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MAINTENANCE INTERVALS - Safety

1. Do not use a spray nozzle Note When the primary air cleaner element is 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 water 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 water directly at the primary air cleaner element Dirt could be forced further into the pleats 92 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace Note Refer to Drying the Primary Air Cleaner Elements Refer to Inspecting the Primary Air Cleaner Elements 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 59 900281692 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 Clean
2. There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 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
3. During an overhaul Caterpillar Inc recommends the removal of both the oil cooler core and the aftercooler core Clean the oil cooler core and the aftercooler core Then pressure test both of these cores NOTICE Do not use caustic cleaners to clean the core Caustic cleaners can attack the internal metals of the core and cause leakage Note Use this cleaning procedure to clean the oil cooler core and the aftercooler core 1 Remove the oil cooler core and the aftercooler core 2 Remove any debris from the oil cooler core and the aftercooler core To remove debris from the oil cooler core turn the oil cooler core onto one end To remove debris from the aftercooler core turn the aftercooler core upside down 3 Flush the oil cooler core and the aftercooler core internally with cleaner in order to loosen foreign substances This will also help to remove oil from the oil cooler core and the aftercooler core Note Caterpillar Inc recommends the use of Hydrosolv Liquid Cleaners Table 34 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer Table 34 HydrosolvLiquid Cleaners Part ree Number Description Size 1U 8812 4 L 1 US gallon Hydrosolv4165 1U 5490 19 L 5 US gallon 8T 7570 208 L 55 US gallon 1U 8804 4 L 1 US gallon Hydrosolv100 1U 5492 19 L 5 US gallon 8T 5571 208 L 55 US gallon 4 Use steam to clean the oil cooler core
4. recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface Refer
5. Aftercooler Core Clean Test sse 80 Cooling System Coolant DEAC Change 82 Cooling System Coolant Extender ELC Add 86 Cooling System Water Temperature Regulator Replace echt A OA 88 Water Pump Inspect sesesesss 113 Every 136 000 L 36 000 US gal of Fuel or 4000 Service Hours Alternator Inspect seeeeeeene 80 Starting Motor Inspect s s 110 Every 228 000 L 60 000 US gal of Fuel or 6000 Service Hours or 6 Years Cooling System Coolant ELC Change 84 Overhaul Overhaul Considerations sss 107 80 Maintenance Section Aftercooler Core Clean Test i00744980 Aftercooler Core Clean Test SMCS Code 1064 070 1064 081 1 Remove the core Refer to the Service Manual for the procedure 2 Turn the aftercooler core upside down in order to remove debris NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 3 Back flush the core with cleaner Caterpillar recommends the use of Hydrosolv liquid cleaner Table 33 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 33 Hydrosolv Liquid Cleaners Container 4 L 1 US gal 19 L 5 US gal 208 L 55 US gal 4 L
6. Install bolt 1 and tighten Do not overtighten the bolt Refer to Specifications for the proper torque 5 Install the hose Install hose clamp 2 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for the proper torque i00687861 Engine Mounts Inspect SMCS Code 1152 040 Inspect the engine mounts for deterioration and for proper bolt torque Engine vibration can be caused by the following conditions e Improper mounting of the engine e Deterioration of the engine mounts Any engine mount that shows deterioration should be replaced Refer to the Service Manual for the recommended torques Refer to your Caterpillar dealer for more information 101481250 Engine Oil Level Check SMCS Code 1348 535 FLV A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin 96 Maintenance Section Engine Oil Sample Obtain 900771169 Illustration 66 1 Oil level gauge 2 Oil filler cap ADD FULL Illustration 67 900110310 Y ADD mark X FULL mark NOTICE Perform this maintenance with the engine stopped 1 Maintain the oil level between ADD mark Y and FULL mark X on oil level gauge 1 Do not fill the crankcase above FULL mark X NOTICE Operating your engine when the oil level i
7. and the aftercooler core This removes any remaining residue from the cleaner Flush the fins of the oil cooler core and the aftercooler core Remove any other trapped debris 5 Wash the oil cooler core and the aftercooler core with hot soapy water Rinse the oil cooler core and the aftercooler core thoroughly with clean water A WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 109 Maintenance Section Overhaul Considerations 6 Dry the oil cooler core and the aftercooler core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the components in order to ensure cleanliness The oil cooler core and the aftercooler core should be pressure tested Repair the oil cooler core and the aftercooler core if necessary Install the oil cooler core and the aftercooler core For more information about cleaning the cores consult your Caterpillar dealer Obtain Coolant Analysis The concentration of supplemental coolant additive SCA should be checked regularly with test kits or with S O S Coolant Analysis Level I Further coolant analysis is recommended when the engine is overhauled For example considerable deposits are found in the water jac
8. below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 86 Maintenance Section Cooling System Coolant Extender ELC Add 100259474 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1395 081 Caterpillar Extended Life Coolant ELC does not require the frequent Supplemental Coolant Additive SCA additions associated with the present conventional coolants The Extender only needs to be added once Check the cooling system only when the engine is stopped and cool 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necess
9. charger should output 5 amperes at 12 VDC After each rental period inspect all the wiring connections for damage and or wear Make repairs to the wiring connections as needed Inspect the safety chains before you tow the trailer package 111 Maintenance Section Turbocharger Inspect Check all of the fasteners for the proper torque prior to renting the package Check the coupler attachment bolts Check the bolts that attach the enclosure to the running gear of the trailer Refer to the torque specifications within this manual for the proper torque for the bolts i00912946 Turbocharger Inspect SMCS Code 1052 040 Periodic inspection and cleaning is recommended for the turoocharger 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 e
10. open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove the cooling system drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Service Technology Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air lo
11. the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged perform a pressure test A 9S 8140 Pressurizing Pump is used to perform the pressure test The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature i01206445 Cooling System Coolant ELC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling System before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is needed when the ELC is drained and replaced Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain A WARNING Pressurized System Hot coolant can cause seri ous burns To
12. 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 an 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 61 900281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air cleaner elements in Volatile Corrosion Inhibited VCI paper Place the primary air cleaner element into a box for storage For identification mark the outside of the box and mark the primary air cleaner element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location For more detailed information on cleaning the primary air cleaner element refer to Special Publication SEBF8062 Procedure to Inspect and Clean Air Filters 100708025 Engine Air Cleaner Element Single Element Inspect Replace SMCS Code 1054 040 1054 510 Perform the Operation and Maintenance Manual Engine Air Cleaner Service Indicator Inspect procedure and perfor
13. to the Service Manual for the replacement procedure of the water temperature regulator or consult your Caterpillar dealer Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 100894991 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine Rubber Damper Your engine may be equipped with a rubber damper The rubber damper uses a ring which is mounted in rubber in order to reduce vibrations in the crankshaft Inspect the damper and repair or replace the damper for any of the following reasons e There is deterioration and cracking of the rubber e There is slippage of the outer ring from the original position e The engine has had a failure because of a broken crankshaft e Analysis of the oil has revealed that the front main bearing is badly worn e There is a large amount of gear train wear that is not caused by lack of oil Refer to the Service Manual or consult your Caterpillar dealer for in
14. 1 US gal Description 1U 8812 Hydrosolv 4165 1U 5490 Hydrosolv 4165 8T 7570 Hydrosolv 4165 1U 8804 Hydrosolv 100 1U 5492 Hydrosolv 100 19 L 5 US gal 81 7571 Hydrosolv 100 208 L 55 US gal 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information 4 Steam clean the core in order to remove any residue Flush the fins of the aftercooler core Remove any other trapped debris 5 Wash the core with hot soapy water Rinse the core thoroughly with clean water A WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 6 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the core in order to ensure cleanliness Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 8 Install the core Refer to the Service Manual for the procedure For more information on cleaning the core consult your Caterpillar dealer 100072207 Alternator Inspect SMCS Code 1405 040 Caterpillar reco
15. 56 900103639 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 87 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add 101463635 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 A WARNING Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and the eyes Do not drink cooling system coolant additive Note Test the concentration of the Supplemental Coolant Additive SCA or test the SCA concentration as part of an S O S Coolant Analysis Test for SCA Concentration Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Use the 8T 5296 Coolant Conditioner Test Kit or use the 40 9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA Refer to the Operation and Maintenance Manual for more information Water and SCA NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Refer to the Operation and Maintenance Manual Water Supplemental Coolant
16. Additive SCA topic Maintenance Section Refer to the Operation and Maintenance Manual Conventional Coolant Antifreeze Cooling System Maintenance topic Maintenance Section S 0 S Coolant Analysis S O S coolant samples can be analyzed at your Caterpillar dealer S O S Coolant Analysis is a program that is based on periodic samples Level 1 Level 1 is a basic analysis of the coolant The following items are tested e Glycol Concentration e Concentration of SCA e pH e Conductivity The results are reported and recommendations are made according to the results Consult your Caterpillar dealer for information on the benefits of managing your equipment with an S O S Coolant Analysis Level 2 This level coolant analysis is recommended when the engine is overhauled Refer to the Operations and Maintenance Manual Overhaul Considerations for further information Add the SCA If Necessary NOTICE Do not exceed the recommended amount of sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temper ature components Excessive supplemental coolant additive concentration could also result in radiator tube blockage overheating and or accelerated water pump seal w
17. Cooling System Coolant DEAC Change 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the cooling system filler cap 4 Start and run the engine at low idle for a minimum of 30 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation a
18. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR vum Operation ane Maintenance manual XQ200 Rental Generator Sets EFA1 Up Gen or Set SQ Up En ain e This Manual Must be Accessible at the Point of Operation 101484606 Maintenance Interval Schedule SMCS Code 1000 7500 When Required Battery Replace o eee ceeeeeeeeeeeeeeeeeeeeeeeeeeeneaeees 81 Battery or Battery Cable Disconnect 82 Enclosure Inspect eseeeeeess 89 Engine Air Cleaner Element Dual Element Clean Replace sees 90 Engine Air Cleaner Element Single Element Inspect Replace seeeen 93 Fuel System Prime sss 101 Trailer INS POC acre tec empti ce renta 110 Daily Cooling System Coolant Level Check 86 Engine Air Cleaner Service Indicator Inspect 94 Engine Oil Level Check n se 95 Fuel System Water Separator Drain 104 Walk Around Inspection eesssssss 112 Between 250 Service Hours and 1000 Service Hours or between first and fourth oil change Magnetic Pickups Clean Inspect 106 Every 1000 Service Hours Engine Clean utei eta 90 Every 8500 L 2200 US gal of Fuel or 250 Service Hours Alternator and Fan Belts Inspect Adjust Repla68 5c i etie
19. Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain A WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove one of the drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Service Technology Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1 Flush the cooling system with clean water in order to remove any debris 83 Maintenance Section
20. SMCS Code 1359 086 BD Illustration 71 900746166 Typical location of the grease fitting that is for the fan drive bearing The pulley is shown with the belt guards 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 100705823 Fuel Control Linkage Check Lubricate SMCS Code 1257 086 1257 535 Check the fuel control linkage for proper operation If necessary adjust the fuel control linkage Refer to the Service Manual for the adjustment procedures 100 Maintenance Section Fuel Injection Nozzles Test Exchange 900309003 Illustration 72 Typical grease fittings on the fuel control linkage Some fuel control linkages require lubrication Lubricate the grease fittings with 1P 0808 Multipurpose Grease or the equivalent 100626014 Fuel Injection Nozzles Test Exchange SMCS Code 1254 013 1254 081 A WARNING Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component Fuel injection nozzles are subject to
21. Specifications for the proper torque Clean up any spilled fuel immediately 12 Perform Steps 9 through 11 on each fuel injection line 13 Push in and hand tighten the priming pump plunger 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 14 Start the engine 100914347 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 fuel system components to fail If the fuel has been contaminated with water the element should be changed before the regularly scheduled interval 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 The primary filter water separator should be changed when the vacuum gauge if equipped registers 50 to 70 kPa 15 to 20 In Hg Replace the Element A WARNING Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately Illustration 75 g00467033 1 Vent valve Base Can Element 5 Drain plug ARUN 1 Close the main fuel supply valve 2 Remove drain pl
22. an container The coolant can be reused 3 Drain the coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose Note For torques on hose clamps see this Operation and Maintenance Manual Torque Specifications Maintenance Section 7 Install the hose clamps with a torque wrench Note For the proper coolant to use see this Operation and Maintenance Manual Coolant Recommendations Maintenance Section 8 Refill the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler cap s gaskets Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks Magnetic Pickups Clean Inspect SMCS Code 1907 040 7400 040 7400 070 Illustration 78 g00293335 Typical example 1 Magnetic pickup 2 Flywheel housing g00293337 Illustration 79 Typical magnetic pickup 1 Remove magnetic pickup 1 from flywheel housing 2 Check the condition of the end of the magnetic pickup Check for signs of wear and contaminants 2 Clean the metal shavings and other debris from the face of the magnet 3 Install the magnetic pickup and adjust the magnetic pickup Refer to the Service Manual for the installation proc
23. and the exhaust outlet piping to the turbocharger housing 100632301 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water Ensure that cooling lines are properly clamped and tight Check for leaks Check the condition of all pipes e Inspect the water pump for coolant leaks Note The water pump seal is lubricated by coolant in the cooling sy
24. are too loose the belts will vibrate This vibration is enough to cause unnecessary wear on the belts and on the pulleys If the belts are too tight unnecessary stresses are placed upon the pulley bearings and upon the belts These stresses will shorten the life of the belts and of the pulley bearings If new belts are installed check the tension again after 30 minutes of engine operation at the rated rpm Replacement For applications that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched The additional load on the new belt could cause the new belt to break Refer to the Service Manual for more information on the procedures for the following topics belt removal and belt installation procedure 81 Maintenance Section Alternator and Fan Belts Inspect Adjust Replace 101492550 Battery Replace SMCS Code 1401 510 A WARNING Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite This can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced A WARNING The battery cables or the batteries should not be removed with the battery co
25. ary to drain enough coolant from the cooling system in order to add the Extender 3 Add Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities in the Maintenance Section for the capacity of the cooling system for your engine Refer to the Operation and Maintenance Manual Cooling System Specifications information for the Caterpillar ELC Extender additions 4 Clean the cooling system filler cap Inspect the cooling system filler cap gaskets Replace the cooling system filler cap if the cooling system filler cap gaskets are damaged Install the cooling system filler cap 101197583 Cooling System Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and cool Illustration 55 g00285520 Cooling system filler cap A WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly in order to relieve pressure 2 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe If the engine is equipped with a sight glass maintain the coolant level to the proper level in the sight glass Illustration
26. at 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 2 Refer to the Operation and Maintenance Manual for more information on lubricant specifications Fill the crankcase with the proper amount of oil Refer to the Operation and Maintenance Manual for more information on refill capacities NOTICE If equipped with an auxiliary oil filter system or a re mote oil filter system follow the OEM or filter manu facturer s recommendations Under filling or overfilling the crankcase with oil can cause engine damage NOTICE To prevent crankshaft bearing damage crank the en gine with the fuel OFF This will fill the oil filters before starting the engine Do not crank the engine for more than 30 seconds 2 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oi
27. bar leds 81 Battery Electrolyte Level Check 82 Cooling System Supplemental Coolant Additive SCA Test Add sssssssesss 87 Engine Crankcase Breather Clean 95 Engine Oil Sample Obtain sss 96 Engine Oil and Filter Change 97 Fan Drive Bearing Lubricate 99 Fuel System Primary Filter Water Separator Element Fieplace oii ale eec aets 102 Fuel System Secondary Filter Replace 103 Fuel Tank Water and Sediment Drain 105 Hoses and Clamps Inspect Replace 105 Radiator Clean ssssssseeeeeene 110 Every 34 000 L 9000 US gal of Fuel or 1000 Service Hours Fuel Control Linkage Check Lubricate 99 Every 67 000 L 18 000 US gal of Fuel or 2000 Service Hours Crankshaft Vibration Damper Inspect 88 79 Maintenance Section Maintenance Interval Schedule Engine Mounts Inspect sseseesssss 95 Engine Valve Lash Inspect Adjust 98 Engine Valve Rotators Inspect 99 Fuel Injection Nozzles Test Exchange 100 Fuel Ratio Control Inspect Adjust 101 Turbocharger Inspect seeesssesss 111 Every 91 000 L 24 000 US gal of Fuel or 3000 Service Hours
28. ch contains a copy of the following literature e this manual e the Generator Operation and Maintenance Manual i01108937 Engine Clean SMCS Code 1000 070 A WARNING Personal injury or death can result from high volt age Moisture could create paths of electrical conduc tivity Make sure the unit is off line disconnected from utility and or other generators locked out and tagged Do Not Operate NOTICE Water or condensation can cause damage to gen erator components Protect all electrical components from exposure to water NOTICE Accumulated grease and oil on an engine is a fire haz ard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumulates on the engine Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits e Fasy detection of fluid leaks e Maximum heat transfer characteristics e Ease of maintenance Note For more information on cleaning and drying electric generators refer to Special Instruction SEHS9124 Cleaning and Drying of Electric Set Generators i01397558 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 prematur
29. cks 3 Fill the cooling system with clean water Install the cooling system filler cap 85 Maintenance Section Cooling System Coolant ELC Change 4 Start 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 valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with Extended Life Coolant ELC Refer to the Operation and Maintenance Manual Cooling System Specifications topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rom to high idle Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch
30. dicator 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 i00972776 Engine Crankcase Breather Clean SMCS Code 1317 070 NOTICE Perform this maintenance with the engine stopped If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage g00495506 Illustration 65 1 Bolt 2 Hose clamp 3 Breather assembly 4 Seal 1 Loosen hose clamp 2 and remove the hose from breather assembly 3 2 Remove bolt 1 Remove breather assembly 3 and seal 4 95 Maintenance Section Engine Crankcase Breather Clean 3 Wash the breather element in solvent that is clean and nonflammable Allow the breather element to dry before installation 4 Install a breather element that is clean and dry Install seal 4 and breather assembly 3
31. e wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air cleaner element e Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element e The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected e The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Dual Element Air Cleaner
32. ear Never use both liquid supplemental coolant additive and the spin on element if equipped at the same time The use of those additives together could result in supplemental coolant additive concen tration exceeding the recommended maximum A WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Slowly loosen the cooling system filler cap in order to relieve the pressure Remove the cooling system filler cap 88 Maintenance Section Cooling System Water Temperature Regulator Replace Note Always discard drained fluids according to local regulations 2 f necessary drain some coolant from the cooling System into a suitable container in order to allow space for the extra SCA 3 Add the proper amount of SCA Refer to the Operation and Maintenance Manual for more information on SCA requirements 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets are damaged replace the old cooling system filler cap with a new cooling system filler cap Install the cooling system filler cap 100912898 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a
33. edure 101090308 Overhaul Considerations SMCS Code 7595 043 Reduced hours of operation at full load will result in a lower average power demand A decreased average power demand should increase both the engine service life and the overhaul interval The need for an overhaul is generally indicated by increased fuel consumption and by reduced power The following factors are important when a decision is being made on the proper time for an engine overhaul e The need for preventive maintenance e The quality of the fuel that is being used e The operating conditions e The results of the S O S analysis Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank 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 ID 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 t
34. formation about damper replacement Visconic Damper Your engine may be equipped with a visconic damper The visconic damper has a weight that is located inside a fluid filled case The weight moves in the case in order to limit torsional 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 e The damper is dented cracked or leaking e The paint on the damper is discolored from heat e The engine has had a failure because of a broken crankshaft e Analysis of the oil has revealed that the front main bearing is badly worn e There is a large amount of gear train wear that is not caused by a lack of oil Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement 89 Maintenance Section Enclosure Inspect i01480884 Enclosure Inspect SMCS Code 7263 040 7274 040 NOTICE Do not spray or splash water into the generator air inlet or exhaust openings Ensure that the openings are covered in order to prevent water from entering the electrical windings and bear
35. gers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check the condition of the gauges Replace any gauges which are cracked or can not be calibrated 101057943 Water Pump Inspect SMCS Code 1361 040 1361 A failed water pump might cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure e Other potential damage to the engine 113 Maintenance Section Water Pump Inspect 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
36. hat 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 105 Maintenance Section Fuel Tank Water and Sediment Drain This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in 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 100907072 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 fi
37. he fuel system 100073301 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive fuel system wear Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Check the fuel daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines t
38. ice indicator 91 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace Cleaning the Primary Air Cleaner Elements 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 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 four common methods that are used to clean primary air cleaner elements e Pressurized water e Pressurized air e Vacuum cleaning e Washing with nonsudsing detergent Pressurized Water Pressurized water will clean the primary air cleaner element unless carbon and oil have accumulated on the surface of the primary air cleaner element The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi
39. iminated e Engine performance is not affected A fuel injection nozzle that is suspected of being defective should be removed A new fuel injection nozzle should be installed in the cylinder in order to determine if the removed fuel injection nozzle is defective Removal and Installation of the Fuel Injection Nozzles For the removal and the installation of fuel injection nozzles special tooling is required Refer to the Service Manual for more information Consult your Caterpillar dealer for assistance 100908934 Fuel Ratio Control Inspect Adjust SMCS Code 1278 025 1278 040 Slow engine response and low power may indicate a need for adjustment or repair of the fuel ratio control Refer to the Service Manual or your Caterpillar dealer for the complete adjustment procedure on the fuel ratio control 100976042 Fuel System Prime SMCS Code 1258 548 Prime the fuel system in order to fill dry fuel filters and purge air from the fuel system Prime the fuel system after the following occurrences e Running the fuel system dry e Removal of the engine from storage e Maintenance of the fuel filter e Disconnecting fuel lines and installing fuel lines e Repair of leaks in the fuel lines A WARNING Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel s
40. ing Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oll Note Refer to Inspecting the Primary Air Cleaner Elements Washing the Primary Air Cleaner Elements with Nonsudsing Detergent A WARNING Do not wash air cleaner elements in any flammable solution such as diesel fuel or gasoline Doing so can cause fire or an engine runaway and can result in personal injury Washing with nonsudsing detergent is effective for cleaning primary air cleaner elements that have deposits of carbon or oil Use a cleaning agent that is specifically manufactured for cleaning primary air cleaner elements Cleaning with pressurized water pressurized air or a vacuum is recommended prior to washing with nonsudsing detergent 1 Place the primary air cleaner element into a wash tank so that the gasket is up The wash tank should be equipped with a rack so that the primary air cleaner element does not sit on the bottom of the wash tank Note Caterpillar does not recommend washing the element with a process of agitation Agitation may cause carbon particles to be distributed 2 Fill the wash tank with the cleaning agent and warm water to a maximum temperature of 60 C 140 F Follow the manufacturers recommendations for the clea
41. ings The interior of the enclosure package and the exterior of the enclosure package should be kept clean Wash the interior of the enclosure package and the exterior of the enclosure package with soap and water Ensure that the air discharge for the exhaust duct is clear Clean debris twigs and leaves away from the enclosure package as needed Lubricate the hinges on the door as needed Use Caterpillar Multipurpose Lithium Complex Grease MPGL If Caterpillar Multipurpose Lithium Complex Grease MPGL is not available use a similar multipurpose grease Note Only chrome hinges require lubrication Powder black door hinges do not require lubrication i im i d 900770940 Illustration 57 Screws for the door hinge Adjust the door hinges as required Visually check the alignment of the door Use the following steps to adjust the alignment of the door 1 Loosen the screws on the door hinge 2 Reposition the door so that the door is square within the door frame 3 Tighten the screws on the door hinge 90 Maintenance Section Engine Clean Check the door seal Adjust the closure fit of the door against the gasket seal Bend the door handle catch loop inward This will tighten the door against the gasket seal Bend the door handle catch loop outward This will loosen the door against the gasket seal The literature pouch is located near the operator console Ensure that the literature pou
42. ket areas on the external cooling system but the concentrations of coolant additives were carefully maintained The coolant water probably contained minerals that were deposited on the engine over time A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system A full water analysis can be obtained by consulting your local water utility company or an agricultural agent Private laboratories are also available for water analysis Caterpillar Inc recommends an S O S Coolant Analysis Level Il S O S Coolant Analysis Level Il An S O S Coolant Analysis Level Il is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system An S O S Coolant Analysis Level II provides the following information e Complete S O S Coolant Analysis Level 1 e Visual inspection of properties e dentification of metal corrosion e Identification of contaminants e Identification of built up impurities corrosion and scale S O S Coolant Analysis Level Il provides a report of the results of both the analysis and the maintenance recommendations 110 Maintenance Section Radiator Clean For more information about coolant analysis see your Caterpillar dealer 101206548 Radiator Clean SMCS Code 1353 070 Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the radiator fo
43. l leaks 3 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes 4 Remove the oil level gauge 4 in order to check the oil level Maintain the oil level between the ADD and FULL marks on the oil level gauge 100869628 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 A WARNING Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clea
44. ltered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts 4 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 for an additional 3 4 turn by hand Do not overtighten the filter i00909035 Fuel System Water Separator Drain SMCS Code 1263 543 A WARNING Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Illustration 77 900467033 1 Vent valve Base Can Element 5 Drain plug AUN Water in the fuel can cause fuel system components to fail Drain the water separator daily Drain the water separator more frequently when a large concentration of water is present in the fuel system 1 Close the fuel supply valve NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 2 Remove drain plug 5 Depress vent valve 1 in order to start the flow Allow the water to drain into a suitable container Allow the water to flow until fuel flows from the drain 3 Install the drain plug Dispose of the liquid properly 4 Open the fuel supply valve 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 t
45. m the Operation and Maintenance Manual Engine Air Precleaner Check Clean procedure if equipped before performing the following procedure NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine 94 Maintenance Section Engine Air Cleaner Service Indicator Inspect Illustration 62 900310663 Illustration 63 900310664 1 Remove the air cleaner cover 1 and remove the element 2 2 Seal the turbocharger air inlet 3 so that debris cannot enter the air inlet Tape or a clean cloth can be used to cover the opening 3 Clean the inside of the air cleaner cover Clean the body that holds the air cleaner element 4 Inspect the replacement element for the following items damage dirt and debris 5 Remove the seal from the opening of the turbocharger inlet 6 Install a clean undamaged element 7 Install the air cleaner cover 1 8 Reset the service indicator i01175055 Engine Air Cleaner Service Indicator Inspect SMCS Code 7452 040 Some engines may be equipped with a differen
46. may be opened with a comb Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary For more detailed information on cleaning and inspection see Special Publication SEBD0518 Know Your Cooling System i00651416 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar Inc recommends a scheduled inspection of the starting motor If the starting motor fails the engine may not start in an emergency situation Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance i01501634 Trailer Inspect SMCS Code 6331 040 Maintenance For Tires Explosive separation of a tire and or rim parts can cause serious injury or death Always follow the manufacturer s recommendations or refer to the tire supplier Always maintain the correct tire pressure Inflate the tires according to the tire manufacturer s instructions Do not inflate the tires above the tire manufacturer s recommended pressure Inspect the tires and wheels prior to moving the trailer package Do not tow the package if the following conditions exist e The tire pressure is too high e The tire pressure is too low e A tire has cuts or bubbles e A tire has exces
47. mmends 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 100841051 Alternator and Fan Belts Inspect Adjust Replace SMCS Code 1357 039 Inspection To maximize the engine performance inspect the belts for wear and for cracking Check the belt tension Adjust the belt tension in order to minimize belt slippage Belt slippage will decrease the life of the belts To check the belt tension apply 110 N 25 Ib of force midway between the pulleys A correctly adjusted belt will deflect 13 to 19 mm 0 50 to 0 75 inch Adjustment If the belts
48. nd Maintenance Manual Torque Specifications topic Maintenance Section for more 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 Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques 84 Maintenance Section Cooling System Coolant ELC Change NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the cooling system filler cap 4 Start and run the engine at low idle for a minimum of 90 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 5 S
49. ngine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartridge must be balanced due to high rpm Severe Service Applications can accelerate component wear Severe Service Applications require more frequent inspections of the cartridge 112 Maintenance Section Walk Around Inspection Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing
50. ngine fails This will provide you with the best cost value relationship Note Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life If an overhaul is performed without overhaul service from your Caterpillar dealer be aware of the following maintenance recommendations 108 Maintenance Section Overhaul Considerations Rebuild or Exchange Cylinder Head Assembly Cylinder Packs Oil Pump and Fuel Transfer Pump These components should be inspected according to the instructions that are found in various Caterpillar reusability publications The Special Publication SEBF8029 lists the reusability publications that are needed for inspecting the engine parts If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline the parts should be reused Parts that are not within the established inspection specifications should be dealt with in one of the following manners e Salvaging e Repairing e Replacing Using out of spec parts can result in the following problems e Unscheduled downtime e Costly repairs e Damage to other engine parts e Reduced engine efficiency e Increased fuel consumption Reduced engine efficiency and increased fuel consumption tra
51. ning agent Allow the primary air cleaner element to soak for six hours 3 Drain the wash tank Do not use the cleaning agent more than one time Remove the primary air cleaner element from the wash tank Rinse the primary air cleaner element with the method for using pressurized water Note Refer to Drying the Primary Air Cleaner Elements Refer to Inspecting the Primary Air Cleaner Elements Drying the Primary Air Cleaner Elements The oven method may be used in order to dry primary air cleaner elements If an oven is used do not expose the primary air cleaner elements to temperatures that exceed 82 C 160 F Note Do not use compressed air in order to dry the primary air cleaner elements Primary air cleaner elements may be allowed to air dry Allow two days for the primary air cleaner elements to air dry before the elements are inspected and installed 93 Maintenance Section Engine Air Cleaner Element Single Element Inspect Replace Inspecting the Primary Air Cleaner Elements Illustration 60 900281693 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
52. nslates into higher operating costs Therefore Caterpillar Inc recommends repairing out of spec parts or replacing out of spec parts Inspection and or Replacement Crankshaft Bearings Valve Rotators and Crankshaft Seals The following components may not last until the second overhaul e Thrust bearings e Main bearings e Rod bearings e Valve rotators e Crankshaft seals Caterpillar Inc recommends the installation of new parts at each overhaul period Inspect these parts while the engine is disassembled for an overhaul Inspect the crankshaft for any of the following conditions e Deflection e Damage to the journals e Bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the following components e Rod bearing e Main bearings Note If the crankshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the crankshaft 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
53. o 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 107 Maintenance Section Overhaul Considerations Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons e Costly unplanned downtime can be avoided e Many original parts can be reused according to the standards for reusable parts e The engine s service life can be extended without the risk of a major catastrophe due to engine failure e The best cost value relationship per hour of extended life can be attained After Failure Overhaul If major engine failure occurs and the engine must be removed from the hull many options are available An overhaul should be performed if the engine block or the crankshaft needs to be repaired If the engine block is repairable and or the crankshaft is repairable the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core This lower cost can be attributed to three aspects e Specially designed Caterpillar engine features e Caterpillar dealer exchange components e Caterpillar Inc remanufactured exchange components Overhaul Recommendation To minimize downtime Caterpillar Inc recommends a scheduled engine overhaul by your Caterpillar dealer before the e
54. 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 battery disconnect switch to the OFF position and remove the key and all electrical loads 2 Disconnect the negative battery terminal at the battery that goes to the start switch Ensure that the cable cannot contact the terminal When four 12 volt batteries are involved the negative side of two batteries must be disconnected 3 Tape the leads in order to help prevent accidental starting 4 Proceed with necessary system repairs Reverse the steps in order to reconnect all of the cables i01206425 Cooling System Coolant DEAC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling System before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated NOTICE Use of commercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines
55. pills 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 Unlock and operate the priming pump plunger until a resistance is felt This may require a considerable number of strokes 2 Push in and hand tighten the priming pump plunger 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 101 Maintenance Section Fuel Ratio Control Inspect Adjust 3 Start the engine The engine may run rough Run the engine at low idle until the engine runs smoothly If the following conditions exist repeat Steps 1 through 3 e The engine will not start e The engine starts but the engine continues to misfire e The engine starts but the engine continues to smoke If operating problems persist after repeating Steps 1 through 3 proceed to Step 4 900502366 Illustration 73 1 Vent plug 2 Fuel injection pump housing NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 4 Loosen vent plug 1 on fuel injection pump housing 2 5 Unlock and operate the priming pump plunger until the flow of fuel from the vent valve is con
56. r these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the radiator if necessary A WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both sides of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water After cleaning start the engine and accelerate the engine to high idle rom This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins
57. rance Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this maintenance is performed Refer to the Service Manual for more information 100937014 Engine Valve Rotators Inspect SMCS Code 1109 040 A WARNING When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to help prevent being burned by hot oil or spray NOTICE A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life If a damaged rotator is not replaced valve face guttering could result and cause pieces of the valve to fall into the cylinder This can cause piston and cylinder head damage Valve rotators cause the valves to rotate when the engine runs This helps to prevent deposits from building up on the valves and the valve seats Perform the following steps after the valve lash is set but before the valve covers are installed 99 Maintenance Section Engine Valve Rotators Inspect 1 Start the engine according to this Operation and Maintenance Manual Engine Starting procedure Operation Section Operate the engine at low idle 2 Observe the top surface of each valve rotator The valve rotators should turn slightly when the valves close If a valve fails to rotate consult your Caterpillar dealer i01423301 Fan Drive Bearing Lubricate
58. revent the battery from freezing If batteries are properly charged ammeter reading should be very near zero A WARNING All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 1U 7298 Coolant Battery Tester C or the 1U 7297 Coolant Battery Tester F 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 L 0 11 qt of baking soda and 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 grease i01501560 Battery or Battery Cable Disconnect SMCS Code 1402 029 A WARNING The battery cables
59. s 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 58 900736431 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 Filter 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 new or cleaned 6 Install the air cleaner cover 7 Reset the serv
60. s 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 3 with a 1U 8760 Chain Wrench 2 Cut the oil filter open with a 40 5084 Oil Filter Cutter Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure 98 Maintenance Section Engine Valve Lash Inspect Adjust 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 Parts that may be affected include the following items main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter Illustration 70 900103713 Typical filter mounting base and filter gasket 3 Clean the sealing surface of the filter mounting base Ensure th
61. s above the FULL mark could cause your crankshaft to dip into the oil The air bubbles created from the crankshaft dipping into the oil reduces the oil s lubricating char acteristics and could result in the loss of power 2 Remove the oil filler cap and add oil if necessary Clean the oil filler cap Install the oil filler cap Engine Oil Sample Obtain SMCS Code 1000 008 1348 554 SM 7542 554 OC SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine Obtain the Sample and the Analysis A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using
62. sive wear e The rims are damaged e Lug bolts or nuts are missing Maintain the proper torque on the lug nuts of the wheels Torque the lug nuts to 129 N m 95 Ib ft Tire pressure will rise during towing This is a normal condition and tire pressure should not be reduced High speeds during transporting may produce excessive tire pressures due to heat Never purge the air from the tires The tires can be cooled by REDUCING THE TOWING SPEED of the package or by stopping the package Adjust the tire pressure from a distance Use a long hose with a self attaching chuck Always stand behind the tread when you adjust the tire pressure Do not inflate the tires with flammable gases or from systems that utilize an alcohol injector Maintenance For The Running Gear Refer to Dexter AxleTrailer Running Gear Operation Maintenance Service Form MM 2 for detailed information about the running gear the brakes the wheels the suspension the hubs and the bearings Inspect the wheel bearings Check the lubrication level of the wheel bearings Fill the wheel bearings only with Multipurpose Lithium Complex Grease MPGL Do not overfill the wheel bearings Inspect the running gear for damage and wear Bi Illustration 80 900778939 Check the battery for the breakaway switch and ensure that the battery is properly charged Check the battery charger that charges the battery for the breakaway switch The battery
63. sonal 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 o A 0 g00772697 LI Illustration 68 1 Oil drain plug 97 Maintenance Section Engine Oil and Filter Change 1 After the engine has been run at the normal operating temperature stop the engine Place a suitable container beneath the oil drain plug 1 in order to catch the draining oil Remove the oil drain plug Illustration 69 900772702 2 Oil filler cap 3 Oil filter 4 Oil level gauge dipstick 5 Oil drain valve 2 Open the oil drain valve 5 Allow the oil to drain 3 After the oil has drained close the oil drain valve Clean the oil drain plug and install the oil drain plug Replace the Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci fication
64. stem It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pump and the installation of water pump and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve cover e Inspect the fuel system for leaks Look for loose fuel line clamps e Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps e Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for 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 engine to frame ground strap for a good connection and for good condition Disconnect any battery char
65. t service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendations in order to service the air cleaner service indicator The service indicator may be mounted on the air cleaner element or in a remote location Illustration 64 900103777 Typical service indicator Observe the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three 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 in
66. t 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 ensure that all components are properly tightened 101484927 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE A WARNING Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately Illustration 76 g00772381 1 Fuel filter 104 Maintenance Section Fuel System Water Separator Drain 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 NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately NOTICE Do not loosen fuel lines or fittings at the fuel manifold or ECM The engine components may be damaged 1 Remove the used fuel filter 2 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 3 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 fi
67. the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 8T 9190 Fluid Sampling Bottle Group is recommended for use with the sampling valve The bottle group includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Do not use the same vacuum sampling pump for ex tracting oil samples that is used for extracting coolant samples A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken Always use a designated pump for oil sampling and a designated pump for coolant sampling Failure to do so may cause a false analysis which could lead to customer and dealer concerns 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 101486293 Engine Oil and Filter Change SMCS Code 1318 510 1348 044 A WARNING Hot oil and hot components can cause per
68. tinuous and free of air bubbles 6 Tighten the vent plug Clean up any spilled fuel immediately 7 Push in and hand tighten the priming pump plunger 102 Maintenance Section Fuel System Primary Filter Water Separator Element Replace 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 8 Start the engine The engine may run rough Run the engine at low idle until the engine runs smoothly Proceed to Step 9 if the following conditions exist e The engine will not start e The engine starts but the engine continues to misfire e The engine starts but the engine continues to smoke 900496813 Illustration 74 NOTICE Do not let the tops of fuel nozzles turn when the fuel line nuts are loosened or tightened The nozzles will be damaged if the top of the nozzle turns in the body The engine will be damaged if a defective fuel injec tion nozzle is used because the shape of fuel spray pattern that comes out of the nozzles will not be cor rect NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 9 Loosen one fuel injection line nut at the fuel injection nozzle 10 Unlock and operate the priming pump plunger until the flow of fuel from the fuel injection line is continuous and free of air bubbles 11 Tighten the fuel injection line nut Refer to
69. tip wear Tip wear is a result of fuel contamination Tip wear can cause the following problems e Increased fuel consumption e Black smoke e Misfire e Rough running Fuel Injection nozzles should be cleaned inspected tested and replaced if necessary Refer to Special Instruction SEHS7292 for using the 8S 2245 Injection Cleaning Tool Group Consult your Caterpillar dealer about cleaning the fuel injection nozzle and testing the fuel injection nozzle NOTICE Never wire brush or scrape a fuel injection nozzle Wire brushing or scraping a fuel injection nozzle will damage the finely machine orifice Proper tools for cleaning and testing the fuel injection nozzles can be obtained from Caterpillar dealers The following items are symptoms of a malfunction of the fuel injection nozzle e Abnormal engine operation e Smoke emission e Engine knock Each fuel injection nozzle must be isolated one at a time in order to determine the malfunctioning fuel injection nozzle 1 Start the engine 2 Loosen each fuel line nut one at a time at the fuel injection pump A cloth or similar material must be used in order to prevent fuel from spraying on the hot exhaust components Tighten each nut before loosening the next nut 3 A defective fuel injection nozzle may be identified when a fuel line nut is loosened and the following conditions are present e The exhaust smoke is partially eliminated or the exhaust smoke is completely el
70. top the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze Refer to the Operation and Maintenance Manual Cooling System Specifications topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rom to 1500 rpm Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on
71. ttings 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 106 Maintenance Section Magnetic Pickups Clean Inspect Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Replace the Hoses and the Clamps A WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop 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 cle
72. ug 5 Depress vent valve 1 in order to start the flow of fuel Allow the fuel to drain into a suitable container Dispose of the fuel properly 3 Install the drain plug 4 Remove can 3 from base 2 5 Remove element 4 from the can Dispose of the used element 6 Remove the gasket Clean the following components e Can e Gasket e Base Inspect the gasket for damage and for deterioration Replace the gasket if necessary 7 Install the gasket Lubricate the gasket with clean diesel fuel 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 8 Install a new element in the can The can may be filled with fuel at this time 103 Maintenance Section Fuel System Secondary Filter Replace 9 Install the can on the base Tighten the can by hand Do not use tools in order to tighten the can NOTICE The water separator is under suction during normal engine operation Ensure that the vent plug is tight ened securely to help prevent air from entering the fu el system 10 Open the main fuel supply valve 11 Start the engine and check for leaks Run the engine for one minute Stop the engine and check for leaks again Leaks are difficult to detec
73. ver 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 Turn the key start switch to the OFF position Remove the key and all electrical loads N Turn OFF the battery charger Disconnect the charger The NEGATIVE cable connects the NEGATIVE battery terminal to the ground plane Disconnect the cable from the NEGATIVE battery terminal A The POSITIVE cable connects the POSITIVE battery terminal to the starting motor Disconnect the cable from the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Return used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before the cables are connected ensure that the key start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 82 Maintenance Section Battery Electrolyte Level Check 8 Connect the cable from the ground plane to the NEGATIVE battery terminal 101206348 Battery Electrolyte Level Check SMCS Code 1401 535 When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help p

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