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C11, C13 and C15 ON-HIGHWAY ENGINES - Safety

1. 107 PM Level 2 Every 320 000 km 200 000 miles or 125 000 L 33 000 US gal of Fuel or 4000 Service Hours or 2 Years Aftercooler Core Clean Test ssssss 75 Cooling System Coolant DEAC Change 80 Cooling System Water Temperature Regulator joe Em 86 Fan Drive Bearing Lubricate 100 Radiator Clean sesseee 106 PM Level 3 Every 483 000 km 300 000 miles or 190 000 L 50 000 US gal of Fuel or 6000 Service Hours or 3 Years Air Compressor Inspect ssssssssssss 75 Compression Brake Inspect Adjust Replace 78 Cooling System Coolant Extender ELC Add 83 Crankshaft Vibration Damper Inspect 87 Electronic Unit Injector Inspect Adjust 89 Engine Clear riu coepti ies 89 Engine Valve Lash Inspect Adjust 99 Turbocharger Inspect sssesesss 107 Valve Actuators Inspect Adjust 107 PM Level 4 Every 966 000 km 600 000 miles or 380 000 L 100 000 US gal of Fuel or 12 000 Service Hours or 6 Years Compression Brake Inspect Adjust Replace 78 Cooling System Coolant ELC Change 82 72 Maintenance Section Maintenance Interval Schedule SEBU7695 13 103636093 Maintenance Interval Schedule C11 and C13 Engines with 500 HP Field Up Rates and 525 HP RV Ratings with S
2. Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Your water separator may look like one of the following water separators 104 Maintenance Section Fuel Tank Water and Sediment Drain SEBU7695 13 Type 1 Illustration 62 1 Bowl 2 Element The bowl should be monitored daily for signs of water If water is present drain the water from the bowl 1 Open the drain The drain is a self ventilated drain Catch the draining water in a suitable container Dispose of the water properly 2 Close the drain NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system Type 2 Illustration 63 901451247 4 Element 5 Spring 6 Drain Compress the spring in order to drain the water from the filter Catch the draining water in a suitable container Dispose of the water properly g01451240 3 Drain 103071053 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepa
3. Belt Tensioner Inspect SMCS Code 1358 040 It is essential to check the position of the belt tightener in order to maintain the proper belt tension A film decal is located on the side of the belt tightener The decal indicates when the belts have stretched beyond the belt tightener s ability Illustration 47 g01526739 Side view of the belt tensioner If the pointer 1 is in green zone 3 the belt tension is correct If the pointer 1 is in the upper red zone 2 the belt has stretched The tension must be adjusted or the belt must be replaced If the pointer 1 is in the lower red zone 4 the belt is too short The belt must be replaced 101426993 Compression Brake Inspect Adjust Replace SMCS Code 1119 025 1119 040 1119 510 S N BXS1 Up S N RKS1 Up The maintenance of the compression brake should be performed in conjunction with scheduled engine maintenance The correct tune up kit is required when parts are replaced on the compression brake Refer to the Parts Manual for additional information SEBU7695 13 79 Maintenance Section Compression Brake Inspect Adjust Replace Note The slave piston lash adjustment must be performed after the engine valve lash adjustment is performed Make the slave piston adjustment while the engine is stopped Refer to the Systems Operation Testing and Adjusting Module for additional infor
4. Inspect Adjust 99 Turbocharger Inspect seeeesess 107 Valve Actuators Inspect Adjust 107 74 Maintenance Section Maintenance Interval Schedule SEBU7695 13 PM Level 4 Every 966 000 km 600 000 miles or 380 000 L 100 000 US gal of Fuel or 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 82 SEBU7695 13 75 Maintenance Section Aftercooler Core Clean Test 101807350 Aftercooler Core Clean Test Air To Air Aftercooler SMCS Code 1064 070 1064 081 The air to air aftercooler is OEM installed in many applications Please refer to the OEM specifications for information that is related to the aftercooler 102413116 Air Compressor Inspect SMCS Code 1803 040 Do not disconnect the air line from the air com pressor governor without purging the air brake and the auxiliary air systems Failure to purge the air brake and the auxiliary air systems before re moving the air compressor and or the air lines could cause personal injury Illustration 44 g01206109 Typical example 1 Pressure relief valve If the air compressor pressure relief valve that is mounted in the air compressor cylinder head is bypassing compressed air there is a malfunction in the air system possibly ice blockage Under these conditions your engine may have insuffi cient air
5. SMCS Code 7554 040 7554 510 Inspect all hoses for leaks that are caused by the following conditions e Cracking e Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings 106 Main
6. 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 Note If equipped be sure to flush the heater and any related supply and return lines 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with clean water Install the cooling system filler cap 4 Start and run the engine at low idle until the 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 Specifications Manual SENR3130 Torque Specifications 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
7. 91 Fuel System Primary Filter Replace 102 Fuel System Secondary Filter Replace 102 Fuel Tank Water and Sediment Drain 104 Hoses and Clamps Inspect Replace 105 PM Level 1 Every 48 000 km 30 000 miles or 17 400 L 4600 US gal of Fuel or 600 Service Hours Fuel System Primary Filter Replace 102 Between 24 000 and 96 000 km 15 000 and 60 000 miles Electronic Unit Injector Inspect Adjust 89 Engine Valve Lash Inspect Adjust 99 Valve Actuators Inspect Adjust 107 PM Level 2 Every 320 000 km 200 000 miles or 125 000 L 33 000 US gal of Fuel or 4000 Service Hours or 2 Years Aftercooler Core Clean Test ssssss 75 Cooling System Coolant DEAC Change 80 Cooling System Water Temperature Regulator Replace eth tees tanc o ie RIA 86 Fan Drive Bearing Lubricate 100 Radiator Clean sssssseee 106 PM Level 3 Every 483 000 km 300 000 miles or 190 000 L 50 000 US gal of Fuel or 6000 Service Hours or 3 Years Air Compressor Inspect esssssessss 75 Cooling System Coolant Extender ELC Add 83 Crankshaft Vibration Damper Inspect 87 Electronic Unit Injector Inspect Adjust 89 Engine Clean eerte be eels 89 Engine Valve Lash
8. Calibrate 92 Fuel System Prime ssssseeeeee 100 Severe Service Application Check 106 Daily Cooling System Coolant Level Check 84 Engine Air Cleaner Service Indicator Inspect 90 Engine Oil Level Check ssesssss 92 Fuel System Water Separator Inspect Drain 103 Walk Around Inspection seesssssss 108 Every 32 000 km 20 000 miles or 9464 L 2500 US gal of Fuel or 300 Service Hours Engine Oil Sample Obtain ssssse 94 Engine Oil and Filter Change 95 PM Level 1 Every 48 000 km 30 000 miles or 15 520 L 4100 US gal of Fuel or 500 Service Hours Air Compressor Filter Clean Replace 75 Air Shutoff Test sessssssssssssseeees 75 Alternator Inspect sssssseeeeeeeees 76 Battery Electrolyte Level Check 77 B lt Inspect idos eas aeaaeae aar akai 77 Belt Tensioner Inspect ceceeeeeeeeeeeeteees 78 Cooling System Supplemental Coolant Additive SCA Test Add sess 85 Cylinder Head Grounding Stud Inspect Clean Tighiten iiie an eei be t eee e ad eode 88 Engine Crankcase Breather Clean 91 Fuel System Primary Filter Replace 102 Fuel System Secondary Filter Replace 102 Fuel T
9. Level 2 OD ain oid moet 85 Crankshaft End Play Test ssssessss 86 Engine Air Cleaner Element Clean Replace 90 Engine Oil Level Gauge Calibrate 92 Fuel System Prime ssssseeeeeee 100 Severe Service Application Check 106 Daily Cooling System Coolant Level Check 84 Engine Air Cleaner Service Indicator Inspect 90 Engine Oil Level Check ssssessss 92 Fuel System Water Separator Inspect Drain 103 Walk Around Inspection suuesssssss 108 Every 32 000 km 20 000 miles or 9464 L 2500 US gal of Fuel or 300 Service Hours Engine Oil Sample Obtain ssssse 94 Engine Oil and Filter Change 95 PM Level 1 Every 48 000 km 30 000 miles or 15 520 L 4100 US gal of Fuel or 500 Service Hours Air Compressor Filter Clean Replace 75 Air Shutoff Test esses 75 Alternator Inspect ssssssseseeeeese 76 Battery Electrolyte Level Check 77 B lt Inspectii eaae aaaea 77 Belt Tensioner Inspect cceeceeeeeeeeeeeeeees 78 Cooling System Supplemental Coolant Additive SCA Test Add s i aas 85 Cylinder Head Grounding Stud Inspect Clean Tighiter iiie nee be eee ce A det 88 Engine Crankcase Breather Clean
10. Hours or 6 Years Cooling System Coolant ELC Change 82 SEBU7695 13 73 Maintenance Section Maintenance Interval Schedule 103636084 Maintenance Interval Schedule C11 and C13 Engines with Optional Shallow Oil Sumps SMCS Code 1000 7500 SIN KCA1 Up SIN KCB1 Up SIN JAM1 Up Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Battery Replace sss 76 Battery or Battery Cable Disconnect 77 Cooling System Coolant Sample Level 1 eec MERE 84 Cooling System Coolant Sample
11. Severe Service Operation Check or consult with your Cat dealer in order to determine whether your engine is operating under severe service conditions Fuel consumption and oil consumption are the most important factors that are used in order to calculate an oil change interval All engines do not consume fuel and oil at the same rate due to several factors manufacturing tolerances maintenance variations and engine application Extended Oil Change Intervals Requirements for Use of Extended Oil Change Intervals The following requirements must be met in order to use Tables 34 35 and 36 e Cat DEO ULS is used or an oil that meets the requirements of the Caterpillar ECF 3 Engine Crankcase Fluid specification 3 specification is used SEBU7695 13 97 Maintenance Section Engine Oil and Filter Change e S O S Services oil analysis is performed at 16 100 km 10 000 mile intervals and all oil change intervals The S O S Services lab must be notified of the extended oil change interval The use of an extended oil change interval makes a difference in the interpretation of the data e A Cat High Efficiency Fuel Filter is used e Fuel with 0 05 500 ppm or less sulfur is used NOTICE Contact your Caterpillar dealer for more information about extended oil change intervals Note Caterpillar cannot guarantee the performance of lubricants or filters that are not sold by Caterpillar The performance guarantee
12. The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is needed when the ELC is drained and replaced Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove the cooling system drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools Group Outside Illinois
13. 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 that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank during the following conditions e Weekly Oil change e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank A four micron c absolute filter for the breather vent on the fuel tank is also recommended Refer to Special Publication SENR9620 Improving Fuel System Durablity 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 102121526 Hoses and Clamps Inspect Replace
14. primed in the following circumstances e The engine runs out of fuel e The secondary fuel filter is replaced If the engine runs out of fuel take the following steps before you prime the engine 1 Turn the ignition to the OFF position 2 Fill the fuel tank with clean diesel fuel Note Refer to Operation and Maintenance Manual Fuel System Secondary Filter Replace for information on replacing the filter Using the Engine to Prime the Fuel System 1 Turn the ignition switch to the OFF position 2 Unlock the fuel priming pump if equipped by turning the cap counterclockwise 3 Purging air from the fuel system requires the air purge screw to be opened Turn the air purge screw counterclockwise by three full turns Do not remove the screw 4 Turn the ignition switch to the ON position 5 Crank the engine for 30 seconds Use a suitable container to catch the fuel while you crank the engine Allow the starting motor to cool for two minutes Note Most of the air should be purged from the system after four or five cranking cycles 6 Repeat Step 5 until the engine starts and runs If the engine runs rough continue to operate the engine at low idle until the engine runs smoothly 7 Observe the air purge screw When a small drop of fuel appears at the threads of the air purge screw close the air purge screw After the air purge screw is closed tighten the air purge screw Refer to Specifications SENR3130 fo
15. 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 96 Maintenance Section Engine Oil and Filter Change SEBU7695 13 Illustration 57 g00103713 3 Clean the sealing surface of the filter mounting base Ensure that all of the old oil filter gasket is removed 4 Apply clean engine oil to the new oil filter gasket NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 5 Install the new oil filter Tighten the oil filter until the oil filter gasket contacts the base Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Fill the Engine Crankcase 1 Remove the oil filler cap Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations topic for more information about selecting the correct engine oil and finding the correct refill capacity for your engine Fill the crankcase with the proper amount of engine oil NOTICE If equipped with an auxiliary oil filter or system extra oil must be added when filling the crankcase F
16. start switch to the OFF position Turn the ignition switch if equipped to the OFF position and remove the key and all electrical loads 2 Disconnect the negative battery terminal at the battery that goes to the start switch Ensure that the cable cannot contact the terminal When four 12 volt batteries are involved the negative side of two batteries must be disconnected 3 Tape the leads in order to help prevent accidental starting 4 Proceed with necessary system repairs Reverse the steps in order to reconnect all of the cables 102126625 Belt Inspect SMCS Code 1357 040 1357 1397 040 1397 Inspection Belt tension should be checked initially between the first 20 to 40 hours of engine operation After the initial check the belt tension should be checked at Every PM Level 1 or Three Months To maximize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged For applications that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched The additional load on the new belt could cause the new belt to break 78 Maintenance Section Belt Tensioner Inspect SEBU7695 13 If the belts are too loose vibration causes unnecessary wear on the belts and pulleys Loose belts may slip enough to cause overheating If the belts are to
17. the correct 2 Check the oil level on the oil level gauge The oil amount of oil that should be poured into the level should be at the ADD mark If the oil level is crankcase Pour the correct amount of oil into the not at the existing ADD mark grind off the ADD crankcase mark and engrave the new ADD level 3 Pour 5 7 L 6 qt of oil into the crankcase Allow enough time for the oil to drain into the crankcase 94 Maintenance Section Engine Oil Sample Obtain SEBU7695 13 Table 33 Engine C11 or C13 C15 Oil Pan Shallow Deep Deep Standard Quantity of oil 3 5 L 3 7 qt 3 5 L 3 7 qt 5 5 L 5 8qt 1 Start the engine and run the engine enough to ensure that the lubrication system is filled Inspect the engine for oil leaks 2 Stop the engine and allow enough time for the oil to drain into the crankcase 3 Check the oil level on the oil level gauge If the oil level is not at the calibrated FULL mark fill the crankcase to the calibrated FULL mark Include the oil that was added in order to raise the level of oil to the FULL mark and record the oil capacity of the lubrication system for future oil changes 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 condi
18. C11 C13 and C15 ON HIGHWAY ENGINES Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU7695 13 2009 Caterpi 2009 cater CATERPILLAR 68 Maintenance Section Maintenance Recommendations SEBU7695 13 Maintenance Recommendations 102909163 System Pressure Release SMCS Code 1250 1300 1350 5050 Coolant System Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure To relieve the pressure from the coolant system turn off the engine Allow the cooling system pressure cap to cool Remove the cooling system pressure cap slowly in order to relieve pressure Fuel System To relieve the pressure from the fuel system turn off the engine High Pressure Fuel Lines If Equipped Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head These fuel lines are different from fuel lines on other fuel systems This is because of the following differences e The high pressure fuel lines are const
19. 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 Use the 4C 9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA Refer to the Special Publication SEBU6385 Caterpillar On highway Diesel Engine Fluid Recommendations for more information Add the SCA If Necessary NOTICE Do not exceed the recommended amount of sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temper ature components Excessive supplemental coolant additive concentration could also result in radiator tube blockage overheating and or accelerated water pump seal wear 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 86 Maintenance Section Cooling System Water Temperature Regulator Replace SEBU7695 13 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 co
20. In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant Complete the information on the label for the sampling bottle before you begin to take the samples Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination SEBU7695 13 85 Maintenance Section Cooling System Coolant Sample Level 2 Obtain e Never collect samples from expansion bottles e Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6385 Caterpillar On highway Diesel Engine Fluids Recommendations or consult your Caterpillar dealer 103085829 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Note Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations f
21. MPG 36287 kg 80000 Ib or less 37 7 L 39 8 qt Less than 20 Oil Classification Kilometers Miles Cat DEO ULS or an oil that meets the requirements of the Caterpillar ECF 3 specification 32 200 48 300 64 350 kilometers kilometers kilometers 20 000 miles 30 000 miles 40 000 miles 1 If the oil sump capacity is greater than the oil sump capacity that is listed in Table 35 the oil change interval can be extended 1600 kilometers 1000 miles for every 2 L 2 qt increase in oil sump capacity SEBU7695 13 99 Maintenance Section Engine Valve Lash Inspect Adjust Table 36 Maximum Permissible Oil Change Intervals for C15 On highway Engines with Deep Sumps Standard Severe Duty Normal Duty Light Duty Fuel Consumption 2 3 km L 5 5 Kilometers Per Liter L SS than MPG to 2 8 Greater than 2 3 km L 5 5 2 8 km L 6 5 Miles Per Gallon MPG km L 6 5 MPG MPG Gross Vehicle Weight More than 36287 kg 36287 kg 36287 kg 80000 Ib 80000 Ib 80000 Ib or less or less Minimum Oil Sump 37 7 L Capacity 37 7 L 39 8 qt 37 7 L 39 8 qt 39 8 qt Idle Time More than 20 to 40 Less than 40 20 Oil Classification Cat DEO ULS or an oil that meets the requirements of the Caterpillar ECF 3 specification 32 200 48 300 64 350 Kilometers Miles kilometers kilometers kilometers 20 000 miles 30 000 miles 40 000 miles 1 If the oil s
22. Manual Refill Capacities and Recommendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap SEBU7695 13 83 Maintenance Section Cooling System Coolant Extender ELC Add 2 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a 98 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 103085827 Cooling Syste
23. Per Liter Miles Per Gallon Gross Vehicle Weight Minimum Oil Sump Capacity Idle Time Severe Duty Less than 2 6 km L 6 MPG More than 36287 kg 80000 Ib 31 7 L 33 5 qt More than 40 Normal Duty 2 6 km L 6 MPG to 3 km L 7 MPG 36287 kg 80000 Ib or less 31 7 L 33 5 qt 2096 to 4096 Light Duty Greater than 3 km L 7 MPG 36287 kg 80000 Ib or less 31 7 L 33 5 qt Less than 20 Oil Classification Kilometers Miles Cat DEO ULS or an oil that meets the requirements of the Caterpillar ECF 3 specification 24 150 32 200 40 250 kilometers kilometers kilometers 15 000 miles 20 000 miles 25 000 miles 1 If the oil sump capacity is greater than the oil sump capacity that is listed in Table 35 the oil change interval can be extended 1600 kilometers 1000 miles for every 2 L 2 qt increase in oil sump capacity Table 35 Maximum Permissible Oil Change Intervals for C11 and C13 On highway Engines with Deep Sumps Standard Fuel Consumption Kilometers Per Liter Miles Per Gallon Gross Vehicle Weight Minimum Oil Sump Capacity Idle Time Severe Duty Less than 2 6 km L 6 MPG More than 36287 kg 80000 Ib 37 7L 39 8 qt More than 40 Normal Duty 2 6 km L 6 MPG to 3 km L 7 MPG 36287 kg 80000 Ib or less 37 7 L 39 8 qt 20 to 40 Light Duty Greater than 3 km L 7
24. aintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Battery Replace seeeeeeeeee 76 Battery or Battery Cable Disconnect TT Cooling System Coolant Sample Level 1 O DfA ime Pii 84 Cooling System Coolant Sample Level 2 Obtain inicie o Pee e Heint dius 85 Crankshaft End Play Test ssssessss 86 Engine Air Cleaner Element Clean Replace 90 Engine Oil Level Gauge Calibrate 92 Fuel System Prime ssssseeeeeee 100 Severe Service Application Check 106 Daily Cooling System Coolant Level Check 84 Engine Air Cl
25. alve cover TA Illustration 55 901445781 3 Wash breather 8 in solvent that is clean and nonflammable Allow the breather to dry before installation 4 Install a breather element that is clean and dry 5 Install valve cover 7 Refer to the Disassembly and Assembly Manual for instructions on installing the valve cover Refer to Specifications SENR3130 in order to locate the proper torques 6 Install hose 6 on valve cover 7 Install hose clamp 5 Refer to Specifications SENR3130 in order to locate the proper torques 92 Maintenance Section Engine Oil Level Check SEBU7695 13 102126741 Engine Oil Level Check SMCS Code 1348 535 FLV Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Note The location of the oil level gauge and the oil filler cap will vary with the truck model Eur C ADD FULL g00110310 Illustration 56 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 the oil level gauge Do not fill the crankcase above FULL mark X NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can cause the crankshaft to dip into the oi
26. and mandates 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 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 If it is necessary make repairs or correct fluid levels 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 e Check the cooling system coolant level Ensure that the cooling lines are properly clamped and that the cooling lines are tight Check for leaks Check the condition of all pipes e Inspect the water pumps for coolant leaks The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal o
27. ank Water and Sediment Drain 104 Hoses and Clamps Inspect Replace 105 Between 24 000 and 96 000 km 15 000 and 60 000 miles Electronic Unit Injector Inspect Adjust 89 Engine Valve Lash Inspect Adjust 99 Valve Actuators Inspect Adjust 107 PM Level 2 Every 320 000 km 200 000 miles or 125 000 L 33 000 US gal of Fuel or 4000 Service Hours or 2 Years Aftercooler Core Clean Test ssssss 75 Cooling System Coolant DEAC Change 80 Cooling System Water Temperature Regulator Replaca rs nett Ret eret 86 Fan Drive Bearing Lubricate 100 Radiator Clean seesseeeee 106 PM Level 3 Every 483 000 km 300 000 miles or 190 000 L 50 000 US gal of Fuel or 6000 Service Hours or 3 Years Air Compressor Inspect sssssusssss 75 Cooling System Coolant Extender ELC Add 83 Crankshaft Vibration Damper Inspect 87 Electronic Unit Injector Inspect Adjust 89 Engine Clean eeeeeeeceseeee einen 89 Engine Valve Lash Inspect Adjust 99 Turbocharger Inspect s esee 107 Valve Actuators Inspect Adjust 107 PM Level 4 Every 966 000 km 600 000 miles or 380 000 L 100 000 US gal of Fuel or 12 000 Service
28. antly charged with high pressure e The internal pressures of the high pressure fuel lines are higher than other types of fuel system Before any service or repair is performed on the engine fuel lines perform the following tasks 1 Stop the engine 2 Wait for ten minutes Do not loosen the high pressure fuel lines in order to remove air pressure from the fuel system Engine Oil To relieve pressure from the lubricating system turn off the engine 103091592 Welding on Engines with Electronic Controls SMCS Code 1000 NOTICE Because the strength of the frame may decrease some manufacturers do not recommend welding onto a chassis frame or rail Consult the OEM of the equip ment or your Caterpillar dealer regarding welding on a chassis frame or rail Proper welding procedures are necessary in order to avoid damage to the engine s ECM sensors and associated components When possible remove the component from the unit and then weld the component If removal of the component is not possible the following procedure must be followed when you weld on a unit that is equipped with a Caterpillar Electronic Engine The following procedure is considered to be the safest procedure to weld on a component This procedure should provide a minimum risk of damage to electronic components NOTICE Do not ground the welder to electrical components such as the ECM or sensors Improper grounding can cause damage to the drive t
29. ation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Battery Replace ooo ee eeeceeeeeeeeeeeeeeeeneeeeeteennaeees 76 Battery or Battery Cable Disconnect TT Cooling System Coolant Sample Level 1 Obtallis tot nete Dent Ce EE 84 Cooling System Coolant Sample Level 2 OD tal oie t dei ien 85 Crankshaft End Play Test sssessss 86 Engine Air Cleaner Element Clean Replace 90 Engine Oil Level Gauge Calibrate 92 Fuel System Prime ssssseeeeee 100 Severe Service Application Check 106 Daily Cooling System Coolant Level Check 84 Engine Air Cleaner Service Indicator Inspect 90 Engine Oil Level Check ssesssss 92 Fuel System Water Separator Inspect Drain 103 Walk Around Inspec
30. ay 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 C The NEGATIVE cable connects the NEGATIVE battery terminal to the ground plane Disconnect the cable from the NEGATIVE battery terminal AR 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 SEBU7695 13 TT Maintenance Section Battery Electrolyte Level Check 8 Connect the cable from the ground plane to the NEGATIVE battery terminal 102601752 Battery Electrolyte Level Check SMCS Code 1401 535 When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and pro
31. ays use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEgj0047 How To Take A Good S O S Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine SEBU7695 13 95 Maintenance Section Engine Oil and Filter Change 102812032 Engine Oil and Filter Change SMCS Code 1318 510 1348 044 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE The vehicle must be parked on a level surface for this maintenance procedure Do not drain the engine oil when the engine is cold As the engine oil cools suspended waste particles settle on the bottom of the engine oil pan The waste particles are not removed with the draining cold engine oil Drain the crankcase while the engine is stopped Drain the crankcase while the engine oil is warm This draining meth
32. cal Electronic component 8 Minimum distance between the component that is being welded and any electrical electronic component 9 The component that is being welded 10 Current path of the welder 11 Ground clamp for the welder 4 Connect the welding ground cable directly to the part that will be welded Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings hydraulic components electrical components and ground straps Note If electrical electronic components are used as a ground for the welder or electrical electronic components are located between the welder ground and the weld current flow from the welder could severely damage the component 5 Protect the wiring harness from welding debris and spatter 6 Use standard welding practices to weld the materials 70 Maintenance Section Maintenance Interval Schedule SEBU7695 13 103635998 Maintenance Interval Schedule C11 and C13 Engines with 500 HP Field Up Rates and 525 HP RV Ratings with Optional Shallow Oil Sumps SMCS Code 1000 7500 SIN KCA1 Up S N KCB1 Up S N JAM1 Up Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the install
33. comb Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary For more detailed information on cleaning and inspection refer to Special Publication SEBD0518 Know Your Cooling System 101357879 Severe Service Application Check SMCS Code 1000 535 Operation and maintenance practices affect the service life of the components when the engine is operated in severe service applications The level of maintenance is crucial to the service life of the engine Other major factors that affect service life are operating speed and loads SEBU7695 13 107 Maintenance Section Turbocharger Inspect The conditions that follow can indicate severe service operation e Operation above 36 320 kg 80 000 Ib gross vehicle weight GVW and other high load factor operations such as off highway Frequent high altitude operation above 1525 m 5000 ft Extended operation at low idle e Arctic operation regular cold starts at temperatures below 18 C 0 F Extending maintenance beyond the recommended maintenance intervals Frequent hot shutdowns minimum five minute cool down periods after high load factor operation e Use of fuels that are NOT recommended by Caterpillar in the Fuel Specifications e Extreme ambient temperature conditions that may cause the lubricating properties of the fuel to diminish Frequent plugging of the fue
34. component wear Therefore more frequent inspections of the cartridge are required Removal and Installation For options regarding the inspection removal installation repair and replacement consult your authorized Caterpillar service center Refer to the Service Manual for this engine for the procedure and specifications 101848805 Valve Actuators Inspect Adjust SMCS Code 1105 025 1105 040 The valve actuators should be inspected and adjusted when adjustments to the following components occur e Valves e Injectors e Compression brakes Refer to the System Operation Test and Adjust Manual for the proper adjustment procedure 108 Maintenance Section Walk Around Inspection SEBU7695 13 102528180 Walk Around Inspection SMCS Code 1000 040 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 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations
35. deep by referring to this Operation and Maintenance Manual Refill Recommendations and Capacities Caterpillar C15 On highway Engines use standard deep oil pans The engine oil level will vary depending on the angle and the slant of the engine installation The angle is the front to back tilt The slant is the sideways tilt The oil level gauge markings must be verified in order to ensure that it is correct Verify the oil level gauge markings at the first oil change Use the following procedure in order to verify the ADD mark and verify the FULL mark that is on the oil level gauge NOTICE The vehicle must be parked on a level surface in order to perform this maintenance procedure SEBU7695 13 93 Maintenance Section Engine Oil Level Gauge Calibrate NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJO003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the engine until normal o
36. e Section Cylinder Head Grounding Stud Inspect Clean Tighten Refer to the Disassembly and Assembly Manual Vibration Damper and Pulley Remove and Install or consult your Caterpillar dealer for information about damper replacement 101823226 Cylinder Head Grounding Stud Inspect Clean Tighten SMCS Code 7423 040 7423 070 7423 079 Illustration 50 900931100 C11 and C13 engines 1 Cylinder head grounding stud 900931103 Illustration 51 C15 Engine 2 Cylinder head grounding stud SEBU7695 13 89 Maintenance Section Electronic Unit Injector Inspect Adjust Inspect the OEM vehicle wiring harness for the following conditions e Connections that are loose or disconnected e Mounting hardware that is missing e Insulation that is chafed or cut e Wires that are bare The cylinder head grounding stud must have a wire ground to the battery Tighten the cylinder head grounding stud at every oil change Ground wires and straps should be combined at engine grounds All grounds should be tight and free of corrosion 1 Clean the cylinder head grounding stud and the terminals for the cylinder head ground strap with a clean cloth 2 If the connections are corroded clean the connections with a solution of baking soda and water 3 Keep the cylinder head grounding stud and the strap clean and coated with MPGM grease or petro
37. e 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 to two articles in the Disassembly and Assembly Manual Water Temperature Regulators Remove and Water Temperature Regulators Install for the replacement procedure of the water temperature regulator o
38. eaner Service Indicator Inspect 90 Engine Oil Level Check ssssessss 92 Fuel System Water Separator Inspect Drain 103 Walk Around Inspection sssesssssss 108 PM Level 1 Every 48 000 km 30 000 miles or 15 520 L 4100 US gal of Fuel or 500 Service Hours Air Compressor Filter Clean Replace 75 Air Sh toff Test eoe RO Ss 75 Alternator Inspect sssssseseeeeeee 76 Battery Electrolyte Level Check 77 Belt INSP trdine renias eetan Lae IERA 77 Belt Tensioner Inspect ceceeeeeeeeeeeeteees 78 Cooling System Supplemental Coolant Additive SCA Test Add 2000 22 cc aiia 85 Cylinder Head Grounding Stud Inspect Clean TIONEM 222i i nee rhe te nece aes dees 88 Engine Crankcase Breather Clean 91 Engine Oil Sample Obtain sssse 94 Engine Oil and Filter Change 95 Fuel System Primary Filter Replace 102 Fuel System Secondary Filter Replace 102 Fuel Tank Water and Sediment Drain 104 Hoses and Clamps Inspect Replace 105 Between 24 000 and 96 000 km 15 000 and 60 000 miles Electronic Unit Injector Inspect Adjust 89 Engine Valve Lash Inspect Adjust 99 Valve Actuators Inspect Adjust
39. erpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJ0003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Caterpillar requires the filtration of all fuels through a primary fuel filter that has a rating of no less than ten microns c absolute and no more than 15 microns c absolute For information on the maintenance of the primary fuel filter refer to the literature that is provided by the OEM of the vehicle 103017560 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publica
40. est available information 102933380 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 damper that is damaged can cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine Visconic Damper The visconic damper has a weight that is located inside a fluid filled case The weight moves in the case in order to limit torsional vibration Inspect the damper for evidence of fluid leaks If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous smooth and adhering If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace the crankshaft seals Inspect the damper and repair or replace the damper for any of the following reasons The damper is dented cracked or leaking The paint on the damper is discolored from heat The engine has had a failure because of a broken crankshaft Analysis of the oil has revealed that the front main bearing is badly worn There is a large amount of gear train wear that is not caused by a lack of oil 88 SEBU7695 13 Maintenanc
41. f water pumps and the installation of water pumps and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer Check the engine oil level 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 Inspect the fuel system for leaks Look for loose fuel line clamps or for loose tie wraps around fuel lines Check the water separator if equipped for water on a daily basis Drain any water from the water separator If necessary drain the water and the sediment from fuel tanks in order to ensure that only clean fuel enters the fuel system Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Ensure that hoses and tubes are not contacting other hoses tubes wiring harnesses etc Check the air cleaner service indicator if equipped 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 Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the ECM t
42. for normal brake operation Do not operate the engine until the reason for the air bypass is identified and corrected Failure to heed this warning could lead to property damage personal injury or death to the operator or by standers The function of the pressure relief valve is to bypass air when there is a malfunction in the system for the air compressor The pressure relief valve for the air compressor releases air at 1723 kPa 250 psi If the pressure relief valve for the air compressor exhausts all personnel should be at a safe distance away from the air compressor All personnel should also stay clear of the air compressor when the engine is operating and the air compressor is exposed Refer to the Service Manual or refer to the OEM specifications in order to find information concerning the air compressor Consult your Caterpillar dealer for assistance 101544231 Air Compressor Filter Clean Replace If Equipped SMCS Code 1803 070 FQ 1803 510 FQ One of the single most important aspects of preventive maintenance for the air compressor is the induction of clean air The type of maintenance that is required for the air compressor and the maintenance interval depends on the type of air induction system that is used Operating conditions dust dirt and debris may require more frequent service Refer to the Service Manual for the type of air compressor that is installed on the engine Follow the maintenance rec
43. he service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in SEBU7695 13 91 Maintenance Section Engine Crankcase Breather Clean 103018600 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 Your engine will have one of the following engine crankcase breathers Type 1 Illustration 53 g01136454 Typical example 1 Loosen hose clamp 1 and remove the hose from breather assembly 2 2 Loosen retaining clamp 3 Remove the breather assembly and seal 4 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 the seal the breather assembly and the clamp Refer to the Specifications SENR3130 in order to locate the proper torques 5 Install the hose Install the hose clamp Refer to Specifications SENR3130 in order to locate the proper torques Type 2 Illustration 54 901445780 1 Loosen hose clamp 5 and remove hose 6 from valve cover 7 2 Remove valve cover 7 Refer to the Disassembly and Assembly Manual for instructions on removing the v
44. ilter NOTICE Do not fill the secondary fuel filter with fuel before in stalling The fuel would not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts 6 Install the new fuel filter Spin the fuel filter onto the fuel filter base until the gasket contacts the base Instructions for the installation of the filter are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter 7 Open the fuel supply valve Turn the ignition switch to the ON position or reconnect the battery Open the fuel supply valve if equipped 8 Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime topic Maintenance Section for more information Start the engine and inspect the fuel system for leaks 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 102919528 Fuel System Water Separator Inspect Drain If equipped SMCS Code 1263 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids
45. l 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 49 g00103639 Typical filler cap gaskets 3 Clean the cooling system filler cap and check the condition of the filler cap gaskets Replace the cooling system filler cap if the filler cap gaskets are damaged Reinstall the cooling system filler cap 4 Inspect the cooling system for leaks 103085830 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Note Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations for the proper maintenance interval for your application NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis Obtain the sample of the coolant as close as possible to the recommended sampling interval
46. l This will reduce the power that is devel oped and also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling oil blowing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber De posits in the combustion chamber lead to the following problems guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately 2 Remove the oil filler cap and add oil if necessary For the correct oil to use see this Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section Do not fill the crankcase above FULL mark X on the oil level gauge Clean the oil filler cap Install the oil filler cap 3 Record the amount of oil that is added For the next oil sample and analysis include the total amount of oil that has been added since the previous sample This will help to provide the most accurate oil analysis 102921153 Engine Oil Level Gauge Calibrate SMCS Code 1326 524 Check the Calibration at the First Oil Change Note For Caterpillar C11 and for C13 On highway Engines determine whether the oil pan is shallow or
47. l filter e Extended maintenance intervals of the fuel system Inadequate maintenance of fuel storage tanks excessive water sediment microorganism growth etc 101894393 Turbocharger Inspect SMCS Code 1052 040 1052 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced A periodic inspection of the turbocharger can minimize unscheduled downtime and the chance for potential damage to other engine parts Note Turbocharger components require precision clearances with proper balancing in order to support high operating speeds Severe Service Applications can accelerate
48. leum jelly 102070777 Electronic Unit Injector Inspect Adjust SMCS Code 1251 025 1251 040 1290 025 1290 040 Be sure the engine cannot be started while this maintenance is being performed To prevent pos sible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting the unit injectors The electronic unit injectors use high voltage Dis connect the unit injector enable circuit connector in order to prevent personal injury Do not come in contact with the injector terminals while the en gine is running The operation of Caterpillar engines with improper adjustments of the electronic unit injector can reduce engine efficiency This reduced efficiency could result in excessive fuel usage and or shortened engine component life Only qualified service personnel should perform this maintenance Refer to the following topics for your engine for the correct procedure Refer to the Systems Operation Testing and Adjusting Electronic Unit Injector Test for the test procedure and Systems Operation Testing and Adjusting Electronic Unit Injector Adjust for the correct procedure for adjusting the injectors NOTICE The camshafts must be correctly timed with the crank shaft before an adjustment of the lash for the fuel in jector is made The timing pins must be removed from the camshafts before
49. m Coolant Extender ELC Add SMCS Code 1352 045 1395 081 Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Check the cooling system only when the engine is stopped and cool 2 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 3 It may be necessary to drain enough coolan
50. mation Refer to the Disassembly and Assembly Module for instructions on replacing the components Table 30 Component Required Maintenance Required Maintenance 300 000 miles 600 000 miles Cd and Terminal Inspect Inspect onnections e MS Adjust Replace Adjust Replace AU E nd Adjust Inspect Adjust Replace Solenoid Valves Inspect Replace ee oo Inspect Inspect ie tle Naa Rocker Inspect Inspect rm Screws Kena Piston Fork Inspect Inspect ssembly Slave pistons Inspect Inspect External Hose Assembly Inspect Inspect Housings Inspect Inspect Fuel Pipes Inspect Inspect Hold Down Bolts Inspect Replace Accumulator Springs Replace Inspect Solenoid Harness Replace Inspect Solenoid Seal Rings Replace Inspect Control Valve Springs Replace Inspect Control Valves Replace Inspect Oil Seal Rings Replace Inspect Bled Piston Return Replace Inspect prings Terminal Lead Out Replace Inspect yino x Replace Inspect 1 Contained in tune up kits 80 Maintenance Section Cooling System Coolant DEAC Change SEBU7695 13 102126636 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 co
51. mmeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs as required 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 102153996 Battery Replace SMCS Code 1401 510 Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite This can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place m
52. ne at low idle for a minimum of 90 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications 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 Refill Capacities and Recommendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rpm to 1500 rpm Run the engine at high idle for one minute in order to purge the air f
53. ns in order to service the air cleaner service indicator The service indicator may be mounted on the air cleaner housing or in a remote location Illustration 52 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 Check for ease of resetting The service indicator should reset in less than three pushes Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of t
54. o 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 If equipped be sure to flush the heater and any related supply and return lines Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications 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 Note If equipped be sure to flush the heater and any related supply and return lines 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the cooling system filler cap 4 Start and run the engi
55. o the cylinder head ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check the condition of the gauges Replace any gauges that are cracked Replace any gauge that can not be calibrated
56. o tight unnecessary stresses are placed on the pulley bearings and on the belts This may shorten the service life of the components Remove the belt guard Inspect the condition and adjustment of the alternator belts and accessory drive belts if equipped To check the belt tension apply 110 N 25 Ib ft of force midway between the pulleys A correctly adjusted belt will deflect 9 mm 0 35 inch to 15 mm 0 59 inch If the belt does not require replacement or adjustment install the belt guard If the belt requires adjustment or replacement perform the following procedure to adjust the belt tension e If the engine is equipped with a refrigerant compressor air conditioner the belt for the fan drive the alternator and the accessories will have an automatic belt tensioner e If the engine is not equipped with a refrigerant compressor the alternator is used to adjust the belt tension Adjustment Alternator Belt Illustration 46 900485289 Typical alternator mounting 1 Adjusting nuts 2 Mounting bolts 1 Slightly loosen mounting bolt 2 and adjusting nut 1 2 Move the pulley in order to adjust the belt tension 3 Tighten adjusting nuts 1 and mounting bolts 2 Refer to the Specifications SENR3130 in order to locate the proper torques 4 Install the belt guard If new belts are installed check the belt tension again after 30 minutes of engine operation at the rated rpm 103019073
57. od allows the waste particles that are suspended in the engine 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 engine oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJO0003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Drain the Engine Oil After the engine has been run at the normal operating temperature stop the engine Attach a DO NOT OPERATE or a similar warning tag to the ignition keyswitch before the engine is serviced Use one of the following methods to drain the engine crankcase oil If the engine is equipped with a drain valve turn the drain valve knob counterclockwise in order to drain the engine oil After the engine oil has drained turn the drain valve knob clockwise in order to close the drain valve If the engine is not equipped with a drain valve remove
58. of any commercially available lubricant is the responsibility of that oil company The performance guarantee of any commercially available filter is the responsibility of the filter manufacturer Tables for Extended Oil Change Intervals In order to understand the tables for maximum permissible oil change intervals use the following procedures 1 Determine the average fuel consumption of the vehicle 2 Determine the gross vehicle weight GVW of the vehicle 3 Determine the percent of idle time for the vehicle A download of the histogram data from the ECM can provide a more accurate percent idle time measurement Contact your nearest Caterpillar dealer for information on obtaining data from the ECM 4 The intersection of the column and the row lists the maximum number of kilometers or miles between oil change intervals For example a C13 Engine with an average fuel consumption of 3 km L 7 mpg in a light duty application will have a maximum permissible oil change interval of 40 250 kilometers 25 000 miles with a shallow oil sump The maximum permissible oil change interval for the same situation with a Deep oil sump would be 64 350 km 40 000 miles 98 Maintenance Section Engine Oil and Filter Change SEBU7695 13 Table 34 Maximum Permissible Oil Change Intervals for C11 and C13 On highway Engines with Shallow Sumps and 500 HP Field Up rates and 525 HP RV Ratings Fuel Consumption Kilometers
59. ol Loosen the cooling system pressure cap slowly in order to relieve the pres sure Follow the instructions that are provided by the OEM or follow the instructions that are provided by the manufacturer of the coolant conditioner element on engines that are equipped with a coolant conditioner element 1 Slowly loosen the cooling system filler cap in order to relieve the pressure Remove the cooling system filler cap Note Always discard drained fluids according to local regulations 2 If necessary drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA 3 Add the proper amount of SCA Refer to Special Publication SEBU6385 Caterpillar On highway Diesel Truck Engine Fluid Recommendations for more information on SCA requirements 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets are damaged replace the old cooling system filler cap with a new cooling system filler cap Install the cooling system filler cap 102623972 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can caus
60. olant is contaminated e The fuel has entered the cooling system and the coolant is contaminated NOTICE Use of commercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove one of the drain plugs Note If equipped be sure to drain the heater and any related supply and return lines 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
61. ollow the OEM or filter manufacturer s recommendations If the extra oil is not added the engine may starve for oil NOTICE To help prevent crankshaft or bearing damage crank engine to fill all filters before starting Do not crank engine for more than 30 seconds 2 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 3 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL marks on the oil level gauge 5 Remove the DO NOT OPERATE tag from the ignition keyswitch Adjustments to the Oil Change Intervals Many conditions affect the selection of an oil change interval Proper oil change intervals are important for maintaining engine service life and engine performance and fully utilizing the lubricant The engine oil must be able to control the following items corrosion oxidation soot and wear metals The engine oil must be able to control the conditions during the time between oil changes In some severe service applications reducing the oil change interval may be necessary in order to maintain the integrity of the engine lubricant Refer to this Operation and Maintenance Manual
62. ommendations that are provided by the OEM of the air compressor Some engines use boost air pressure so the engine air cleaner will require servicing Air Shutoff Test Engines that are Equipped with Optional Air Shutoff Systems SMCS Code 1078 081 The air inlet shutoff switch can be used to manually activate the air inlet shutoff When the switch is depressed a one second pulse is sent to the air inlet shutoff relay In order to test the air shutoff system perform the following steps e Start the engine 76 Maintenance Section Alternator Inspect SEBU7695 13 e Place the transmission in the NEUTRAL position e Push the AIR SHUTOFF switch The engine should shut down x Illustration 45 901402506 Typical air shutoff The air shutoff must be manually reset before further engine operation The OPEN CLOSED switch will be open during engine operation Move the indicator from the CLOSED position to the OPEN position If the engine does not shut down further testing of the air shutoffs may be accomplished through the use of Cat ET Refer to the Troubleshooting Guide Air Inlet Shutoff Circuit Test information for your engine 102676048 Alternator Inspect SMCS Code 1405 040 Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the a
63. on dirt grease insects leaves oil and other debris Clean the radiator if necessary Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the air nozzle is deadheaded Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both sides of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water After cleaning start the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a
64. or the proper maintenance interval for your application NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Refer to this Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6385 Caterpillar On highway Diesel Engines Fluids Recommendations or consult your Caterpillar dealer 103085828 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 Note This procedure is NOT required for applications that use Cat Extended Life Coolant ELC NOTICE 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 Supplemental Coolant Additive SCA or test the SCA concentration as part of an S O S Coolant Analysis Test the SCA Concentration Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration
65. perating temperature is achieved Stop the engine Remove the crankcase oil drain plugs The oil drain plug from the deep portion of the oil pan should be removed The oil drain plug from the shallow portion of the oil pan should be removed This will allow all of the oil to drain Drain the oil from the crankcase for 20 minutes 2 Remove the used oil filter s Install the new oil filter s Install the oil drain plugs and tighten to 70 15 N m 50 11 Ib ft Your engine may be equipped with auxiliary oil filters The auxiliary oil filters require a different volume of oil Refer to the OEM specifications for the auxiliary oil filter 3 Refer to table 32 in order to determine the correct amount of oil that should be poured into the crankcase Pour the correct amount of oil into the crankcase Table 32 Engine C11 or C13 C15 Oil pan Shallow Deep Deep Standard Quantity of oil 22 5 L 23 8 qt 28 5 L 30 1 at 26 5 L 28 qt 1 Allow enough time for the oil to drain into the 4 Check the oil level on the oil level gauge The oil crankcase Approximately 20 minutes should level should be at the FULL mark If the oil level be allowed Check the oil level Wait for several is not at the existing FULL mark grind off the minutes and check the oil level again Proceed FULL mark and engrave the new FULL mark after the oil level stops changing 5 Refer to table 33 in order to determine
66. r 125 000 L 33 000 US gal of Fuel or 4000 Service Hours or 2 Years Aftercooler Core Clean Test ssssss 75 Cooling System Coolant DEAC Change 80 Cooling System Water Temperature Regulator Replaca rs nett Ret eret 86 Fan Drive Bearing Lubricate 100 Radiator Clean seesseeeee 106 PM Level 3 Every 483 000 km 300 000 miles or 190 000 L 50 000 US gal of Fuel or 6000 Service Hours or 3 Years Air Compressor Inspect sssssusssss 75 Cooling System Coolant Extender ELC Add 83 Crankshaft Vibration Damper Inspect 87 Electronic Unit Injector Inspect Adjust 89 Engine Clean eeeeeeeceseeee einen 89 Engine Valve Lash Inspect Adjust 99 Turbocharger Inspect s esee 107 Valve Actuators Inspect Adjust 107 PM Level 4 Every 966 000 km 600 000 miles or 380 000 L 100 000 US gal of Fuel or 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 82 SEBU7695 13 71 Maintenance Section Maintenance Interval Schedule 103635992 Maintenance Interval Schedule C11 C13 and C15 Engines with Standard Deep Oil Sumps SMCS Code 1000 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any m
67. r 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 103604133 Crankshaft End Play Test SMCS Code 1202 081 EP S N KCA1 Up S N KCB1 Up SIN JAM1 Up Note This maintenance is for an engine that is coupled to a transmission which uses a single plate clutch Note Refer to this Operation and Maintenance Manual Severe Service Application Check in order to determine the operating conditions for the engine This maintenance procedure should be completed at the following intervals SEBU7695 13 87 Maintenance Section Crankshaft Vibration Damper Inspect Every oil change for an engine which operates in a severe service application e Alternate oil changes every other oil change for an engine which operates in normal conditions Do not perform this maintenance and do not order any parts until the entire instruction has been read and understood Follow the procedure that is listed below in order to check the end play of the crankshaft without removing the engine The current specification for crankshaft end play is 0 1 mm 0 00394 inch to 0 5 mm 0 01969 inch 1 Bleed the system pressure from the transmission This is necessary for an accurate reading of the crankshaft s end play Note Refer to the transmission manufacturer s instruction manual for mo
68. r priming is necessary 102 Maintenance Section Fuel System Primary Filter Replace SEBU7695 13 7 Observe the air purge screw When a small drop of fuel appears at the threads of the air purge screw close the air purge screw After the air purge screw is closed tighten the air purge screw Refer to Specifications SENR3130 for the correct torque Note Failure to tighten the screw could result in serious fuel leaks 8 Clean any residual fuel from the engine components 9 Once the engine runs smoothly stop the engine Turn the ignition switch to the OFF position 103017559 Fuel System Primary Filter Replace SMCS Code 1260 510 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Cat
69. r the correct torque Note Failure to tighten the screw could result in serious fuel leaks 8 After the engine has operated smoothly for 30 seconds turn the priming valve to the LOCK position Note The life of the injectors may be shortened if the priming valve is left in the unlocked position 9 Clean any residual fuel from the engine components 10 Once the engine runs smoothly stop the engine Turn the ignition switch to the OFF position Using the Fuel Priming Pump If Equipped to Prime the Fuel System 1 Turn the ignition to the OFF position 2 Unlock the priming pump by turning the cap counterclockwise 3 Purging air from the fuel system requires the air purge screw to be opened three full turns Open the air purge screw Do not remove the screw 4 Continue to operate the fuel priming pump until a strong resistance is felt Listen for an audible click from the fuel manifold The click will indicate that the valve has opened and the fuel system is pressurized Lock the fuel priming pump Note The life of the injectors may be shortened if the priming valve is left in the unlocked position 5 Turn the ignition to the ON position 6 Crank the engine If the engine starts but the engine runs rough continue to operate the engine at low idle until the engine runs smoothly Note If the engine will not start further priming is necessary If the engine starts but the engine continues to misfire furthe
70. rain bearings hydraulic components electrical components and other com ponents Clamp the ground cable from the welder to the com ponent that will be welded Place the clamp as close as possible to the weld This will help reduce the pos sibility of damage Note Perform the welding in areas that are free from explosive hazards 1 Stop the engine Turn the switched power to the OFF position SEBU7695 13 69 Maintenance Section Maintenance Recommendations 2 Disconnect the negative battery cable from the battery If a battery disconnect switch is provided open the switch 3 Disconnect the J1 P1 and J2 P2 connectors from the ECM Move the harness to a position that will not allow the harness to accidentally move back and make contact with any of the ECM pins EU Ss 6 Illustration 43 g01075639 Use the example above The current flow from the welder to the ground clamp of the welder will not cause damage to any associated components 1 Engine 2 Welding electrode 3 Keyswitch in the OFF position 4 Battery disconnect switch in the open position 5 Disconnected battery cables 6 Battery 7 Electri
71. rastically accelerate internal engine wear e Operating conditions dust dirt and debris may require more frequent service of the air cleaner element 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 Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air cleaner element or follow the instructions that are provided by the OEM Engine Air Cleaner Service Indicator Inspect If Equipped SMCS Code 7452 040 Some engines may be equipped with a different service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendatio
72. re information on this procedure 2 Place a dial gauge on the end of the crankshaft pulley in order to check the end play Zero the dial gauge in order to get an accurate reading 3 Use a prybar and use a wood block to move the crankshaft The block of wood should be placed between the prybar and the vibration damper The block of wood is used to protect the vibration damper from getting punctured Move the crankshaft and observe the dial gauge 4 Inspect the thrust bearing if the end play is greater than 0 5 mm 0 01969 inch 5 f the end play is greater than the maximum specification the 246 3144 Thrust Plate should be replaced Reference Disassembly and Assembly Crankshaft Main Bearings Remove Disassembly and Assembly Crankshaft Main Bearings Install 6 Use a surface finish comparator in order to determine the reusability Measure the surface finish If the surface finish is less than 0 40 RA the crankshaft can be reused 7 If a comparator is not available visually inspect the crankshaft s bearing surfaces Check the bearing s surface for scuffing or check the bearing s surface for the transfer of material 8 Replace the crankshaft if any obvious signs of scuffing or transfer of material is found Reference Disassembly and Assembly Crankshaft Removal Disassembly and Assembly Crankshaft Installation Whenever questions arise about this maintenance consult the local Caterpillar dealer for the lat
73. red to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJOO003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable Sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks SEBU7695 13 105 Maintenance Section Hoses and Clamps Inspect Replace 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
74. rom the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged perform a pressure test A 9S 8140 Pressurizing Pump is used to perform the pressure test The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 82 Maintenance Section Cooling System Coolant ELC Change SEBU7695 13 102126647 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
75. t from the cooling system in order to add Cat ELC Extender 4 Refer to the schedule that is found in Operation and Maintenance Manual Maintenance Interval Schedule This schedule lists the interval for adding Cat ELC Extender to this engine 5 Use the formula in Table 31 to determine the proper amount of Cat ELC Extender for your cooling system The total cooling capacity will vary depending on the radiator that is provided by the vehicle manufacturer Table 31 Formula For Adding Cat ELC Extender To Cat ELC V x 0 02 X V is the total capacity of the cooling system X is the amount of Cat ELC Extender that is required 6 Clean the cooling system filler cap Inspect the filler cap gaskets Replace the filler cap if the filler cap gaskets are damaged Install the cooling system filler cap For more information about Cat ELC Extender refer to Special Publication SEBU6385 Caterpillar On highway Diesel Engine Fluid Recommendations 84 Maintenance Section Cooling System Coolant Level Check SEBU7695 13 101197583 Cooling System Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and cool 4 Illustration 48 g00285520 Cooling system filler cap Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are coo
76. tandard Deep Oil Sumps SMCS Code 1000 7500 S N KCA1 Up S N KCB1 Up S N JAM1 Up Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Battery Replace ooo ee eeeceeeeeeeeeeeeeeeeneeeeeteennaeees 76 Battery or Battery Cable Disconnect TT Cooling System Coolant Sample Level 1 Obtallis tot nete Dent Ce EE 84 Cooling System Coolant Sample Level 2 OD tal oie t dei ien 85 Crankshaft End Play Test sssessss 86 Engine Air Cleaner Element Clean Replace 90 Engine Oil Level Gauge
77. tective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water e A mixture of 0 1 L 0 11 qt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM 101492654 Battery or Battery Cable Disconnect SMCS Code 1402 029 The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Turn the
78. tenance Section Radiator Clean SEBU7695 13 Replace the Hoses and the Clamps Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine Allow the engine to cool 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suitable clean container The coolant can be reused 3 Drain the coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose 7 Install the hose clamps with a torque wrench Note Refer to the Specifications SENR3130 Torque Specifications in order to locate the proper torques 8 Refill the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler 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 102559063 Radiator Clean SMCS Code 1353 070 Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the radiator for these items damaged fins corrosi
79. the crankshaft is turned or dam age to the cylinder block will be the result 101646701 Engine Clean SMCS Code 1000 070 Personal injury or death can result from high volt age Moisture can create paths of electrical conductiv ity Make sure that the electrical system is OFF Lock out the starting controls and tag the controls DO NOT OPERATE NOTICE Accumulated grease and oil on an engine is a fire haz ard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumulates on the engine Periodic cleaning of the engine is recommended Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits e Easy detection of fluid leaks e Maximum heat transfer characteristics e Ease of maintenance Note Caution must be used in order to prevent electrical components from being damaged by excessive water when you clean the engine Avoid electrical components such as the alternator the starter and the ECM 90 Maintenance Section Engine Air Cleaner Element Clean Replace SEBU7695 13 i00857000 Engine Air Cleaner Element Clean Replace SMCS Code 1054 070 1054 510 NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will d
80. the oil drain plug in order to allow the engine oil to drain If the engine is equipped with a shallow sump remove the bottom oil drain plugs from both ends of the engine oil pan After the engine oil has drained the oil drain plugs should be cleaned and installed Tighten the oil drain plugs to the proper torque Refer to the Specifications Module Engine Oil Pan topic for additional information Replace the Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 1 Remove the oil filter with a 185 3630 Chain Wrench 2 Cut the oil filler open with a 175 7546 Oil Filter Cutter Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are 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
81. tion seesssssss 108 Every 24 140 km 15 000 miles or 7950 L 2100 US gal of Fuel or 230 Service Hours Engine Oil Sample Obtain sssssse 94 Engine Oil and Filter Change 95 PM Level 1 Every 48 000 km 30 000 miles or 15 520 L 4100 US gal of Fuel or 500 Service Hours Air Compressor Filter Clean Replace 75 Air Shutoff Test sessssssssssssseeees 75 Alternator Inspect sssssseeeeeeeees 76 Battery Electrolyte Level Check 77 B lt Inspect idos eas aeaaeae aar akai 77 Belt Tensioner Inspect ceceeeeeeeeeeeeteees 78 Cooling System Supplemental Coolant Additive SCA Test Add suse 85 Cylinder Head Grounding Stud Inspect Clean Tighiten iiie an eei be t eee e ad eode 88 Engine Crankcase Breather Clean 91 Fuel System Primary Filter Replace 102 Fuel System Secondary Filter Replace 102 Fuel Tank Water and Sediment Drain 104 Hoses and Clamps Inspect Replace 105 Between 24 000 and 96 000 km 15 000 and 60 000 miles Electronic Unit Injector Inspect Adjust 89 Engine Valve Lash Inspect Adjust 99 Valve Actuators Inspect Adjust 107 PM Level 2 Every 320 000 km 200 000 miles o
82. tion NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJOO003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Stop the engine Turn the ignition switch to the OFF position or disconnect the battery Refer to the Operation and Maintenance Manual Battery or Battery Cable Disconnect topic Maintenance Section for more information Shut off the fuel supply valve if equipped SEBU7695 13 103 Maintenance Section Fuel System Water Separator Inspect Drain AOE Illustration 61 g01269066 1 Air purge fitting 2 In order to relieve fuel pressure turn the air purge fitting counterclockwise by three full turns Do not remove the fitting 3 Remove the used fuel filter and discard the used fuel filter 4 Close the air purge fitting Refer to Special Publication SENR3130 Torque Specifications for the proper torque 5 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed Apply clean diesel fuel to the new fuel filter gasket NOTICE Caterpillar requires the use of a 4 micron c absolute high efficiency secondary fuel f
83. tion of the engine and the maintenance requirements of the engine S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The fluid sampling bottle includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Alw
84. ump capacity is greater than the oil sump capacity that is listed in Table 35 the oil change interval can be extended 1600 kilometers 1000 miles for every 2 L 2 qt increase in oil sump capacity 103011879 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 Systems Operation Testing and Adjusting Manual Valve Lash and Valve Bridge Adjustment article or consult your Caterpillar dealer for the complete valve lash adjustment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adj
85. used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools 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 Specifications Manual SENR3130 Torque Specifications 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 SEBU7695 13 81 Maintenance Section Cooling System Coolant DEAC Change 5 Stop the engine and allow the engine t
86. usting valve lash clearance Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this maintenance is performed The following components should be inspected and adjusted when the valves are inspected and adjusted e Valve actuators e Injectors e Compression brakes Refer to Systems Operations Testing and Adjusting Engine Valve Lash Inspect Adjust for more information 100 Maintenance Section Fan Drive Bearing Lubricate SEBU7695 13 101771215 Fan Drive Bearing Lubricate SMCS Code 1359 086 BD Illustration 58 g00746166 Typical location of the grease fitting that is for the fan drive bearing The belt guards have been removed in this illustration Note In some applications the fan drives are supplied by the OEM Refer to the OEM specifications if the fan drive is not supplied by Caterpillar 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 103086300 Fuel System Prime SMCS Code 1258 548 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start s
87. witch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJ0003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 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 NOTICE Do not crank the engine for more than 30 seconds Allow the starting motor to cool for two minutes before cranking again Illustration 59 g01568053 C11 and C13 On highway Engines 1 Fuel priming pump 2 Air purge screw 3 Priming valve If equipped SEBU7695 13 101 Maintenance Section Fuel System Prime Illustration 60 901568054 C15 On highway Engines 1 Fuel priming pump 2 Air purge screw 3 Priming valve If equipped The engine may need to be

C11, C13 and C15 ON-HIGHWAY ENGINES - Safety

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