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3126E COMMERCIAL and TRUCK ENGINES and 3126B

1. oh g TT hog i Fuel Inlet Screen Left Side View Illustration 35 g00845620 1 Remove the fuel inlet screen The fuel inlet screen is positioned at the inlet to the fuel transfer pump 2 Wash the fuel inlet screen in a clean nonflammable solvent 3 Inspect the fuel inlet screen If the fuel inlet screen is damaged replace the fuel inlet screen 4 Use pressure air to dry the fuel inlet screen 5 Inspect the seal in the fuel transfer pump If the seal is damaged replace the seal 6 Install the seal in the fuel transfer pump Install the clean fuel inlet screen in the fuel transfer pump SEBU7011 17 179 Maintenance Section Fuel System Prime 102113137 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 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 Prime the fuel system in order to fill the fuel filter Prime the fuel system in order to purge trapped air The fuel system should be primed under the following conditions e Running out o
2. cccccceceeeeeeeeeesenteeeeeees 119 Battery Electrolyte Level Check ceccccceeeeeeteeeeeeeentieeeeeetnneeeeeeeeee 123 Belt INS peCt xc iscsi ince e ects otis atl eed he ad aaa 124 Cooling System Supplemental Coolant Additive SCA Test Add 139 Cylinder Head Grounding Stud Inspect Clean Tighten 144 Engine Crankcase Breather Clean eeceeceeeeeteeeeeeeeneeeeeeetnteeeeeeeeee 148 Engine Oil Sample Obtain eee eee eeceeee eee eeneeeeeeeeaeeeeeeenaeeeeeeaas 155 Engine Oil and Filter Change eee ceeeeeceeeeee eset eee eeeeteeeeeeenneeeeeeeees 157 Fan Drive Bearing Lubricate 0 cc ccececeeeeeeeeeeeeeeeeeceeeeeetteeeeeeeeee 177 Fuel Inlet Screen Clean Inspect Replace cccceeeeceeeeseeteeeees 178 Fuel System Primary Filter Clean Replace n 182 Fuel System Secondary Filter Replace ceeeeeceeeeeeeeseeeeeeeeeee 182 Fuel Tank Water and Sediment Drain cccceceeeeeeeeeeeeneeteeeees 186 Hoses and Clamps Inspect Replace cccccceceeeeeeeeeesenenaeeees 187 Radiator O T a EEE EE AEE E A een atthe 191 PM Level 2 Every 161 000 km 100 000 miles or 56 850 L 15 000 US gal of Fuel or 2000 Service Hours or 2 Years Aftercooler Core Clean Test eececceeeeseteeeeeeeecteeeeeeeneeeeeeeeneeeeeeenaaes 115 Air Compressor Inspect cccccceceeeeeeeeeeeeeaaeeeceeeeeeeeeseesessnntunaeees 118 Alternator
3. ee eee etree etna 172 Fuel System PME esre sirra tra E AA EAE EEEE ERNEA 179 Severe Service Application Check 0 ccceeceeeeeeeeceeeeeeeeeeeeeeeteeseees 192 Daily Cooling System Coolant Level Check 0 00 cceeeeeeeeeeeeeeeteeeeeeeeneeees 138 Engine Air Cleaner Service Indicator Inspect ceeeeeeeeeteeeeeeeeee 146 Engine Oil Level Check ou ccceccccccccieeceeeecaeeeceeeseeeeceeedeaneceeenedateeeeeteas 150 Fuel System Water Separator Drain ccceeeeceeeeeeeeeeeeeeeesteeeeeeenaas 184 Walk Around Inspection 0 0 cccceceeeeeeeeeeeceeeceeceeeeeeeeeseseccenaaeeeeeeeeeneees 196 SEBU7011 17 113 Maintenance Section Maintenance Interval Schedule Initial 24 000 km 15 000 miles or 5700 L 1500 US gal of Fuel or 400 Service Hours or 6 Months Engine Valve Lash Inspect AdjUst ecceceeeeeeeeeeeeeeetneeeeeetnteeeeeeeees 165 PM Level 1 Every 24 000 km 15 000 miles or 5700 L 1500 US gal of Fuel or 400 Service Hours or 6 Months Aftercooler Core Inspect cccccccececeeeeeeeeeeececaceeeceeeeeeeeteeeessensunaeees 116 Air Compressor Filter Clean Replace cccccceceeeeeeeseesenteeeeeees 119 Battery Electrolyte Level Check ceccecceeeeenreeceeeettieeeeeetnneeeeeeeees 123 Belt INS peCt xc iscsi ince e ects otis atl eed he ad aaa 124 Cooling System Supplemental Coolant Additive SCA Test Add 139 Cylinder Head Grounding Stud Inspect Clean Ti
4. 21 000 16 800 14 800 1 Typical applications are Recreational Vehicles and intercity delivery average that is greater than 10 mpg 2 Typical applications are intracity driving average 8 to 10 mpg 3 Typical applications are bus services and pickup and or delivery services less than 8 mpg 4 Less than 6 mpg refer to the Operation and Maintenance Manual Severe Service Application Check for the requirements 5 The capacity of the shallow oil sump is 21 L 22 qt 6 It is important to understand the operation of your vehicle Use the fuel consumption service hours or calendar time whichever occurs first in order to determine the maintenance intervals Engines which operate in severe operating conditions may require more frequent maintenance 7 The capacity of the deep oil sump is 28 L 30 qt There are many applications of medium duty truck engines It is important to understand the operation of your vehicle Use the fuel consumption service hours or calendar time whichever occurs first in order to determine the maintenance intervals Engines which operate in severe operating conditions may require more frequent maintenance Instructions for the Table 1 Determine your type of vehicle application Locate the column which lists your type of vehicle application Determine your available oil in liters or quarts The oil quantity equals the sum of the capacities of the oil sump and the o
5. Change 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 used co
6. Note 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 154 SEBU7011 17 Maintenance Section Engine Oil Level Gauge Calibrate Table 14 Refill Capacities for 3126 On highway Engines ADD Full E Total Sump Mark Mark Additional Fill Shallow 178mm 16L 21L 7 inch i7qty 4449 TEM AD a9 ty deep Deep 241mm 23L 28 L 9 5inch 24qt 4L A TEM at 39 gty deep 3 Determine the sump that is installed on the engine and locate the sump capacity in table 14 4 Pour the correct volume of oil into the crankcase The correct volume will be found under the ADD Mark in table 14 Allow enough time for the oil to drain into the crankcase Approximately 20 minutes should be allowed Check the oil level Wait for several minutes and check the oil level again Proceed after the oil level stops changing 5 Check the oil level on the oil level gauge The oil level should be at the ADD mark If the oil level is not at the existing ADD mark grind off the ADD mark and engrave the new ADD level Use an engraving pen in order to engrave the new ADD mark 6 Locate the sump capacity of the engine again in table 14 Pour the correct volume of oil into the crankcase The correct volume will be found under the Full M
7. 2 Cut the oil filter open with a 175 7546 Oil Filter Cutter Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element Ferrous metals may indicate wear on the steel and cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts brass parts or bronze parts of the engine Parts that may be affected include the following items main bearings rod bearings turbocharger bearings and cylinder heads SEBU7011 17 159 Maintenance Section Engine Oil and Filter Change Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter Illustration 28 g00103713 Typical filter mounting base and filter gasket 3 Clean the sealing surface of the filter mounting base Ensure that all of the old oil filter gasket is removed 4 Apply clean engine oil to the new oil filter gasket NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 5 Install the oil filter
8. 1102 025 The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust ment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this maintenance is performed Refer to the Service Manual for more information 166 SEBU7011 17 Maintenance Section Exhaust Filter Particulate Trap Clean 102657492 Exhau
9. Drain the crankcase with the engine stopped Drain the crankcase while the oil is warm This draining method will allow the waste particles that are suspended in the oil to be properly drained Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil Drain the Engine Oil After the engine has been run at the normal operating temperature stop the engine Attach a DO NOT OPERATE or a similar warning tag to the ignition key switch before the engine is serviced Catch the oil in a suitable container Recycle the used oil or dispose of the used oil properly 1 Remove the oil drain plug in order to allow the oil to drain 2 After the oil has drained the oil drain plug should be cleaned and installed Tighten the oil drain plug to the following torque 70 158 SEBU7011 17 Maintenance Section Engine Oil and Filter Change Replace the Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 1 Remove the oil filter with a 185 3630 Chain Wrench Illustration 27 g00588944 Element with debris
10. INSD Ct rr a ee a a aie era aa ee E EA 120 Belt Tensioner Inspect cccccceeceeeeeeeeeeeeeeeceeeeeeeeeeeeeesennsaneeeees 128 Cooling System Water Temperature Regulator Replace 4 142 Crankshaft Vibration Damper Inspect 2 cecceeceeeeeeeeeeeeeeeseeee 143 Engine s Clean aere e E T A E E a 145 Engine Air Cleaner Element Clean Replace s s s 146 Engine Mounts Inspect 2 0 ccc ccceceeceeenceeeddhecceeeddenccceeedenccnenenddaeeeenetteas 150 Engine Valve Lash Inspect AdjUst 0 0 0 cceceeeeteeeeeeettteeeeeetnteeeeeeeeee 165 Starting Motor INSPEC oe ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeaeeees 193 Turbocharger INSPOCt uo eee eeceeeeeeeeeeeeeeeeeeeeeeeaaeeeeeeenaeeeeseeenaeeeeeeenaaes 193 Water Pump Inspect cccccccceeeeeeceeeceeeeeeeeeceeeeeeeeesetcecnceaeeeeeseeeeeess 198 Every 3 Years or 322 000 km 200 000 miles Cooling System Coolant DEAC Change ecceeeceeeeeeeeeteeeeeeees 128 SEBU7011 17 111 Maintenance Section Maintenance Interval Schedule Every 483 000 km 300 000 miles Cooling System Coolant Extender ELC Add s es 136 Every 6 Years or 966 000 km 600 000 miles Cooling System Coolant ELC Change 0 ccceeceeeeeeeeeeeeetteeeeeees 133 Every 114 000 L 30 000 US gal of Fuel Overhaul Considerations cccccccccccccceeccesceeeeeeeceesueeeessaueeeeeeseeeuaeeeeaas 190 112 SEBU7011 17 Maintenance Section Mainte
11. 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 124 SEBU7011 17 Maintenance Section Battery or Battery Cable Disconnect 101492654 Battery or Battery Cable Disconnect SMCS Code 1402 029 The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Turn the start switch to the OFF position Turn the ignition switch if equipped to the OFF po
12. 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 Maintenance Section for more information Fill the crankcase with the proper amount of oil 160 SEBU7011 17 Maintenance Section Engine Oil and Filter Change NOTICE If equipped with an auxiliary oil filter or system extra oil must be added when filling the crankcase Follow 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 ENGINE STOPPED side of the oil level gauge Oil Change Interval Adjustments The
13. 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 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Cat ELC Extender 138 SEBU7011 17 Maintenance Section Cooling System Coolant Level Check 3 Add Cat ELC Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations article for more information 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 101197583 Cooling System Coolant Level Check SMCS Code 1395 082 Check
14. 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 SEBU7011 17 189 Maintenance Section Hoses and Clamps Inspect Replace 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
15. s Clean aere e E T A E E a 145 Engine Air Cleaner Element Clean Replace s s s 146 Engine Mounts Inspect 2 0 ccc ccceceeceeenceeeddhecceeeddenccceeedenccnenenddaeeeenetteas 150 Engine Valve Lash Inspect AdjUst 0 0 0 cceceeeeteeeeeeettteeeeeetnteeeeeeeeee 165 Starting Motor INSPEC oe ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeaeeees 193 Turbocharger INSPOCt uo eee eeceeeeeeeeeeeeeeeeeeeeeeeaaeeeeeeenaeeeeseeenaeeeeeeenaaes 193 Water Pump Inspect cccccccceeeeeeceeeceeeeeeeeeceeeeeeeeesetcecnceaeeeeeseeeeeess 198 Every 3 Years or 322 000 km 200 000 miles Cooling System Coolant DEAC Change ecceeeceeeeeeeeeteeeeeeees 128 114 SEBU7011 17 Maintenance Section Maintenance Interval Schedule Every 483 000 km 300 000 miles Cooling System Coolant Extender ELC Add s es 136 Every 6 Years or 966 000 km 600 000 miles Cooling System Coolant ELC Change cceeeeeeseeeeeeeettteeeeeees 133 Every 114 000 L 30 000 US gal of Fuel Overhaul Considerations ccccccccccccceeccssceeeeeeeeesseeueessaueeeeeeseesuaeeeeaas 190 SEBU7011 17 115 Maintenance Section Aftercooler Core Clean Test 101546702 Aftercooler Core Clean Test SMCS Code 1064 070 1064 081 1 Remove the core Refer to the Service Manual for the procedure 2 Turn the aftercooler core upside down in order to remove debris NOTICE Do not use a high concentration of caustic cleaner to clean th
16. system components SEBU7011 17 181 Maintenance Section Fuel System Prime Illustration 36 g01076450 1 Plug 2 Fuel filter 1 Remove plug 1 in order to fill fuel filter 2 Ensure that air is able to vent from the fitting of the plug while the fuel filter is being filled Clean up any spilled fuel immediately Clean plug 1 Install plug 1 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 2 Start the engine and operate the engine at low idle Do not raise the engine speed above an idle until the engine operates smoothly Fuel Filter Bases that are Not Equipped with a Plug 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 1 Operate the starting motor This will fill the fuel filter and the fuel lines with fuel 2 Once the engine starts operate the engine at low idle Do not raise the engine speed above an idle until the engine operates smoothly 182 SEBU7011 17 Maintenance Section Fuel System Primary Filter Clean Replace 100861167 Fuel System Primary Filter Clean Replace SMCS Code 1260 070 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
17. that can not be calibrated 198 SEBU7011 17 Maintenance Section Water Pump Inspect 100864339 Water Pump Inspect SMCS Code 1361 040 1361 Overconcentration of coolant additive conditioner mineral deposits from hard water or cooling system contamination can accelerate the wear on the water pump seal Replace the Water Pump Seal If Necessary Inspect the water pump for 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 Removal and Installation Refer to the Service Manual for more information on the removal and installation of the water pump or consult your Caterpillar dealer for assistance Inspect the Bearing for the Water Pump Pulley Inspect the water pump pulley for unusual noise excessive looseness and or vibration of the bearings Refer to the Service Manual for more information on the removal and installation of the water pump pulley or consult your Caterpillar dealer for assistance
18. the water properly 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 2 Close drain 1 186 SEBU7011 17 Maintenance Section Fuel Tank Water and Sediment Drain 102571779 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment
19. to indicate the direction of flow prior to disassembly SEBU7011 17 167 Maintenance Section Exhaust Filter Particulate Trap Clean Om am T ee ie Illustration 29 g01335326 1 Inlet module 2 Clamp 3 Gasket 4 Outlet module 5 Filter module 6 Catalyst module Note Lifting equipment should be used for a DPF that is installed in a horizontal position and for a DPF that is installed in a vertical position A filter that is damaged from contact is not covered by the Caterpillar warranty The DPF is divided into 4 modules Each module of the DPF is secured to the previous module with a clamp and with a gasket Use the following procedure in order to disassemble the DPF 1 Remove the gasket and the clamp between the inlet module and the catalyst module Separate the inlet module from the catalyst module 2 Remove the gasket and the clamp between the catalyst module and the filter module Separate the catalyst module from the filter module 3 Remove the gasket and the clamp between the filter module and the outlet module Separate the filter module from the outlet module 4 Inspect the inlet module and inspect the outlet module If there is damage to either of the modules replace the module that is damaged 5 Inspect the clamps If the clamps are not damaged the clamps can be used again The gaskets can not be used again Dispose of the gaskets 168 SEBU7011 17 Mai
20. 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 190 SEBU7011 17 Maintenance Section Overhaul Considerations 102394984 Overhaul Considerations SMCS Code 7595 043 Refer to the Operation and Maintenance Manual Maintenance Interval Schedule topic Maintenance Section for the proper intervals in order to perform an overhaul of the engine Several factors are important when an overhaul of the engine is considered The following factors are included The performance of preventive maintenance The ratio of oil consumption to fuel consumption Fuel consumption The quality of the fuel that has been consumed The mileage of the vehicle The operating conditions of the vehicle The results of the S O S oil analysis The loss of engine power An overhaul is a regular maintenance interval when the engine is inspected and worn components are replaced with rebuilt parts or new parts A top end overhaul is generally indicated by increased fuel consumption and reduced power This interval consists of completely reconditioning the cylinder head Normally it is not necessary to repair the cylinder components at this time A major overhaul is an interval when th
21. 20 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 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 188 SEBU7011 17 Maintenance Section Hoses and Clamps Inspect Replace Replace hoses that are cracked or soft Tighten any loose clamps NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque
22. 3126E COMMERCIAL and TRUCK ENGINES and 3126B ENGINE Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU701 1 17 01 2007 Caterpillar CATERPILLAR All Rights Reserved SEBU7011 17 109 Maintenance Section Maintenance Interval Schedule i02660876 Maintenance Interval Schedule Engines with a Shallow Oil Sump SMCS Code 1000 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICHEVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed When Required Air Dryer ChOGKscieciiticcecdittstecietaltigectabbonnetedt iavigened a lelsdeeat id ne 120 Battery Replace a r cies tee ceadtied chitinase EAE EE EAA 121 Battery or Battery Cable Disconnect eee eeeeree
23. A an 3 p al w w 14 Illustration 33 g01335329 Typical example 10 Inlet Module 11 Catalyst module 12 Filter module 13 Outlet Module 14 Test location 15 Tee fitting 16 Copper tubing 17 Thermocouple 176 SEBU7011 17 Maintenance Section Exhaust Filter Particulate Trap Test Note Do not test the exhaust back pressure if the Over pressure alarm 3 has been activated Clean the DPF Refer to Operation and Maintenance Manual SEBU7011 Exhaust Filter Particulate Trap Clean for the proper procedure 1 Remove Tee fitting 15 from test port 14 The test location is on the DPF 2 Connect the pressure port of the differential pressure gauge to the test port 3 Leave the vacuum port of the differential pressure gauge open to the atmosphere Note Watch the back pressure reading as the engine begins to warm up Stop the test immediately if the back pressure goes above 25 kPa 100 inch of H2O The filter module needs to be cleaned Refer to Operation and Maintenance Manual Exhaust Filter Particulate Trap Clean for the proper cleaning procedure 4 Start the engine and run the engine in the no load condition at high idle until the engine reaches normal operating temperature 5 Record the value while the engine is operating at high idle 6 Multiply the value from 5 by 1 8 7 If the results from Step 6 are grea
24. BU7011 17 127 Maintenance Section Belt Inspect Water Pump Belt Illustration 18 g01075753 Exploded view of the drive assembly for a water pump belt 1 Mounting bolt 2 Square hole 3 Adjusting bolt 1 Slightly loosen mounting bolts 1 and adjusting bolt 3 2 Adjust the belt tension with a square drive in square hole 2 3 Tighten adjusting bolt 3 and mounting bolt 1 For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications 4 Install the belt guard If new belts are installed check the belt tension after 30 minutes of engine operation at the rated rom 128 SEBU7011 17 Maintenance Section Belt Tensioner Inspect 101555583 Belt Tensioner Inspect If Equipped SMCS Code 1358 040 Illustration 19 g00426964 Belt tensioner Inspect the belt tensioner for unusual noise excessive looseness and or shaking of the bearings If the belt tensioner should require disassembly refer to the Service Manual for the procedure 102139869 Cooling System Coolant DEAC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated SEBU7011 17 129 Maintenance Section Cooling System Coolant DEAC
25. Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Check the fuel daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure SEBU7011 17 187 Maintenance Section Hoses and Clamps Inspect Replace 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 e Oil change e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank A 4 micron c filter for the breather vent on the fuel tank is also recommended Refer to Special Publication SENR96
26. The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber 4 Use a dial indicator to check the end clearance on the shaft If the measured end play is greater than the Service Manual specifications the turbocharger should be repaired or replaced An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications 5 Inspect the bore of the turbine housing for corrosion 6 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 7 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 196 SEBU7011 17 Maintenance Section Walk Around Inspection 101185304 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts wo
27. afety and Health Administration MSHA when cleaning the diesel particulate filter Failure to do so could result in personal injury The following equipment is required to clean the DPF e Dry pressurized air supply with 690 kPa 100 psi e A high pressure sprayer with a short rubber hose on the end of the nozzle SEBU7011 17 169 Maintenance Section Exhaust Filter Particulate Trap Clean e 229 0766 filter bag or equivalent filter bag Filter Bags The filter bags are available from your Caterpillar dealer The filter bags will trap particles as small as 5 microns A filter bag can be used 5 to 10 times Note Disposal of filter bags and disposal of the contents of the filter bags should be in accordance with the following applicable laws and regulations e Federal laws e State laws e Local laws or local regulations Disposal of the filter bags and disposal of the contents of the filter bags should also be in accordance with best management practices 170 SEBU7011 17 Maintenance Section Exhaust Filter Particulate Trap Clean Cleaning of the Filter Module Illustration 30 g01335327 1 Outlet surface 2 Rubber hose 3 Filter module 4 Inlet surface 5 Filter bag Use the following procedure in order to properly clean the filter module 1 Place a filter bag around the inlet side of the filter module Secure the filter bag to the filter module with the draw string Position the filte
28. ar dealer for assistance 101491325 Air Compressor Filter Clean Replace 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 recommendations that are provided by the OEM of the air compressor Some engines use boost air pressure so the engine air cleaner will require servicing 120 SEBU7011 17 Maintenance Section Air Dryer Check 100863920 Air Dryer Check SMCS Code 4285 535 Follow the maintenance recommendations that are provided by the OEM or consult your Caterpillar dealer for assistance 100072207 Alternator Inspect SMCS Code 1405 040 Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the ammeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs as required Refer to the Service Manual Check the alternator and the battery charger for proper operation If the batteries are
29. ark in table 14 Allow enough time for the oil to drain into the crankcase 7 Check the oil level on the oil level gauge The oil level should be at the FULL mark If the oil level is not at the existing FULL mark grind off the FULL mark Use an engraving pen in order to engrave the new FULL mark 8 Locate the sump capacity of the engine again in table 14 and add the additional amount in order to allow oil to fill the engine oil filter SEBU7011 17 155 Maintenance Section Engine Oil Sample Obtain NOTICE Do not crank the engine for more than 30 seconds Allow the starting motor to cool for two minutes before cranking again 9 Start the engine and run the engine enough to ensure that the lubrication system is filled Inspect the engine for oil leaks 10 Stop the engine and allow enough time for the oil to drain into the crankcase 11 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 Record the amount of oil that was added This additional oil and the Total Fill volume of oil that was in the crankcase is the oil capacity of the lubrication system Record the oil capacity of the lubrication system for future oil changes 101935337 Engine Oil Sample Obtain SMCS Code 1000 008 1348 554 SM 7542 554 OC SM In addition to a good preventive maintenance program Caterpillar recom
30. ble by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tool 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 Note If equipped be sure to flush the heater and any related supply and return lines SEBU7011 17 135 Maintenance Section Cooling System Coolant ELC Change 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications 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 For the proper torque refer to the Spe
31. cifications Manual SENR3130 Torque Specifications 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 See Special Publication SEBU6385 Caterpillar On highway Diesel Truck Engine Fluids Recommendations for more information on cooling system specifications Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass if equipped 136 SEBU7011 17 Maintenance Section Cooling System Coolant Extender ELC Add Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling syst
32. 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 SEBU7011 17 153 Maintenance Section Engine Oil Level Gauge Calibrate 102005382 Engine Oil Level Gauge Calibrate SMCS Code 1326 524 Check Calibration at the First Oil Change 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 the markings are correct Verify the oil level gauge markings at the first oil change Verify the ADD mark and verify the FULL mark that is on the oil level gauge Use the following procedure NOTICE The vehicle must be parked on a level surface in order to perform this maintenance procedure 1 Operate the engine until normal operating 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 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
33. e sampling valve The fluid sampling bottle includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEHP6001 How To Take A Good Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine SEBU7011 17 157 Maintenance Section Engine Oil and Filter Change 101947041 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 oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil
34. e core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 3 Back flush the core with cleaner Caterpillar recommends the use of Hydrosolv liquid cleaner Table 13 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 13 Hydrosolv Liquid Cleaners Part E Number Description Size 1U 5490 Hydrosolv 4165 19 L 5 US gallon 174 6854 Hydrosolv 100 19 L 5 US gallon 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information 4 Steam clean the core in order to remove any residue Flush the fins of the aftercooler core Remove any other trapped debris 5 Wash the core with hot soapy water Rinse the core thoroughly with clean water 116 SEBU7011 17 Maintenance Section Aftercooler Core Inspect Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 6 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the core in order to ensure cleanlin
35. e items that have major wear in the engine should be replaced Items that can have major wear include the following items piston rings main bearings rods and valves SEBU7011 17 191 Maintenance Section Radiator Clean Overhaul Options Caterpillar Dealer Consult your Caterpillar dealer in order to schedule a before failure overhaul 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 corrosion dirt grease insects leaves oil and other debris Clean the radiator if necessary Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro 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
36. eeeteeeeeeetnteeeeeeeees 124 Engine Oil Level Gauge Calibrate cc eeeeeeeeetneeeeeetnteeeeeeeees 153 Engine Storage Procedure Check eeecccceeeeeeeeeeeeeescneeeeeeeneeeeeeeaas 164 Exhaust Filter Particulate Trap Clean eeecceeeeeeeeeeeeeeeeteeeeeeenaes 166 Exhaust Filter Particulate Trap Test 0 ee eee etree etna 172 Fuel System PME esre sirra tra E AA EAE EEEE ERNEA 179 Severe Service Application Check 0 ccceeceeeeeeeeceeeeeeeeeeeeeeeteeseees 192 Daily Cooling System Coolant Level Check 0 00 cceeeeeeeeeeeeeeeteeeeeeeeneeees 138 Engine Air Cleaner Service Indicator Inspect ceeeeeeeeeteeeeeeeeee 146 Engine Oil Level Check ou ccceccccccccieeceeeecaeeeceeeseeeeceeedeaneceeenedateeeeeteas 150 Fuel System Water Separator Drain ccceeeeceeeeeeeeeeeeeeeesteeeeeeenaas 184 Walk Around Inspection 0 0 cccceceeeeeeeeeeeceeeceeceeeeeeeeeseseccenaaeeeeeeeeeneees 196 110 SEBU7011 17 Maintenance Section Maintenance Interval Schedule Initial 17 700 km 11 000 miles or 4150 L 1100 US gal of Fuel or 250 Service Hours or 6 Months Engine Valve Lash Inspect AdjUst ceceeecteeeeeeettneeeeeeetieeeeeeeeee 165 PM Level 1 Every 17 700 km 11 000 miles or 4150 L 1100 US gal of Fuel or 250 Service Hours or 6 Months Aftercooler Core Inspect ccccccccceceeceeeeeeeeeccaeeeeeeeeeeeeeseeseesnnsinaeees 116 Air Compressor Filter Clean Replace
37. em Coolant DEAC Change 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water 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 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 coolin
38. em filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 102482066 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1395 081 Cat ELC Extended Life Coolant does not require the frequent additions of any supplemental cooling additives which are associated with the present conventional coolants The Cat ELC Extender only needs to be added once NOTICE Use only Cat Extended Life Coolant ELC Extender with Cat ELC Do NOT use conventional supplemental coolant addi tive SCA with Cat ELC Mixing Cat ELC with conven tional coolants and or conventional SCA reduces the Cat ELC service life Check the cooling system only when the engine is stopped and cool SEBU7011 17 137 Maintenance Section Cooling System Coolant Extender ELC Add 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
39. engine If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear 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 101900118 Engine Air Cleaner Service Indicator Inspect If Equipped SMCS Code 7452 040 Some engines may be equipped with a different service indicator SEBU7011 17 147 Maintenance Section Engine Air Cleaner Service Indicator Inspect 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
40. er to the Operation and Maintenance Manual for the proper torques 5 Install the hose Install hose clamp 2 For proper torque refer to the Specifications Manual SENR3130 Torque Specifications 150 SEBU7011 17 Maintenance Section Engine Mounts Inspect 102139969 Engine Mounts Inspect SMCS Code 1152 040 Inspect the engine mounts for deterioration and for proper bolt torque Engine vibration can be caused by the following conditions e Improper mounting of the engine e Deterioration of the engine mounts Any engine mount that shows deterioration should be replaced Refer to the Specifications Manual SENR3130 Torque Specifications Refer to your Caterpillar dealer for more information 102113104 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 SEBU7011 17 151 Maintenance Section Engine Oil Level Check 1 2 a ae EAN H 5 j Ms bo A A Illustration 25 g01076429 1 Oil filler cap 2 Oil level gauge C ADD FULL 5 g00110310 Illustration 26 Y ADD mark X FULL mark NOTICE Perform this maintenance with the engine stopped Note Before you per
41. erature Refer to this Operation and Maintenance Manual Exhaust Particulate Filter Test for the testing procedure i02660911 Exhaust Filter Particulate Trap Test SMCS Code 1091 081 S N DPF1 Up The particulate trap exhaust filter will become restricted with ash and soot from the engine The restriction will cause the back pressure of the exhaust from the DPF to increase Testing the back pressure of the exhaust system will determine when the filter module and catalyst module needs to be cleaned SEBU7011 17 173 Maintenance Section Exhaust Filter Particulate Trap Test Testing Back Pressure Table 16 Required Tools Part i Number Part Name Quantity 1U 5470 Engine Pressure Group or or 198 4240 Digital Pressure Indicator 1 or or 220 3778 Adapter Cable As Illustration 31 901331083 1U 5470 Engine Pressure Group 174 SEBU7011 17 Maintenance Section Exhaust Filter Particulate Trap Test 1 234 5 E NS P o 0 0 0 a a O X O 9 g01335328 Illustration 32 diagnostic module for the DPF 1 Mounting holes 2 System status 3 Over pressure alarm 4 Over temp alarm 5 System problem 6 Alarm reset button 7 Pressure transducer port 8 Wire passage 9 Serial data comm port Rea NN Na Back pr
42. ess Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 8 Install the core Refer to the Service Manual for the procedure For more information on cleaning the core consult your Caterpillar dealer 101468985 Aftercooler Core Inspect SMCS Code 1064 040 Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the aftercooler for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the aftercooler if necessary For air to air aftercoolers use the same methods that are used for cleaning radiators SEBU7011 17 117 Maintenance Section Aftercooler Core Inspect Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning p
43. essure can be measured in many different ways The diagnostic module for the DPF can be connected to a computer and port 9 with 220 3778 Adapter Cable As You will be able to monitor the back pressure The history of the back pressure can be downloaded Refer to Special Instruction REHS1342 CRTdm Interface Software Guide The back pressure can also be measured with 198 4240 Digital Pressure Indicator Refer to Special Instruction NEHS0818 Using the 198 4240 Digital Pressure Indicator for the instructions that are needed to use the tool The 1U 5470 Engine Pressure Group can also be used to measure the back pressure Refer to Special Instruction SEHS8907 Using the 1U 5470 Engine Pressure Group for the instructions that are needed to use the tool Back pressure measurements are required at the following intervals e Amber dash light turns on SEBU7011 17 175 Maintenance Section Exhaust Filter Particulate Trap Test e Every 6 months e 40 234 kilometers 25 000 miles The muffler and converter will become extrem ly hot during engine operation A hot muffler and converter can cause serious burns Allow adaquate cooling time before working on or near the muffler and converter Making contact with a running engine can cause burns from hot parts and can cause injury from rotating parts When working on an engine that is running avoid contact with hot parts and rotating parts 11 REN
44. f fuel e Storage e Replacement of the fuel filter Engines that are Equipped with a Fuel Priming Pump NOTICE Do not loosen the fuel lines at the fuel manifold The fittings may be damaged and or a loss of priming pres sure may occur when the fuel lines are loosened 1 Open the fuel priming pump and operate the fuel priming pump until a strong pressure is felt This procedure will require considerable strokes Lock the fuel priming pump 180 SEBU7011 17 Maintenance Section Fuel System Prime 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 2 Promptly start the engine If the engine runs rough continue to operate the engine at low idle Do not raise the engine rpm above an idle until the engine operates smoothly 3 If the engine does not start open the fuel priming pump and repeat Steps 1 and 2 in order to start the engine Engines that are Not Equipped with a Fuel Priming Pump If the engine is not equipped with a fuel priming pump you can use the following procedures to prime the fuel system These procedures will allow only filtered fuel to enter the fuel system Fuel Filter Bases that are Equipped with a Plug 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
45. form this maintenance do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan 1 Maintain the oil level between ADD mark Y and FULL mark X on oil level gauge 1 Do not fill the crankcase above FULL mark X 152 SEBU7011 17 Maintenance Section Engine Oil Level Check NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can enable the crankshaft to dip into the oil This will reduce the power that is de veloped and also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling of the pistons oil blow ing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will enable deposits to form on the pistons and in the combustion chamber De posits in the combustion chamber lead to the following problems guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately 2 Remove oil filler cap 2 and add oil if necessary For the correct oil to use refer to Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations Do not fill the
46. 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 For more information on the maintenance of the primary fuel filter refer to the literature that is provided by the OEM of the vehicle or refer to the literature that is provided by the OEM of the primary fuel filter 101503750 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 SEBU7011 17 183 Maintenance Section Fuel System Secondary Filter Replace NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 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 informa
47. g system capacity Install the cooling system filler cap Start and run the engine at low idle for a minimum of 90 minutes The coolant temperature should be at least 82 C 180 F 132 SEBU7011 17 Maintenance Section Cooling System Coolant DEAC Change 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 Capacitites and Recommendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling sys
48. ge must be balanced due to high rpm Severe Service Applications can accelerate component wear Severe Service Applications require more frequent inspections of the cartridge Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil Clean the interior of the pipes in order to prevent dirt from entering during reassembly SEBU7011 17 195 Maintenance Section Turbocharger Inspect 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal
49. ghten 144 Engine Crankcase Breather Clean eeceeceeeeeteeeeeeeeneeeeeeetnteeeeeeeeee 148 Engine Oil Sample Obtain eee eee eeceeee eee eeneeeeeeeeaeeeeeeenaeeeeeeaas 155 Engine Oil and Filter Change eee ceeeeeceeeeee eset eee eeeeteeeeeeenneeeeeeeees 157 Fan Drive Bearing Lubricate 0 cc ccececeeeeeeeeeeeeeeeeeceeeeeetteeeeeeeeee 177 Fuel Inlet Screen Clean Inspect Replace cccceeeeceeeeseeteeeees 178 Fuel System Primary Filter Clean Replace n 182 Fuel System Secondary Filter Replace ceeeeeceeeeeeeeseeeeeeeeeee 182 Fuel Tank Water and Sediment Drain cccceceeeeeeeeeeeeneeteeeees 186 Hoses and Clamps Inspect Replace cccccceceeeeeeeeeesenenaeeees 187 Radiator O T a EEE EE AEE E A een atthe 191 PM Level 2 Every 161 000 km 100 000 miles or 56 850 L 15 000 US gal of Fuel or 2000 Service Hours or 2 Years Aftercooler Core Clean Test eececceeeeseteeeeeeeecteeeeeeeneeeeeeeeneeeeeeenaaes 115 Air Compressor Inspect cccccceceeeeeeeeeeeeeaaeeeceeeeeeeeeseesessnntunaeees 118 Alternator INSD Ct rr a ee a a aie era aa ee E EA 120 Belt Tensioner Inspect cccccceeceeeeeeeeeeeeeeeceeeeeeeeeeeeeesennsaneeeees 128 Cooling System Water Temperature Regulator Replace 4 142 Crankshaft Vibration Damper Inspect 2 cecceeceeeeeeeeeeeeeeeseeee 143 Engine
50. he crankshaft which is located behind the belt guard on the front of the engine Removal and Installation Refer to the Service Manual for the damper removal procedure and for the damper installation procedure 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 dents cracks or leaks of the fluid Replace the damper if the damper is dented cracked or leaking Refer to the Service Manual or consult your Caterpillar dealer for damper replacement 144 SEBU7011 17 Maintenance Section Cylinder Head Grounding Stud Inspect Clean Tighten 100856194 Cylinder Head Grounding Stud Inspect Clean Tighten SMCS Code 7423 040 7423 070 7423 079 Illustration 22 g00427181 Cylinder head grounding stud Inspect the OEM harness for good connections and condition 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 Clean the cylinder head grounding stud and the terminals for the cylinder head ground strap with a clean cloth If the connections are corroded clean
51. il filter Locate the row which lists your available oil The intersection of the column and the row lists the maximum permissible number of kilometers or miles between oil change intervals SEBU7011 17 163 Maintenance Section Engine Oil and Filter Change Example You determined that the vehicle application is light duty commercial The oil capacity of the engine is 21 L 22 qt and the oil capacity of the auxiliary oil filter is 10 L 10 qt With S O S Oil Analysis verification the maximum permissible oil change interval is 30900 kilometers 19200 miles For more information on optimizing oil change intervals see your Caterpillar dealer 164 SEBU7011 17 Maintenance Section Engine Storage Procedure Check 101458399 Engine Storage Procedure Check SMCS Code 1000 535 The oil change interval may be extended to 12 months for a vehicle that is operated seasonally and placed in storage for the remainder of the year by using the required storage procedures and the required start up procedures This extension is permitted if the following categories for oil change intervals in the Operation and Maintenance Manual Maintenance Interval Schedule have not been reached e Mileage e Operating hours e Fuel consumption If an engine is out of operation and if use of the engine is not planned special precautions should be made If the engine will be stored for more than three months a complete protection procedure is
52. ing inlet side Any fumes from the crankcase are filtered through the air inlet system Therefore by products from oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause additional damage to the pistons the valves and the cylinder head 194 SEBU7011 17 Maintenance Section Turbocharger Inspect NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartrid
53. itions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is needed when the ELC is drained and replaced Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary 134 SEBU7011 17 Maintenance Section Cooling System Coolant ELC Change Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove the cooling system drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method accepta
54. lator 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 SEBU7011 17 143 Maintenance Section Crankshaft Vibration Damper Inspect 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 or consult your Caterpillar dealer Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 100072369 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive gear train noise at variable points in the speed range The damper is mounted to t
55. mends using S O S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information 156 SEBU7011 17 Maintenance Section Engine Oil Sample Obtain e Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with th
56. nance Interval Schedule i02660875 Maintenance Interval Schedule Engines with a Deep Oil Sump SMCS Code 1000 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICHEVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed When Required Air Dryer CHECK orini aa iavigened aaa 120 Battery Replace e o r E T AEA EAE EE EA 121 Battery or Battery Cable Disconnect eee eeeereeeeeteeeeeeetnteeeeeeeees 124 Engine Oil Level Gauge Calibrate cc eeeeeeeeetneeeeeetnteeeeeeeees 153 Engine Storage Procedure Check eeecccceeeeeeeeeeeeeescneeeeeeeneeeeeeeaas 164 Exhaust Filter Particulate Trap Clean eeecceeeeeeeeeeeeeeeeteeeeeeenaes 166 Exhaust Filter Particulate Trap Test 0
57. ntenance Section Exhaust Filter Particulate Trap Clean Note See your Caterpillar dealer in order to replace any of the components of the DPF Also see your Caterpillar dealer in order to replace the entire DPF Inspection of the Filter Module The inlet surface of the filter module will be black due to a coating of soot The outlet surface should show no evidence of soot Replace the filter module if there are black deposits on the outlet side The black deposits are soot Note Inspect the inlet surface and inspect the outlet surface of the filter module for missing or cracked ceramic pieces Replace the filter module if any ceramic pieces are damaged or lost A damaged filter module will not meet the emissions requirements A damaged filter module must be replaced Refer to the Installation of the DPF information in this article Inspection of the Catalyst Module Inspect the inlet surface and inspect the outlet surface of the catalyst module for missing or cracked ceramic pieces Replace the catalyst module if any ceramic pieces are damaged or lost A damaged catalyst module will not meet the emissions requirements A damaged catalyst module must be replaced Refer to the Installation of the DPF information in this article Filter Module Cleaning Equipment Wear goggles gloves protective clothing and a dust respirator certified by the National Institute for Occupational Safety and Health NIOSH and by the Mine S
58. 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 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 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 Add the proper amount of SCA Refer to Operation and Maintenance Manual SEBU6385 Caterpillar On highway Diesel Truck Engines Fluids Recommendation
59. olant 130 SEBU7011 17 Maintenance Section Cooling System Coolant DEAC Change For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tool 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 SEBU7011 17 131 Maintenance Section Cooling Syst
60. oncentration as part of an S O S Coolant Analysis 140 SEBU7011 17 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add Test the SCA Concentration Coolant and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration 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 8T 5296 Coolant Conditioner Test Kit or use the 4C 9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA See Special Publication SEBU6385 Caterpillar On highway Diesel Truck Engine Fluids Recommendations for more information S O S Coolant Analysis S 0 S coolant samples can be analyzed at your Caterpillar dealer S O S Coolant Analysis is a program that is based on periodic samples Level Level is a basic analysis of the coolant The following items are tested e Glycol Concentration e Concentration of SCA pH e Conductivity The results are reported and recommendations are made according to the results Consult your Caterpillar dealer for information on the benefits of managing your equipment with an S O S Coolant Analysis SEBU7011 17 141 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add Add the SCA If Necessary 1 NOTICE Do not exceed the recommended amount
61. onto the inlet module Refer to figure 29 1 Verify that the arrow on the catalyst module is pointed away from the inlet module 2 Install a new gasket and an undamaged clamp between the inlet module and the catalyst module Tighten the clamps to a torque of 20 N m 15 Ib ft 3 Install a new gasket and an undamaged clamp between the catalyst module and the filter module Verify that the arrow on the filter module is pointed away from the catalyst module Tighten the clamps to a torque of 20 N m 15 Ib ft 4 Install a new gasket and an undamaged clamp between the filter module and the outlet module Tighten the clamps to a torque of 20 N m 15 Ib ft 172 SEBU7011 17 Maintenance Section Exhaust Filter Particulate Trap Test 5 Use proper lifting equipment and reinstall the assembled DPF to the chassis A chassis clamp attaches the DPF to the chassis When possible the chassis clamp that attaches the DPF to the chassis should not be installed around the filter module If the chassis clamp that attaches the DPF to the chassis is attached around the filter module ensure that the clamp does not exceed 2580 kPa 374 psi on the filter module 6 Check the system for leaks by running the engine at high idle with no load 7 Reset the diagnostic module if any alarms have been activated Performing the Back Pressure Test on the DPF Perform a back pressure test after cleaning the DPF The engine should be at operating temp
62. or 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 Note There should be enough residual fuel in the cylinder head in order to start the engine If the engine stops after starting do not crank the engine for more than 30 seconds Then allow the starting motor to cool for two minutes Repeat this procedure until the engine starts and the engine operates 102112513 Fuel System Water Separator Drain SMCS Code 1263 543 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE The water separator is not a filter It separates water from the fuel The engine should never be allowed to run with the water level in the separator more than 1 2 full or en gine damage may result SEBU7011 17 185 Maintenance Section Fuel System Water Separator Drain A water separator is recommended The water separator should be installed between the fuel tank and the engine fuel inlet Drain the water and sediment from the water separator on a daily basis Illustration 37 g01076474 1 Drain 1 Open drain 1 Catch the draining water in a suitable container Dispose of
63. 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 SEBU7011 17 121 Maintenance Section Battery Replace 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 may cause a battery explosion resulting in personal injury 1 Turn the key start switch to the OFF position Remove the key and all electrical loads 2 Turn OFF the battery charger Disconnec
64. r module in a vertical position Positioning the filter module in this manner will allow the ash to fall into the bag SEBU7011 17 171 Maintenance Section Exhaust Filter Particulate Trap Clean 2 Blow the ash from the filter module with compressed air The compressed air must be regulated at 690 kPa 100 psi The compressed air must be reduced to 205 kPa 30 psi when the nozzle is deadheaded and with effective chip guarding if applicable and personal protective equipment The air should be dry and free from oil Do not damage the DPF with the nozzle 3 The nozzle should be 12 70 mm 0 5 inch away from the filter module By using slow circular motions direct the compressed air through the filter module Work from the center of the filter module toward the outside of the filter module Cleaning the DPF will require 30 to 40 minutes Larger filters generally require longer cleaning times Installation of the DPF Note The filter module and the catalyst module must be installed with the correct orientation of flow in order to properly function Note The gaskets that are removed from the DPF can not be used again The clamps that are removed from the DPF can be used again if the clamps are undamaged If necessary contact your Caterpillar dealer for new gaskets and for new clamps Apply 4C 5599 anti seize compound to the threads of each clamp before installation Perform the following procedure to install the catalyst module
65. rake 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 L AE eS ei ia 1 rela CA ey co a iTo Illustration 16 g01076630 1 Pressure relief valve SEBU7011 17 119 Maintenance Section Air Compressor Filter Clean Replace If the air compressor pressure relief valve that is mounted in the air compressor cylinder head is bypassing compressed air there is a malfunction in the air system possibly ice blockage Under these conditions your engine may have insuffi cient air for normal brake operation Do not operate the engine until the reason for the air bypass is identified and corrected Failure to heed this warning could lead to property damage personal injury or death to the operator or by standers The function of the pressure relief valve is to bypass air when there is a malfunction in the air compressor system The pressure relief valve releases air at 1723 kPa 250 psi Do not stand near the pressure relief valve Compressed air may be released without warning 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 Caterpill
66. re are many circumstances under certain conditions that may allow an adjustment to the normal oil change interval Many conditions that can affect the selection of the best oil change interval exist The decision is based on the fundamental requirement that lubrication oil should be in an acceptable condition that provides continuous engine protection The quality of the oil and amount of the oil that is available is balanced against the oil s ability to absorb by products that are caused by combustion Due to the manufacturing tolerances the engine application and the maintenance variations all engines do not consume fuel and oil at the same rate The amount of fuel that is consumed is in direct relation to the maximum oil change interval that is selected It is essential to include an S O S oil analysis before an adjustment of the oil change interval is considered For more information on extending oil change intervals contact your local Caterpillar dealer S O S oil analysis should be used to verify the oil change interval adjustments Table 15 can be used in order to determine the oil change interval adjustments SEBU7011 17 161 Maintenance Section Engine Oil and Filter Change S O S oil analysis should be used to verify the oil change interval adjustments Table 15 can be used in order to determine your oil change interval adjustments Table for the Oil Change Interval Adjustments Note Metric units are listed before English uni
67. recommended For more detailed information on engine storage see Special Instruction SEHS9031 Storage Procedure For Caterpillar Products If the engine will not be started for several weeks the lubricating oil will drain from the cylinder walls and from the piston rings Rust can form on the cylinder liner surface Rust on the cylinder liner surface will cause increased engine wear and a reduction in engine service life Caterpillar recommends the use of volatile corrosion inhibitor VCI oil in order to prevent internal engine damage due to moisture during storage These inhibitors in the VCI oil act by evaporating inside the engine The inhibitors then condense over the inside surfaces of the engine The evaporation process and the condensing process offers full protection to surfaces that cannot be reached with preservatives 0 9 L 1 0 qt of 4C 6792 VCI oil will treat 28 4 L 30 0 qt of engine oil This will give a 3 percent concentration of VCI oil The engine must be completely sealed when the engine is stored in order for the VCI oil to function properly The VCI oil is easily cleaned from the engine when you remove the engine from storage The volatile vapors are removed by simply running the engine to operating temperature A mineral oil base is left behind after the volatile vapors are removed SEBU7011 17 165 Maintenance Section Engine Valve Lash Inspect Adjust i00869628 Engine Valve Lash Inspect Adjust SMCS Code
68. rn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water e 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 SEBU7011 17 197 Maintenance Section Walk Around Inspection Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pumps and the installation of water pumps and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the fron
69. s for more information on SCA requirements 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 142 SEBU7011 17 Maintenance Section Cooling System Water Temperature Regulator Replace 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 cause overheating or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regu
70. sition 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 102149963 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 SEBU7011 17 125 Maintenance Section Belt Inspect Check the belt tension Refer to the Operation and Maintenance Manual Maintenance Interval Schedule topic Maintenance Section for the proper intervals 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 To maximize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged For applications that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched The additional load on the new belt could cause the new belt to break If the belts are too loose vibra
71. 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 192 SEBU7011 17 Maintenance Section Severe Service Application Check After cleaning start the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary For more detailed information on cleaning and inspection refer to Special Publication SEBD0518 Know Your Cooling System 102385785 Severe Service Application Check SMCS Code 1000 535 Operation and maintenance practices affect the service life of the component when the engine is operated in certain applications that require severe service 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 Reduce the maintenance intervals for engines that operate under conditions that are severe e Frequent operation with more than 22700 kg 50000 Ib of gross vehicle weight Freq
72. st Filter Particulate Trap Clean SMCS Code 1091 070 S N DPF1 Up Wear goggles gloves protective clothing and a dust respirator certified by the National Institute for Occupational Safety and Health NIOSH and by the Mine Safety and Health Administration MSHA when cleaning the diesel particulate filter Failure to do so could result in personal injury The diesel particulate filter DPF can be cleaned Perform a back pressure test in order to determine if the DPF needs to be cleaned Refer to Operation and Maintenance Manual Exhaust Particulate Filter Test Note If the red warning light has been activated do not perform a back pressure test The catalyst section could begin to regenerate This will damage the DPF Caterpillar recommends recording when the DPF is cleaned Record the cleaning in the Operation and Maintenance Manual Maintenance Log Perform a back pressure test prior to cleaning the DPF and record the results After cleaning the DPF run the engine on high idle for 5 to 15 minutes Perform another back pressure test and record the results Refer to this Operation and Maintenance Manual Exhaust Particulate Filter Test for the testing procedure Removal of the Filter Module Hot engine components can cause injury from burns Before performing maintenance on the engine allow the engine and the components to cool Use a marker on the catalyst module and on the filter module in order
73. t 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 fuel line tie wraps Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Ensure that hoses and tubes are not contacting other hoses tubes wiring harnesses etc Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the ECM to the cylinder head ground strap for a good connection and for good condition 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
74. t the charger 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the ground plane Disconnect the cable from the NEGATIVE battery terminal 4 The POSITIVE cable connects the POSITIVE battery terminal to the starting motor Disconnect the cable from the POSITIVE battery terminal 122 SEBU7011 17 Maintenance Section Battery Replace 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 8 Connect the cable from the ground plane to the NEGATIVE battery terminal SEBU7011 17 123 Maintenance Section Battery Electrolyte Level Check 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 protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery
75. tem 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 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 SEBU7011 17 133 Maintenance Section Cooling System Coolant ELC Change 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 95 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 102173402 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 cond
76. ter than 25 kPa 100 inch of H20 the DPF needs to be cleaned Refer to the Operation and Maintenance Manual SEBU7011 Exhaust Particulate Filter Clean for the proper cleaning procedure SEBU7011 17 177 Maintenance Section Fan Drive Bearing Lubricate 102239650 Fan Drive Bearing Lubricate SMCS Code 1359 086 BD Some of the fan drives have grease fittings and some of the fan drives do not have grease fittings If there is no grease fitting periodic lubrication is not required The fan drive requires grease only if the fan drive is equipped with a zerk Illustration 34 g00746166 Typical location of the grease fitting if equipped that is for the fan drive bearing The pulley is shown with the belt guards that have been removed Lubricate the grease fitting that is on the fan drive bearing with Bearing Lubricant or the equivalent Inspect the fan drive pulley assembly for wear or for damage If the shaft is loose an inspection of the internal components should be performed Refer to the Service Manual for additional information 178 SEBU7011 17 Maintenance Section Fuel Inlet Screen Clean Inspect Replace 101632506 Fuel Inlet Screen Clean Inspect Replace If Equipped SMCS Code 1250 510 Z3 1250 571 Z3 1252 040 Z3 1252 070 Z3 1252 510 Z3 1252 571 Z3 1252 571 1252 1256 040 Z3 1256 070 Z3 1256 510 Z3 1256
77. the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendations in order to service the air cleaner service indicator The service indicator may be mounted on the air cleaner housing or in a remote location Illustration 23 g00103777 Typical service indicator Observe the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three pushes 148 SEBU7011 17 Maintenance Section Engine Crankcase Breather Clean e Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are se
78. the connections with a solution of baking soda and water Keep the cylinder head grounding stud and the strap clean and coated with MPGM grease or petroleum jelly SEBU7011 17 145 Maintenance Section Engine Clean 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 146 SEBU7011 17 Maintenance Section Engine Air Cleaner Element Clean Replace 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
79. the coolant level when the engine is stopped and cool 4 Illustration 20 g00285520 Cooling system filler cap Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly in order to relieve pressure SEBU7011 17 139 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add 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 21 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 102440893 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 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 c
80. tion Shut off the fuel supply valve if equipped 2 Remove the used fuel filter and discard the used fuel filter 3 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 4 Apply clean diesel fuel to the new fuel filter gasket NOTICE Do not fill the secondary fuel filter with fuel before in stalling The fuel would not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts NOTICE In order to maximize fuel system life and prevent pre mature wear out from abrasive particles in the fuel a two micron absolute high efficiency fuel filter is re quired for all Caterpillar Hydraulic Electronic Unit In jectors Caterpillar High Efficiency Fuel Filters meet these requirements Consult your Caterpillar dealer for the proper part numbers 184 SEBU7011 17 Maintenance Section Fuel System Water Separator Drain 5 Install the new fuel filter Spin the fuel filter onto the fuel filter base until the gasket contacts the base Use the rotation index marks on the filters as a guide for proper tightening Tighten the filter for an additional one turn 360 degrees by hand Do not overtighten the filter 6 Open the fuel supply valve 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 f
81. tion causes unnecessary wear on the belts and pulleys Loose belts may slip enough to cause overheating If the belts are too 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 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 126 SEBU7011 17 Maintenance Section Belt Inspect Adjustment Alternator Belt Illustration 17 g01075759 1 Adjusting bolt 2 Mounting bolts 1 Slightly loosen mounting bolts 2 and adjusting bolt 1 2 Move the pulley in order to adjust the belt tension 3 Tighten adjusting bolt 1 and mounting bolts 2 For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications 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 SE
82. ts Note Use of table 15 assumes the use of a recommended oil type Table 15 Permissible Oil Change Interval Oil Vehicle Applications Capacity of the Light Medam neay Severe Engine Duty Duty Duty Service in Liters KM Miles to Next Oil Change quarts 18 20 19 320 16 000 12 890 9 670 12 000 10 000 8 000 6 000 21 22 21 260 17 710 14 170 10 960 13 200 11 000 8 800 6 800 23 24 23 190 19 320 15 460 12 230 14 400 12 000 9 600 7 600 25 26 25 110 20 930 16 750 13 530 15 600 13 000 10 400 8 400 27 28 27 040 22 540 18 040 14 810 16 800 14 000 11 200 9 200 28 30 28 980 24 000 19 320 16 100 18 000 15 000 12 000 10 000 30 32 30 900 25 760 20 510 17 380 19 200 16 000 12 800 10 800 32 34 32 850 27 370 21 900 18 670 20 400 17 000 13 600 11 600 34 36 34 770 28 980 23 190 19 970 21 600 18 000 14 400 12 400 36 38 36 700 30 590 24 470 21 260 22 800 19 000 15 200 13 200 continued 162 SEBU7011 17 Maintenance Section Engine Oil and Filter Change Table 15 contd 38 40 38 640 32 200 25 760 22 540 24 000 20 000 16 000 14 000 40 42 40 580 33 810 27 050 23 830 25 200
83. uent low speed operation less than 20 Miles per Hour Use of API CF 4 oil e Use of fuel with more than 0 05 sulfur e No water separator Frequent operation in dusty conditions or off highway operation High load factor operation less than 6 miles per gallon or off highway operation Frequent high altitude operation above 1525 m 5000 ft SEBU7011 17 193 Maintenance Section Starting Motor Inspect Frequent operation at low idle more than 20 Frequent cold starts at temperatures below 18 C 0 F Frequent dry starting starting after more than 3 days of shutdown Frequent hot shutdowns minimum three minute cool down periods after high load factor operation If the engine is stored over 3 months see Special Instruction SEHS9031 Storage Procedure for Caterpillar Products 100651416 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar Inc recommends a scheduled inspection of the starting motor If the starting motor fails the engine may not start in an emergency situation Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance 101539769 Turbocharger Inspect SMCS Code 1052 040 1052 Periodic inspection and cleaning is recommended for the turbocharger compressor hous
84. urposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both sides of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water After cleaning start the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Note If parts of the aftercooler system are repaired or replaced a leak test is highly recommended The FT1984 Aftercooler Testing Group is used to perform leak tests on the aftercooler Refer to the Systems Operation Testing and Adjusting Aftercooler Test and the Special Instruction SEHS8622 for the proper testing procedure Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary For more detailed information on cleaning and inspection see Special Publication SEBD0518 Know Your Cooling System 118 SEBU7011 17 Maintenance Section Air Compressor Inspect 102113479 Air Compressor Inspect SMCS Code 1803 040 Do not disconnect the air line from the air com pressor governor without purging the air b
85. verely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 102150070 Engine Crankcase Breather Clean SMCS Code 1317 070 NOTICE Perform this maintenance with the engine stopped NOTICE If the crankcase breather is not maintained on a regu lar basis it can become plugged A plugged breather will cause excessive crankcase pressure that may cause crankshaft seal leakage SEBU7011 17 149 Maintenance Section Engine Crankcase Breather Clean AR md LG aR alli ic Illustration 24 g00428148 1 Bolt 2 Hose clamp 3 Breather assembly 4 Hose 1 Loosen hose clamp 2 and remove the hose from breather assembly 3 2 Loosen the retaining clamp Remove the breather assembly 3 and the seal 3 Wash the breather element in solvent that is clean and nonflammable Allow the breather element to dry before installation 4 Install a breather element that is clean and dry Install breather assembly and seal 3 and install the retaining clamp Ref

3126E COMMERCIAL and TRUCK ENGINES and 3126B

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