proper safeguards must be followed to help prevent accidents 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 necessar
77. 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 i00072207 Alternator Inspect SMCS Code 1405 040 Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the ammeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs as required Refer to the Service Manual Check the alternator and the battery charger for proper operation If the batteries are properly charged the ammeter reading should be very near zero All batteries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine The battery will not crank the engine even if the engine is warm When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge
78. 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 Note If the crankshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the crankshaft 84 Maintenance Section Power Take Off Clutch Check Adjust Lubricate SEBU7901 01 Inspect the camshaft for damage to the journals and to the lobes Note If the camshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the camshaft Inspect the following components for signs of wear or for signs of scuffing e Camshaft bearings e Camshaft followers Caterpillar Inc recommends replacing the crankshaft vibration damper Oil Cooler Core and Aftercooler Core During an overhaul the removal of the oil cooler core and the aftercooler core is recommended The oil cooler core and the aftercooler core should be cleaned and pressure tested NOTICE Do not use caustic cleaners to clean the core Caustic cleaners can attack the internal metals of the core and cause leakage Obtain Coolant Analysis The concentration of supplemental coolant additive SCA s
79. tinue to flush the system until all signs of the cleaning agent are gone 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual for your particular engine for more specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper torques Fill Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations topic for the capacity of the engine s system and for coolant recommendations Engines that are Equipped with a Coolant Recovery Tank NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start the engine 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 t
80. tly in order to pre vent possible damage to the engine To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately 101464654 Engine Speed Timing Sensors Check Clean Calibrate SMCS Code 1912 040 1912 070 1912 524 Illustration 38 g00765246 Left side view 1 Secondary speed timing sensor 2 Primary speed timing sensor 1 Remove the speed timing sensors from the front housing Check the condition of the plastic end of the speed timing sensors for wear and or contaminants 2 Clean the metal shavings and other debris from the face of the speed timing sensors Use the procedure in the Service Manual in order to calibrate the speed timing sensors Refer to the Service Manual for more information on the speed timing sensors SEBU7901 01 75 Maintenance Section Engine Storage Procedure Check 101458399 Engine Storage Procedure Check SMCS Code 1000 535 The oil change interval may be extended to 12 months for a vehicle that is operated seasonally and placed in storage for the remainder of the year by using the required storage procedures and the required start up procedures This extension is permitted i
81. ues Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 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 the engine and run the engine at low idle for a minimum of 30 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone SEBU7901 01 57 Maintenance Section Cooling System Coolant DEAC Change 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual for your particular engine for more
82. urge screw 2 for the fuel filter by three full turns Do not remove the air purge screw 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 5 Crank the engine for 30 seconds Use a suitable container to catch the fuel while you crank the engine Allow the starter motor to cool for 2 minutes Note You may use the fuel priming pump 1 IF EQUIPPED for the fuel filter instead of cranking the engine 6 Crank the engine for 30 seconds Allow the starter motor to cool for 2 minutes 7 Repeat Step 6 until the engine starts and the engine runs Note Failure to tighten all fittings could result in serious fuel leaks 8 After the engine has operated smoothly for 30 seconds turn the priming valve 3 to the Open Run position Note Shortened injector life may occur if the priming valve 3 is left in the Closed Prime position 9 Clean any residual fuel from the engine components 101341997 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 Use a suitable container to catch any fuel that might spill Clean up any sp
83. y Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both 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 s

C11 and C13 Industrial Engines-Maintenance - Safety

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