Home

1 - Safety - Caterpillar

1. Fin N X J Ka ih P 5 2 WJ H BE 7 e Ke 77 ke N T ad mm per aon if Z Ao Illustration 47 g00425598 Secondary fuel filters 1 Remove the used fuel filter with a 1U 8760 Chain Wrench Discard the used fuel filter 2 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 3 Apply clean diesel fuel to the new fuel filter gasket 89 Maintenance Section Fuel Tank Water and Sediment Drain NOTICE Do not fill the fuel filters with fuel before installing the fuel filters The fuel will not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts 4 Install the new fuel filter Spin the new fuel filter onto the fuel filter base until the gasket contacts the base Tighten the fuel filter by hand by one full turn Do not overtighten the fuel filter Use the rotation index marks that are on the fuel filter as a guide for proper tightening 5 Prime the fuel system See this Operation and Maintenance Manual Fuel System Prime topic Maintenance Section 1000733
2. ES ian an S Illustration 40 1 Oil filler 2 Oil level gauge R i 2 ADD RSS FULL ENGINE STOPPED WITH OIL COLD po TULL 3 ENGINE AT LOW IDLE WITH WARN OTL Illustration 41 g00438568 3 ENGINE STOPPED WITH OIL COLD side 4 ENGINE AT LOW IDLE WITH WARM OIL side 5 ADD mark 6 FULL mark 1 Ensure that oil level gauge 1 is seated a If the engine is stopped remove the oil level gauge Observe the oil level on ENGINE STOPPED WITH OIL COLD side 3 b If the engine is operating reduce the engine speed to low idle Remove the oil level gauge and observe the oil level on ENGINE AT LOW IDLE WITH WARM OIL side 4 The oil level should be between ADD mark 5 and FULL mark 6 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 o
3. Illustration 28 g00103639 Filler cap gaskets 73 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add 3 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 4 Start the engine Inspect the cooling system for leaks 101065856 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 This maintenance procedure is required for conventional coolants such as DEAC and for mixtures of water and SCA This maintenance is NOT required for cooling systems that are filled with Extended Life Coolant Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and eyes Do not drink cooling system coolant additive Note Test the concentration of the SCA or obtain an S O S coolant analysis Level 1 Test the Concentration of the SCA Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit or the 4C 9301 Coolant Conditioner Test Kit Follow the instructions that are on the label of the test kit Water and SCA NOTICE Do not exceed the recommended eight pe
4. Illustration 49 g00541431 Costs of overhauls over time Y Cost X Time 1 Cost of maintenance and repair that is planned 2 Cost of maintenance and repair that is not planned In Illustration 49 line 1 represents the maintenance and repair costs for an owner that followed the recommendations for inspection maintenance and repair The peaks represent overhauls Line 2 represents the maintenance and repair costs for an owner that chose to operate beyond the recommended intervals The initial cost of the repair after failure philosophy is lower Also the first overhaul was delayed However the peaks are significantly higher than the peaks for the customer that used the repair before failure philosophy The higher peaks result from two key factors Delaying an overhaul until a breakdown increases the chance of a catastrophic failure This type of failure requires more parts labor and cleanup Excessive wear means that fewer components will be reusable More labor may be required for salvage or repair of the components 97 Maintenance Section Overhaul Considerations When all of the costs are considered REPAIR BEFORE FAILURE is the least expensive alternative for most components and engines It is not practical to wait until the engine exhibits symptoms of excessive wear or failure It is not less costly to wait A planned overhaul before failure may be the best value for the follo
5. Cylinder temperature 2 Cylinder temperature 3 Cylinder temperature 4 Cylinder temperature 5 Cylinder temperature 6 Cylinder temperature 7 Cylinder temperature 8 Cylinder temperature 9 Cylinder temperature 10 Cylinder temperature 11 Cylinder temperature 12 Auxiliary Equipment Transmission oil pressure Transmission oil temperature Comments 93 Maintenance Section Magnetic Pickups Clean Inspect 100738324 Magnetic Pickups Clean Inspect SMCS Code 1907 040 S eat ae a g00293337 Illustration 48 Typical magnetic pickup 1 Remove the magnetic pickup from the flywheel housing Check the condition of the end of the magnetic pickup Check for signs of wear and contaminants 2 Clean the metal shavings and other debris from the face of the magnet 3 Install the magnetic pickup according to the information in the Service Manual Specifications i00867892 Overhaul Major SMCS Code 7595 020 MJ Major Overhaul Information A major overhaul includes the work that is done for a top end overhaul All other parts that are visible during the major overhaul are completely inspected The seals and gaskets that are exposed are also replaced The
6. e Camshaft 94 Maintenance Section Overhaul Major e Camshaft bearings Crankshaft Crankshaft vibration damper Driven equipment alignment e Gear train e Gear train bushings e Spacer plates Inspect the camshaft for damage to the journals and the lobes Inspect the following components for signs of wear and or for signs of fatigue e camshaft bearings e camshaft followers Inspect the crankshaft for any of the following conditions e deflection e damage to the journals e bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the following components e rod bearing e main bearings Note If the crankshaft or the camshaft are removed for any reason use the magnetic particle inspection process to check for cracks Replace the crankshaft vibration damper if any of the following conditions occur e Engine failure due to a broken crankshaft e Excessive wear of the front bearing for the crankshaft e Excessive wear of the gear train that is not caused by a lack of lubrication Inspect the gears of the gear train and inspect the gear train bushings for the following conditions e Worn gear teeth e Unusual fit e Unusual wear In addition to the inspection of components inspect the alignment of the driven equipment See the Application and Installation Guide for the engin
7. Systems Operation Testing and Adjusting module Consult your Caterpillar dealer for assistance Valve Bridge Check the valve bridge and adjust the valve bridge if necessary Perform the procedure for both valve bridges for each cylinder After the valve bridge is checked for each cylinder proceed with the valve lash adjustment if necessary Engine Valve Lash 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 The valve bridge adjustment must be performed before making a valve lash adjustment If the valve lash is within the tolerance an adjustment of the valve lash is NOT necessary Perform the valve lash setting when the engine is cold After the engine has been shut down and the valve covers are removed the engine is considered cold Before performing maintenance prevent the entry of foreign matter into the top of the cylinder head and the valve mechanism Thoroughly clean the area around the valve mechanism covers For the valve lash setting see this Operation and Maintenance Manual Engine Description topic Product Information Section 101225410 Fuel Injector Inspect
8. There is a large amount of gear train wear that is not caused by a lack of oil 75 Maintenance Section Driven Equipment Check Removal and Installation Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement i00449093 Driven Equipment Check SMCS Code 3279 535 To minimize bearing problems and vibration of the engine crankshaft and the driven equipment the alignment between the engine and driven equipment must be maintained properly Check the alignment according to the instructions that are provided by the following manufacturers e Caterpillar e OEM of the coupling e OEM of the driven equipment i00935098 Driven Equipment Inspect Replace Lubricate SMCS Code 3279 040 Observe the driven equipment during operation Look for the following items e Unusual noise and vibration e Loose connections e Damaged parts Perform any maintenance that is recommended by the OEM of the driven equipment Refer to the literature of the OEM of the driven equipment for the following service instructions e Inspection e Lubricating grease and lubricating oil requirements e Specifications for adjustment e Replacement of components e Requirements for ventilation 100737417 Engine Clean SMCS Code 1000 070 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 qua
9. 100849995 Cooling System Coolant DEAC Change SMCS Code 1350 044 Clean the cooling system before the recommended maintenance interval if the following conditions exist The engine overheats frequently Foaming is observed Oil has entered the cooling system and the coolant is contaminated Fuel has entered the cooling system and the coolant is contaminated Drain the Cooling System 1 Stop the engine and allow the engine to cool Ensure that the engine will not start when the cooling system is drained 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 5 Illustration 25 g00421242 Locations of the drain plugs 1 Jacket water pump 2 Cylinder block 3 Open the cooling system drain valves if equipped If the cooling system is not equipped with drain valves remove drain plugs 1 and 2 Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant 69 Maintenance Section Cooling System Coolant DEAC Change For information regarding the disposal and the recycling of used coolant con
10. Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets of the cooling system filler cap are damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gaskets of the cooling system filler cap are not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure is stamped on the face of the cooling system filler cap If the cooling system filler cap does not maintain 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 100850204 Cooling System Coolant ELC Change SMCS Code 1350 044 NL Use only clean water to flush the cooling system when Extended Life Coolant ELC is drained and replaced Drain the Cooling System 1 Stop the engine and allow the engine to cool Ensure that the engine will not start when the cooling system is drained 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Illustration 26 g00421242 Locations of the cooling system drain plugs 1 Jacket water pump 2 Cylinder block 3 Open the cooling system drain valves if equipped If the cooling system is not eq
11. Secondary air cleaner element 4 Turbocharger air inlet 1 Remove the cover Remove the primary air cleaner element 2 The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element Note Refer to Cleaning the Primary Air Filter Elements 3 Cover the turbocharger air inlet with tape in order to keep dirt out 4 Clean the inside of the air cleaner cover and body with a clean dry cloth 5 Remove the tape for the turbocharger air inlet Install the secondary air cleaner element Install a primary air cleaner element that is new or cleaned 6 Install the air cleaner cover 7 Reset the service indicator Cleaning the Primary Air Cleaner Elements The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected When the primary air cleaner element is cleaned check for rips or tears in the filter material The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean primary air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the
12. Tighten the clamp to the torque that is listed in the Service Manual Specifications 100855827 Engine Mounts Check SMCS Code 1152 535 Misalignment of the engine and the driven equipment Illustration 39 4 Remove two clamps 6 Remove both breathers 5 from hose tee 7 g00597466 will cause extensive damage Excessive vibration can lead to misalignment Excessive vibration of the engine and the driven equipment can be caused by the following conditions e Improper mounting e Loose bolts e Deterioration of the isolators Ensure that the mounting bolts are tightened to the proper torque For standard torques see this Operation and Maintenance Manual Torque Specifications Maintenance Section 82 Maintenance Section Engine Oil Level Check Ensure that the isolators are free of oil and contamination Inspect the isolators for deterioration Ensure that the bolts for the isolators are tightened to the proper torque Replace any isolator that shows deterioration For more information see the literature that is provided by the OEM of the isolators Also see the Application and Installation Guide for the engine Consult your Caterpillar dealer for assistance 101071237 Engine Oil Level Check SMCS Code 1348 535 FLV The most accurate check of the oil level is obtained when the engine is stopped Perform this maintenance on a surface that is as level as possible
13. starting motor pinion does not engage the flywheel ring gear The teeth of the starting motor pinion and the flywheel ring gear can be damaged because of irregular engagement Inspect the starting motor for proper operation Listen for grinding when the engine is started Inspect the teeth of the starting motor pinion and the flywheel ring gear Look for patterns of wear on the teeth Look for teeth that are broken or chipped If damaged teeth are found the starting motor pinion and the flywheel ring gear must be replaced Electric Starting Motor Note Problems with the electric starting motor can be caused by the following conditions malfunction of the solenoid and malfunction of the electric starting system Inspect the electrical system for the following conditions e Loose connections e Corrosion e Wires that are worn or frayed e Cleanliness Make repairs if necessary Air Starting Motor Personal injury or death can result from improp erly checking for a leak Always use a board or cardboard when checking for a leak Escaping air or fluid under pressure even a pin hole size leak can penetrate body tis sue causing serious injury and possible death If fluid is injected into your skin it must be treated immediately by a doctor familiar with this type of injury Inspect all of the components in the air circuit for the starting motor Inspect all of the air lines and connections for leaks If the teet
14. when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing If batteries are properly charged ammeter reading should be very near zero All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 1U 7298 Coolant Battery Tester C or the 1U 7297 Coolant Battery Tester F 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 L 0 11 qt of baking soda and 1 L 1 qt of clean water e A mixture of 0 1 L 0 11 qt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM grease
15. Adjust SMCS Code 1290 025 Note Perform this procedure when the engine valve lash is inspected NOTICE The camshafts must be correctly timed with the crank shaft before an adjustment of the lash for the fuel in jector is made The timing pins must be removed from the camshafts before the crankshaft is turned or dam age to the cylinder block will be the result Inspect the adjustment of the lash for the fuel injector according to the Systems Operation Testing And Adjusting Fuel System topic Adjust the lash for the fuel injector if necessary 100850285 Fuel System Prime SMCS Code 1250 548 1258 548 1 Open the fuel supply valve Ensure that the engine will not start during the priming procedure Turn the start switch to the OFF position 87 Maintenance Section Fuel System Primary Filter Clean Inspect Replace ail Ye Illustration 45 g00421659 1 Fuel priming pump plunger 2 Turn the fuel priming pump plunger counterclockwise in order to release the lock plate from the retainer 3 Operate the fuel priming pump until the air in the fuel system has been pumped through the fuel return line back to the
16. Approximately 1 L 1 qt of oil will remain in the housing after the sump has been completely drained This oil will pour out of the housing when the cover is removed Prepare to catch the oil in a pan Clean up any spilled oil with rags DO NOT use absorbent particles to clean up the oil 1 Remove the screen assembly according to the instructions in the Service Manual Disassembly and Assembly module Discard the used O ring seals 2 Wash the screen assembly in clean nonflammable solvent Allow the screen assembly to dry before installation 3 Inspect the screen assembly for good condition Obtain a new screen assembly if necessary Install the screen assembly Install new O ring seals 101045650 Overhaul Considerations SMCS Code 7595 043 Overhaul Information An overhaul is replacing the major worn components of the engine An overhaul interval is a maintenance interval that is planned The engine is rebuilt with certain rebuilt parts or new parts that replace the worn parts An overhaul also includes the following maintenance e Inspection of all the parts that are visible during the disassembly e Replacement of the seals and gaskets that are removed Cleaning of the internal passages of the engine and the engine block Most owners will save money by overhauling the engine at the intervals that are recommended in this Operation and Maintenance Manual Consider the graph in Illustration 49
17. Inspect 74 Driven Equipment Check ccccccceseseeeeeeeaeeeees 75 Engine Mounts Check sssesseeirsseerrrsseress 81 Engine Valve Lash Inspect Adjust 0 0 0 eee 86 Fuel Injector Inspect Adjust ceeeeeeeeeeees 86 Turbocharger Inspect ee ceeeeeeeeeeeeeeeeteeeeeeeaes 99 Every 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 68 Every 3000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 72 Every 4000 Service Hours Overhaul Top End eecceeeeeeeeeeeeeeeeeeteeeeteeenanees 95 Overhaul Considerations 96 Every 6000 Service Hours or 6 Years Alternator Inspect cccecceeeeeeeeeeeeeeteeneeneees 66 Cooling System Coolant ELC Change 70 Cooling System Water Temperature Regulator RE PIACEE PE EE A 74 Magnetic Pickups Clean Inspect n 93 Starting Motor Inspect eese 99 Water Pump Inspect sssssssssseninnensessseeseerrrrnrreen 101 Every 18 000 Service Hours Overhaul Major 0 0 ceeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeees 93 Overhaul Considerations ccccccceeeeeeeeeeeeeeeeas 96 64 Maintenance Section Maintenance Recommendations 100855646 Maintenance Recommendations SMCS Code 1000 Service Hours and Fuel Consumption Table 32 Service Hours and Fuel Consumption for 3512 Engines Interval Fuel Consumpti
18. components main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter If an excessive amount of debris is found consult your Caterpillar dealer in order to arrange for further oil analysis Fill the Crankcase NOTICE Only use oils that are recommended by Caterpillar For the proper oil to use refer to this Operation and Maintenance Manual Engine Oil topic Maintenance Section NOTICE If the engine is equipped with an auxiliary oil filter system extra oil must be added when filling the crankcase If equipped with an auxiliary oil filter system that is not supplied by Caterpillar follow the recommendations of the OEM 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 pr
19. data to the data that was previously recorded Comparing the new data to the recorded data will establish the normal gauge readings for the engine A gauge reading that is abnormal may indicate a problem with operation or a problem with the gauge Record the Performance of the Engine Records of engine performance are an important element of a maintenance program Record information about the engine operation on a daily basis This will help to reveal the trends of the engine performance The data on engine performance can help to predict problems with operation Also the data can provide your Caterpillar dealer with information that is useful for recommending optimum operation Table 33 is offered for use as a log for engine performance Make several copies of Table 33 for continued use Retain the recorded information for reference 92 Maintenance Section Instrument Panel Inspect Table 33 Engine Performance Engine Serial Number Authorization Date Engine hours Engine rpm Percent of load Ambient temperature Inlet manifold air temperature Inlet manifold air pressure Air restriction left Air restriction right Jacket water temperature Engine oil temperature Engine oil pressure Fuel pressure Fuel filter differential pressure Exhaust manifold temperature left Exhaust manifold temperature right Cylinder temperature 1
20. is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose Note For torques on hose clamps see this Operation and Maintenance Manual Torque Specifications Maintenance Section 7 Install the hose clamps with a torque wrench Note For the proper coolant to use see this Operation and Maintenance Manual Coolant Recommendations Maintenance Section 8 Refill the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler cap s gaskets Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks 100849266 Instrument Panel Inspect SMCS Code 7451 040 Inspect the instrument panel for good condition Perform the self test All of the warning lamps should illuminate If a warning lamp does not illuminate replace the bulb immediately If the alarm does not sound investigate the problem and correct the problem Check the condition of all of the gauges If a gauge is broken repair the gauge or replace the gauge immediately Frequently monitor the following parameters during normal operation e Fuel filter differential pressure e Inlet air restriction e Oil filter differential pressure 91 Maintenance Section Instrument Panel Inspect Record the data in a log Compare the new
21. loads that are greater than the rated load Operating the engine at speeds that are greater than the rated rom e Use of the engine for an application that is not approved Improper Maintenance Practices e Extension of maintenance intervals e Not using recommended fuel lubricants and coolant antifreeze 100855723 Actuator Control Linkage Lubricate SMCS Code 1265 086 Illustration 21 g00426785 1 Grease Fitting Apply grease to the grease fittings 1 Use a hand grease gun and lubricate the grease fittings with MPGM Check the Linkage Use the following procedure to check the linkage for binding 1 Stop the engine 2 Move the linkage by hand If the linkage binds repair the linkage For information on adjustment removal and replacement see the Service Manual Consult your Caterpillar dealer for assistance i00691569 Air Starting Motor Lubricator Bowl Clean SMCS Code 1451 070 1 Ensure that the air supply to the lubricator is OFF 2 0 Ue ul sll Illustration 22 g00270335 1 Plug 2 Bowl 3 Drain Note Always dispose of fluids according to local regulations 2 Open drain 3 Drain the oil into a suitable container Dispose of the used oil 3 Remove bowl 2 Clean the bowl with warm water 4 Dry the bowl Inspect the bowl for cracks If the bowl is cracked replace th
22. system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 6 Allow the water to drain Flush the cooling system with clean water until the water that drains is clean Close the cooling system drain valves if equipped Clean the drain plugs and install the drain plugs Cleaning a Cooling System that has Heavy Deposits or Plugging Note For the following procedure to be effective there must be an active flow through the cooling system components 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the cooling system drain valves if equipped Clean drain plugs and install drain plugs 1 and 2 See Illustration 25 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the cooling system filler cap 4 Start the engine Operate the engine for a minimum of 90 minutes with a coolant temperature of at least 82 C 180 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 cooling system drain valves if equipped or remove drain plugs 1 and 2 See Illustration 25 Allow the water to drain NOTICE Improper or incomple
23. to the FULL mark on the ENGINE STOPPED WITH OIL COLD side of the oil level gauge 100626013 Engine Protective Devices Check SMCS Code 7400 535 Alarms and shutoffs must function properly Alarms provide timely warning to the operator Shutoffs help to prevent damage to the engine It is impossible to determine if the engine protective devices are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints Ensure that the engine protective devices are functioning properly 86 Maintenance Section Engine Valve Lash Inspect Adjust NOTICE During testing abnormal operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately 101071128 Engine Valve Lash Inspect Adjust SMCS Code 1102 025 Note For procedures on adjusting the valve bridge and adjusting the engine valve lash see the Service Manual
24. 01 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive fuel system wear Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Check the fuel daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly fro
25. 031 for identification of the sample In order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 8T 9190 Fluid Sampling Bottle Group is recommended for use with the sampling valve The bottle group includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Do not use the same vacuum sampling pump for ex tracting oil samples that is used for extracting coolant samples A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken Always use a designated pump for oil sampling and a designated pump for coolant sampling Failure to do so may cause a false analysis which could lead t
26. 3512 INDUSTRIAL ENGINES Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU6759 02 01 2007 Caterpillar CATERPILLAR All Rights Reserved 63 Maintenance Section Maintenance Interval Schedule 101226639 Maintenance Interval Schedule SMCS Code 1000 7500 Before performing any operation or maintenance procedures ensure that the Safety Information warnings and instructions are read and understood Before each consecutive interval is performed all of the maintenance requirements from the previous interval must be performed When Required Maintenance Recommendations cceeee 64 Batteries Replace 2 cccceceeeeeeecceeceeeeeeeeeeetees 67 Engine Air Cleaner Element Dual Element Clean Replace 22 0 cccccceeeeeeeeeeeeeeeeeeeeeeeeeteeeeees 75 Engine Air Cleaner Element Single Element Inspect Replace eeeeeeeeeeteeeeeeeeeeeeeeeeetteeeeeeeaaes 78 Fuel System Prime ccceeceeeeeeeeeeeeeeeeeeeeenenes 86 Fuel System Primary Filter Water Separator Element REPIACC cis as ere easier tat oat neta heen pee tetas 88 Daily Air Starting Motor Lubricator Oil Level Check 66 Cooling System Coolant Level Check 72 Driven Equipment Inspect Replace Lubricate 75 Engine Air Cleaner Service Indicator Inspect 79 Engine Air Precleaner Clean 80 Engine Oil Level Check ecceeeeeceeeeteeeeeeenneeees 82 Fue
27. 787902 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component Replace the element of the primary filter water separator according to the instructions that are provided by the OEM of the primary filter water separator Note It may be necessary to prime the fuel system before the engine will start See this Operation and Maintenance Manual Fuel System Prime topic Maintenance Section i00854690 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component
28. 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 3 Apply clean engine oil to the gasket of the new oil filter 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 4 Place the oil filter in position Tighten the oil filter until the gasket contacts the base Tighten the oil filter by hand for an additional 3 4 turn 270 degrees Do not overtighten the oil filter Inspect the Used Oil Filter Elements 1 Cut the used oil filter element open with a 4C 5084 Oil Filter Cutter Spread apart the pleats and inspect the filter material for metal debris An excessive amount of debris in the element may indicate early wear or a pending failure 2 Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the filter 85 Maintenance Section Engine Protective Devices Check Ferrous metals may indicate wear on the steel and the cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts the brass parts or the bronze parts of the engine Parts that may be affected include the following
29. aintenance that is needed for your specific engine The following factors can contribute to severe operation environment improper operating procedures and improper maintenance practices Environmental Factors Extreme Ambient Temperatures Extended operation in environments that are extremely cold or hot can damage components Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures Extremely hot inlet air reduces the performance capabilities of the engine Note Refer to this Operation and Maintenance Manual Cold Weather Operations topic Operation Section or refer to Supplement SEBU5898 Cold Weather Recommendations Cleanliness Unless the equipment is cleaned regularly extended operation in a dirty environment and in a dusty environment can damage components Built up mud dirt and dust can encase components This can make maintenance difficult The buildup can contain corrosive chemicals Corrosive chemicals and salt can damage some components Altitude Engines are set to operate within a certain altitude Operating above this altitude can cause engine damage Adjustments are necessary for operation at higher altitudes 65 Maintenance Section Actuator Control Linkage Lubricate Improper Operating Procedures e Extended operation at low idle e Minimum cool down periods after high load factor operation Operating the engine at
30. aner element or in a remote location t f D g00329643 Illustration 34 1 Service indicator Some engines may be equipped with a different service indicator Observe the service indicator Clean the air cleaner element or replace the air cleaner element when the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position e The air restriction reaches 6 kPa 25 inches of H20 Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three pushes e Check the movement of the yellow core when the engine is accelerated to the engine rated rpm The yellow core should latch approximately at the greatest vacuum that is attained 80 Maintenance Section Engine Air Precleaner Clean 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 fitting for the service indicator may be plugged Illustration 35 g00351792 Porous filter A porous filter is part of a fitting that is used for mounting of the service indicator Inspect the filter for cleanliness Clean the filter if necessary Use c
31. athers as a unit g00597463 Illustration 38 3 Remove O ring seals 4 from the valve covers Inspect the O ring seals for good condition Obtain new O ring seals if necessary g00597465 led 6 Inspect the hose tee for cracks If the tee is cracked discard the old tee and obtain a new tee for installation Turn the breathers upside down in order to inspect the condition of the breather elements Clean the breather elements with clean nonflammable solvent If the breather elements remain contaminated after the cleaning discard the breathers and obtain new breathers Do not attempt to disassemble the breathers Allow the breather elements to dry before installation Note Coat the rubber parts with clean engine oil or petroleum jelly in order to make installation easier 6 Place clamps 6 over the parts of hose tee 7 that will receive breathers 5 Install the breathers into the tee Tighten the clamps to the torque that is listed in the Service Manual Specifications Coat O ring seals 4 with clean engine oil Place the O ring seals on the valve covers Place clamps 3 around the parts of the breathers that will be attached to the valve covers Install both breathers as a unit Tighten the clamps Place clamp 1 on the part of the hose tee that will receive tube 2 Install the tube into the hose tee
32. cator with a constant rate of air flow After the adjustment the lubricator will release oil in proportion to variations of the air flow 1 Ensure that the fuel supply to the engine is OFF 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 Operate the air starting motor Observe the drops of oil that are released in dome 1 Note Some lubricators have an adjustment screw rather than a knob 3 If necessary adjust the lubricator in order to release two drops of oil per 30 seconds To increase the rate turn knob 2 counterclockwise To decrease the rate turn the knob clockwise 100839754 Alternator Inspect SMCS Code 1405 040 Inspect the alternator for the following conditions e Loose connections e Proper charging of the battery Observe the ammeter during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs if necessary See the Service Manual for service procedures Consult your Caterpillar dealer for assistance 100738285 Alternator and Fan Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 1405 Inspection To maximize the engine performance inspect the drive belt for wear and for cracking Check the drive belt tension Adjust the drive belt tension in order to minimize belt slippage Belt slip
33. e Cleaning of Components Clean the oil cooler core and the aftercooler core Then pressure test both of these cores 1 Remove the core 2 Remove any debris from the core To remove debris from the oil cooler core turn the oil cooler core onto one end To remove debris from the aftercooler core turn the aftercooler core upside down NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 3 Back flush the core internally with cleaner in order to loosen foreign substances This will also help to remove oil Note Hydrosolv Liquid Cleaners are recommended Table 34 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer Table 34 Hydrosolv Liquid Cleaners Part Description Size Number 1U 8812 Hydrosolv 4165 4 L 1 US gal 1U 5490 19 L 5 US gal 8T 7570 208 L 55 US gal 1U 8804 Hydrosolv 100 4 L 1 US gal 1U 5492 19 L 5 US gal 8T 5571 208 L 55 US gal Use these cleaners at a concentration of two to five percent and at a temperature up to 93 C 200 F For more information see Application Guide NEHS0526 Service Technical Group Consult your Caterpillar dealer for assistance 4 Steam clean the core in order to remove any residue Flush the f
34. e damaged bowl with a new bowl 5 Install the bowl Close drain 3 6 Remove plug 1 Fill bowl 2 with oil Use nondetergent 10W oil for temperatures that are greater than 0 C 32 F Use air tool oil for temperatures that are below 0 C 32 F Install oil filler plug 1 7 If necessary adjust the lubricator in order to release two drops of oil per 30 seconds For instructions see this Operation and Maintenance Manual Air Starting Motor Lubricator Oil Level Check topic Maintenance Section 66 Maintenance Section Air Starting Motor Lubricator Oil Level Check 100691572 Air Starting Motor Lubricator Oil Level Check SMCS Code 1451 535 NOTICE Never allow the lubricator bowl to become empty The air starting motor will be damaged by a lack of lubrica tion Ensure that sufficient oil is in the lubricator bowl Illustration 23 g00349048 1 Dome 2 Knob 3 Sight gauge 4 Plug 1 Observe the oil level in sight gauge 3 If the oil level is less than 1 2 add oil to the lubricator bowl 2 Ensure that the air supply to the lubricator is OFF 3 Remove plug 4 Pour oil into the lubricator bowl Use 10W oil for temperatures that are greater than 0 C 32 F Use air tool oil for temperatures that are below 0 C 32 F 4 Install plug 4 Adjust the Lubricator Note Adjust the lubri
35. e for oil analysis to indicate a decrease of wear metals in the lube oil The cylinder liners may be worn so that polishing of the bore occurs Also the increased use of lube oil will dilute the wear metals Monitor the engine as the engine accumulates service hours Consult your Caterpillar dealer about scheduling a major overhaul Note The driven equipment may also require service when the engine is overhauled Refer to the literature that is provided by the OEM of the driven equipment Using Fuel Consumption For Calculating the Overhaul Intervals The total fuel consumption is the most important factor for estimating the overhaul interval Fuel consumption compensates for the application and for the engine load If the total fuel consumption has not been recorded use the equation in Table 35 in order to estimate the hours until the overhaul The equation may also be used to estimate overhaul intervals for new engines Table 35 Equation For Calculating Overhaul Intervals H F R H is the number of estimated hours until the overhaul interval F is the estimated total amount of fuel consumption of the engine R is the rate of fuel consumption in liters per hour or gallons per hour Use the actual records of fuel consumption when possible If the actual records are not available use the following procedure in order to estimate the fuel consumption 1 Estimate the average percent of th
36. e load for the operation of the engine 98 Maintenance Section Overhaul Considerations 2 Refer to the engine s Caterpillar Engine Specifications spec sheet This will determine the fuel consumption for the percent of the load that was estimated in Step 1 Use this figure for the equation in Table 35 Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases The oil consumption rate brake specific oil consumption is measured in grams per kW h lb per bhp The brake specific oil consumption BSOC depends on the engine load Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine When an engine s oil consumption has risen to three times the original oil consumption rate due to normal wear an engine overhaul should be scheduled There may be a corresponding increase in blowby and a slight increase in fuel consumption Overhaul Inspection Refer to the Service Manual for the disassembly and assembly procedure
37. eaner Element Dual Element Clean Replace e The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected e The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings The secondary air cleaner element is not serviceable or washable The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element When the engine is operating in environments that are dusty or dirty air cleaner elements may require more frequent replacement Illustration 29 g00123209 1 Cover 2 Primary air cleaner element 3
38. ed in the cooling system A full water analysis can be obtained by consulting your local water utility company or an agricultural agent Private laboratories are also available for water analysis Caterpillar recommends an S O S coolant analysis Level Il S O S Coolant Analysis Level II An S O S coolant analysis Level Il is a comprehensive coolant analysis which completely analyzes the coolant An S O S coolant analysis Level II provides the following information e Complete S O S coolant analysis Level e Properties of the coolant are visually inspected e Metal corrosion and contaminants are identified e Identification of built up impurities that can cause problems BEFORE the problems make repairs necessary A report of the results of the S O S coolant analysis Level II is provided Maintenance recommendations are based on the results For more information about S O S coolant analysis consult your Caterpillar dealer 100868225 Overhaul Top End SMCS Code 7595 020 TE Cylinder Head Assembly Inspect the cylinder head assembly according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropr
39. ents Primary air cleaner elements may be allowed to air dry Allow two days for the primary air cleaner elements to air dry before the elements are inspected and installed Inspecting the Primary Air Cleaner Elements Illustration 31 g00281693 Inspect the clean dry primary air cleaner element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element for tears and or holes Inspect the primary air cleaner element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air cleaner element to a new primary air cleaner element that has the same part number Do not use a primary air cleaner element that has any tears and or holes in the filter material Do not use an primary air cleaner element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will not be used the primary air cleaner element can be stored for future use Illustration 32 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage Restricted air flow may result To protect against dirt and damage wrap the primary air cleaner elements in Volalite Corrosion Inhibited VCI
40. er element e Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element e The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected e The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Illustration 33 g00310664 1 Cover 2 Element 3 Air inlet 1 Remove the air cleaner cover Remove the air cleaner element 2 Cover the air inlet with tape in order to keep dirt out 3 Clean the inside of the air cleaner cover and body with a clean dry cloth 4 Remove the tape for the air inlet Install an air cleaner element that is new or cleaned 5 Install the air cleaner cover 6 If necessary reset the air cleaner service indicator 100823657 Engine Air Cleaner Service Indicator Inspect SMCS Code 7452 040 A service indicator may be mounted on the air cle
41. essive supplemental coolant additive concentra tion could also result in blockage of the heat exchang er overheating and or accelerated wear of the water pump seal Do not exceed the recommended amount of supple mental coolant additive concentration 3 Add the proper amount of SCA The concentration of the SCA depends on the type of coolant that is used a For cooling systems that use conventional coolant antifreeze see this Operation and Maintenance Manual Conventional Coolant Antifreeze Cooling System Maintenance topic Maintenance Section 74 Maintenance Section Cooling System Water Temperature Regulator Replace b For cooling systems that use only a mixture of water and SCA see this Operation and Maintenance Manual Water Supplemental Coolant Additive SCA topic Maintenance Section 4 Clean the cooling system filler cap Install the cooling system filler cap 100912898 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overhea
42. fuel tank 4 Press the fuel priming pump plunger to the locking position Turn the fuel priming pump plunger clockwise in order to engage the lock plate in the retainer Note Enable the starting system only after all maintenance has been completed i00735594 Fuel System Primary Filter Clean Inspect Replace SMCS Code 1260 510 1260 571 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 1 Stop the engine Ensure that the engine will not start during this procedure 2 Shut off the fuel supply valve to the engine NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately g00330404 Illustration 46 1 Filter case 2 Nut 3 Loosen nut 2 Hold filter case 1 and remove nut 2 Prepare to catch the fuel that is inside of the filter case with a suitable container Remove the filter case from the mounting bolt 4 Remove the element and wash the element in clean nonflammable solvent Allow the element to dry Inspect the element Install a new element
43. h of the starting motor pinion and or the flywheel ring gear are damaged the air circuit for the starting motor must be examined in order to determine the cause of the problem Removal and Installation of the Starting Motor Refer to the Service Manual Disassembly and Assembly module for information on removing the starting motor and installing the starting motor Consult your Caterpillar dealer for assistance 100912946 Turbocharger Inspect SMCS Code 1052 040 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Any fumes from the crankcase are filtered through the air inlet system Therefore by products from oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause additional damage to the pistons the valves and the cylinder head 100 Maintenance Section Walk Around Inspection 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 n
44. he parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pump and the installation of water pump and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve cover Inspect the fuel system for leaks Look for loose fuel line clamps Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break e Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the engine to frame ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and
45. iate specifications The use of out of spec parts will cause unscheduled downtime and or costly repairs Fuel Injectors Replace the fuel injectors Consult your Caterpillar dealer about exchanging the fuel injectors Your Caterpillar dealer can provide these services and components The wear of fuel injectors is affected by the following considerations e Quality of the fuel e Quality of the filtration of the fuel The wear of the fuel injectors can result in elevated levels of exhaust emissions and or poor engine performance The misfire of a single cylinder is not typically attributed to normal wear This condition can be repaired by replacing the defective fuel injector The following list of circumstances indicate that the fuel injectors should be inspected more frequently e Use of fuels that are not recommended in this Operation and Maintenance Manual Fuel Specifications 96 Maintenance Section Overhaul Considerations e Extreme ambient temperatures that reduce the ability of the fuel to provide lubrication Frequent plugging of the fuel filters Insufficient maintenance of the fuel tank or the fuel storage tank that can allow excessive water sediment etc Insufficient maintenance of the fuel filters Oil Suction Screen Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Clean the oil suction screen after the oil has been drained Note
46. if the old element is damaged or deteriorated 5 Clean the inside of the filter case Allow the filter case to dry 6 Inspect the seal rings Ensure that the surfaces for the seal rings are clean Install new seal rings if the old seal rings are damaged or deteriorated NOTICE Do not fill the fuel filters with fuel before installing them The fuel would not be filtered and could be contami nated Contaminated fuel will cause accelerated wear to fuel system parts 7 Place the element in the filter case Slide the filter case over the mounting bolt 8 Install the nut 9 Open the fuel supply valve 88 Maintenance Section Fuel System Primary Filter Water Separator Drain 100744357 Fuel System Primary Filter Water Separator Drain SMCS Code 1260 543 1263 543 Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately Drain the primary filter water separator on a daily basis before starting the engine For specific instructions for draining the primary filter water separator see the service information that is provided by the OEM of the primary filter water separator 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 100
47. il 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 If necessary remove oil filler cap 2 and add oil For the correct oil to use see this Operation and Maintenance Manual Engine Oil topic Maintenance Section Do not fill the crankcase above the FULL mark 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 oil change This will help to provide the most accurate oil analysis 101070756 Engine Oil Sample Obtain SMCS Code 1348 554 SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine 83 Maintenance Section Engine Oil and Filter Change 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 PEEP5
48. ing e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Replace the Hoses and the Clamps 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
49. ins of the oil cooler core and the aftercooler core Remove any other trapped debris 5 Wash the core with hot soapy water Rinse the core thoroughly with clean water 95 Maintenance Section Overhaul Top End 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 components in order to ensure cleanliness Pressure test the core Many shops that service radiators are equipped to perform pressure tests Repair the core if necessary Install the core Obtain Coolant Analysis The concentration of supplemental coolant additive SCA should be checked regularly with test kits The concentration of SCA can also be checked with an S O S coolant analysis Level 1 A more detailed coolant analysis is recommended periodically For example considerable deposits are found in the water jacket areas on the external cooling system but the concentrations of coolant additives were carefully maintained The coolant water probably contained minerals which were deposited on the engine over time A coolant analysis can be conducted in order to verify the condition of the water that is being us
50. internal passages of the engine are cleaned Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications If you elect to perform an overhaul without the services of a Caterpillar dealer be aware of the following recommendations Components for Replacement Replace the following components during the major overhaul In addition replace the components that are specified in this Operation and Maintenance Manual Overhaul Top End topic Connecting rod bearings Crankshaft seals Exhaust shields Gaskets and seals Main bearings Piston rings Valve rotators Components for Inspection Rebuilding or Exchanging Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts Camshaft followers Connecting rods Cylinder liners Fuel transfer pump Oil pump Pistons Piston pins Prelube pump Scavenge oil pump Turbochargers Inspection of Components Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts
51. ized water pressurized air or a vacuum is recommended prior to washing with nonsudsing detergent 1 Place the primary air cleaner element into a wash tank so that the gasket is up The wash tank should be equipped with a rack so that the primary air cleaner element does not sit on the bottom of the wash tank Note Caterpillar does not recommend a process for washing the primary air cleaner element which includes agitation Agitation may cause carbon particles to be distributed 2 Fill the wash tank with the cleaning agent and warm water to a maximum temperature of 60 C 140 F Follow the manufacturers recommendations for the cleaning agent Allow the primary air cleaner element to soak for six hours 3 Drain the wash tank Do not use the cleaning agent more than one time Remove the primary air cleaner element from the wash tank Rinse the primary air cleaner element with the method for using pressurized water Note Refer to Drying the Primary Air Cleaner Elements Refer to Inspecting the Primary Air Cleaner Elements 78 Maintenance Section Engine Air Cleaner Element Single Element Inspect Replace Drying the Primary Air Cleaner Elements The oven method may be used in order to dry primary air cleaner elements If an oven is used do not expose the primary air cleaner elements to temperatures that exceed 82 C 160 F Note Do not use compressed air in order to dry the primary air cleaner elem
52. l System Primary Filter Water Separator Drain Sek ahh celeste crear entreaties 88 Fuel Tank Water and Sediment Drain 89 Instrument Panel Inspect eceeeeeeeeteeeeee 90 Walk Around Inspection cceeceseeeeeeeeeeeeees 100 Initial 250 Service Hours Engine Valve Lash Inspect Adjust c eee 86 Fuel Injector Inspect Adjust eeeeeeeeeeeeeees 86 Magnetic Pickups Clean Inspect 065 93 Every 250 Service Hours Alternator and Fan Belts Inspect Adjust ReplaGe ttc a E a We ath ioe toe 66 Battery Electrolyte Level Check seese 68 Cooling System Supplemental Coolant Additive SCA Test Add cccccccceteceecteceeeeetecesedecareerentere 73 Engine Oil Sample Obtain 0 82 Engine Oil and Filter Change n se 83 Fuel System Primary Filter Clean Inspect Replace inian dei apri aaea teddies 87 Fuel System Secondary Filter Replace 88 Hoses and Clamps Inspect Replace 89 Every 1000 Service Hours Cooling System Coolant Analysis Level II OD tain IE T E T E tele taatea raised 71 Engine Clean 20 eccceccecteceeeteeteceeeeeeecctenenteedeeeeetees 75 Engine Crankcase Breather Clean aaeain 80 Engine Protective Devices Check 85 Every 2000 Service Hours Actuator Control Linkage Lubricate 0 0 65 Air Starting Motor Lubricator Bowl Clean 65 Crankshaft Vibration Damper
53. ling system The following services are provided Full Level analysis Identification of the source of metal corrosion and of contaminants Identification of buildup of the impurities that cause corrosion Identification of buildup of the impurities that cause scaling Determination of possible electrolysis within the engines cooling system A report of the results of the analysis is provided Maintenance recommendations are based on the results For more information about S O S coolant analysis consult your Caterpillar dealer 72 Maintenance Section Cooling System Coolant Extender ELC Add 100259474 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Caterpillar Extended Life Coolant ELC does not require the frequent Supplemental Coolant Additive SCA additions associated with the present conventional coolants The Extender only needs to be added once Check the cooling system only when the engine is stopped and cool 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Extender 3 Add Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities in the Maintenance Section for the capacity of the cooling system for your engine Refer to
54. m 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 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 i00907072 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Inspect all hoses for leaks that are caused by the following conditions e Cracking e Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps 90 Maintenance Section Instrument Panel Inspect 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 leak
55. n and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 30 g00281692 Note When the primary air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements Washing the Primary Air Cleaner Elements with Nonsudsing Detergent Do not wash air cleaner elements in any flammable solution such as diesel fuel or gaso line Doing so can cause fire or an engine runaway and can result in personal injury Washing with nonsudsing detergent is effective for cleaning primary air cleaner elements that have deposits of carbon or oil Use a cleaning agent that is specifically manufactured for cleaning primary air cleaner elements Cleaning with pressur
56. n the cooling system drain valves if equipped If the cooling system is not equipped with drain valves remove drain plugs 1 and 2 See Illustration 26 Allow the coolant to drain Flush the cooling system with clean water Close the cooling system drain valves if equipped Install the drain plugs 6 Repeat Steps 3 4 and 5 Fill the Cooling System 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 the Operation and Maintenance Manual Refill Capacities for the correct cooling system capacity Do not install the cooling system filler cap 2 Start the engine Operate the engine in order to purge the air from the cavities of the engine block Allow the ELC to warm and allow the coolant level to stabilize Stop the engine 3 Check the coolant level Maintain the coolant to the proper level on the sight gauge if equipped If a sight gauge is not equipped maintain the coolant within 13 mm 5 inch below the bottom of the filler pipe 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets of the cooling system filler cap are damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gaskets of the cooling system filler cap are not damaged use a 9S 8140 Pressurizing Pump in orde
57. nd for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted 101 Maintenance Section Water Pump Inspect NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water Ensure that cooling lines are properly clamped and tight Check for leaks Check the condition of all pipes e Inspect the water pump for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and t
58. ntity accumulates on the engine 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 Engine Air Cleaner Element Dual Element Clean Replace SMCS Code 1051 1054 037 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air cleaner element e Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element 76 Maintenance Section Engine Air Cl
59. nto a suitable container Dispose of the oil according to local regulations 84 Maintenance Section Engine Oil and Filter Change eee lt x Yy ee AECE i N g00425765 Illustration 42 Oil drain a Open oil drain 1 After the oil has drained close the oil drain b If a suction device is inserted into the oil pan ensure that the suction device is clean This will prevent dirt from entering into the oil pan Be careful not to strike the engine oil suction tubes or the piston cooling jets c If a suction device that attaches to the oil drain is used ensure that the suction device is clean Attach the suction device to the oil drain Open the oil drain After the oil has drained close the oil drain and remove the suction device Replace the Oil Filter Elements FL eA Illustration 43 g00425766 Oil filters 1 Remove the oil filter with a 1U 8760 Chain Wrench Illustration 44 g00103713 Mounting base and gasket 2 Clean the sealing surface of the mounting base Ensure that all of the old gasket is removed NOTICE Caterpillar oil filters are built to Caterpillar speci fications
60. o customer and dealer concerns If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEHP6001 How To Take A Good Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine 100854772 Engine Oil and Filter Change SMCS Code 1318 510 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin The S O S oil analysis program analyzes used oil in order to determine if the oil change interval is suitable for your specific engine Drain the Oil 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 when the cold oil is drained Drain the crankcase when the oil is warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will allow the waste particles to be recirculated through the engine lubrication system with the new oil 1 After the engine has been operated at normal operating temperature STOP the engine 2 Drain the oil according to the equipment on the engine Note Drain the oil i
61. oblems 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 1 Remove the oil filler cap Fill the crankcase through the oil filler tube only For the amount of oil to use see this Operation and Maintenance Manual Refill Capacities topic Maintenance Section 2 Clean the oil filler cap Install the oil filler cap NOTICE To prevent crankshaft or bearing damage crank en gine with fuel off to fill all filters before starting Do Not crank engine for more than 30 seconds 3 Close the fuel supply line and crank the engine until the oil pressure gauge indicates 70 kPa 10 psi Open the fuel supply line Allow the starting motor to cool for two minutes before cranking again 4 Follow the Operation and Maintenance Manual Starting The Engine procedure Operation Section Operate the engine at low idle for two minutes This will ensure that the lubrication system has oil and that the oil filters are filled with oil Inspect the engine for oil leaks Ensure that the oil level is at the FULL mark on the ENGINE AT LOW IDLE WITH WARM OIL side of the oil level gauge 5 Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes 6 Remove the oil level gauge and check the oil level Maintain the oil level
62. ompressed air or a clean nonflammable solvent The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 101190885 Engine Air Precleaner Clean SMCS Code 1055 070 L Typical precleaner 1 Wing nut 2 Cover 3 Body Illustration 36 g00287039 Remove wing nut 1 and cover 2 Check for an accumulation of dirt and debris in body 3 Clean the body if necessary After cleaning the precleaner install cover 2 and wing nut 1 Note When the engine is operated in dusty applications more frequent cleaning is required 101225429 Engine Crankcase Breather Clean SMCS Code 1317 070 If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage 81 Maintenance Section Engine Mounts Check Illustration 37 1 Loosen clamp 1 Slide the clamp down on tube 2 2 Loosen clamps 3 Remove both bre
63. on 250 service 43 750 L 11 500 US gal hours 500 service 87 500 L 23 000 US gal hours 1000 service hours 175 000 L 46 000 US gal 2000 service hours 350 000 L 92 000 US gal 3000 service hours 525 000 L 138 000 US gal Top end overhaul 4000 service hours 787 500 L 206 250 US gal 6000 service hours 1 050 000 L 276 000 US gal Major overhaul 18 000 service hours 1 575 000 L 412 500 US gal Severe Operation Severe operation is the use of an engine that exceeds current published standards for that engine Caterpillar maintains standards for the following engine parameters e Horsepower e Range of rpm e Fuel consumption Fuel quality e Altitude e Maintenance intervals Selection of oil Selection of coolant e Environmental qualities e Installation Refer to the standards for your engine or consult your Caterpillar dealer in order to determine if your engine is operating within the defined parameters Severe operation can accelerate component wear Engines that are operating under severe conditions may need more frequent maintenance intervals for the following reasons e Maximum reliability e Retention of full service life Because of individual applications it is not possible to identify all of the factors which can contribute to severe operation Consult your Caterpillar dealer about the m
64. ot cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartridge must be balanced due to high rpm Severe Service Applications can accelerate component wear Severe Service Applications require more frequent inspections of the cartridge Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indica
65. page will decrease the life of the drive belt Check the drive belt tension according to the information in the Service Manual Systems Operation Testing and Adjusting Replacement For applications that require multiple drive belts replace the drive belts in matched sets Replacing one drive belt of a matched set will cause the new drive belt to carry more load because the older drive belts are stretched The additional load on the new drive belt could cause the new drive belt to fail 67 Maintenance Section Batteries Replace Alternator Belt Adjustment Illustration 24 g00122875 1 Adjusting nuts 2 Mounting bolt 1 2 5 Remove the drive belt guard Loosen mounting bolt 2 and adjusting nuts 1 Turn adjusting nuts 1 in order to increase or decrease the drive belt tension Tighten adjusting nuts 1 Tighten mounting bolt 2 Refer to the Operation and Maintenance Manual for the proper torques Reinstall the drive belt guard If new drive belts are installed check the drive belt tension again after 30 minutes of engine operation at the rated rpm Fan Drive Belt Adjustment 1 2 Loosen the mounting bolt for the pulley Loosen the adjusting nut for the pulley Move the pulley in order to adjust the belt tension Tighten the adjusting nut Tighten the mounting bolt 101041029 Batteries Replace SMCS Code 1401 510 Batteries give off combu
66. paper Place the primary air cleaner element into a box for storage For identification mark the outside of the box and mark the primary air cleaner element Include the following information e Date cleaned e Number of cleanings Store the box in a dry location For more detailed information on cleaning the primary air cleaner element refer to Special Publication SEBF8062 Procedure to Inspect and Clean Air Filters 100736823 Engine Air Cleaner Element Single Element Inspect Replace SMCS Code 1054 040 1054 510 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine 79 Maintenance Section Engine Air Cleaner Service Indicator Inspect Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air clean
67. primary air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are four common methods that are used to clean primary air cleaner elements e Pressurized water e Pressurized air e Vacuum cleaning e Washing with nonsudsing detergent 77 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace Pressurized Water Pressurized water will clean the primary air cleaner element unless carbon and oil have accumulated on the surface of the primary air cleaner element The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Do not use a spray nozzle Note When the primary air cleaner element is cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the water flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of water directly at the primary air cleaner element Dirt could be forced further into the pleats Note Refer to Drying the Primary Air Cleaner Elements Refer to Inspecting the Primary Air Cleaner Elements Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbo
68. r to pressure test the cooling system filler cap The correct pressure is stamped on the face of the cooling system filler cap If the cooling system filler cap does not maintain 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 101065859 Cooling System Coolant Analysis Level Il Obtain SMCS Code 1350 For conventional heavy duty coolant antifreeze check the concentration of supplemental coolant additive SCA regularly The concentration of SCA can be checked with an S O S coolant analysis Level 1 A more detailed coolant analysis is recommended periodically For example considerable deposits are found in the water jacket areas on the external cooling system but the concentrations of coolant additives were carefully maintained The coolant water probably contained minerals which were deposited on the engine over time A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system A full water analysis may be obtained from the following sources e Caterpillar dealer e Local water utility company e Agricultural agent e Independent laboratory Caterpillar recommends an S O S coolant analysis Level Il This is a comprehensive chemical evaluation of the coolant This analysis is also a check of the overall condition of the inside of the coo
69. rcent sup plemental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Follow the instructions that are in this Operation and Maintenance Manual Water Supplemental Coolant Additive SCA topic Maintenance Section S O S Coolant Analysis Level I Level is a basic analysis of the coolant The following items are tested SCA concentration glycol concentration pH and 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 analysis Add the SCA If Necessary Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly Note Always dispose of fluids according to local regulations 2 If necessary drain some coolant in order to allow space for the addition of the SCA NOTICE Excessive supplemental coolant additive concentra tion can form deposits on the higher temperature sur faces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temperature components Exc
70. rpillar and certified for use The following components are examples of the remanufactured parts e Cylinder heads e Oil Pumps e Turbochargers e Water pumps Consult your Caterpillar dealer for details and for a list of the remanufactured parts that are available Your Caterpillar dealer may be offering a variety of overhaul options A Flat Rate Overhaul guarantees the maximum price that you will pay for an overhaul Flat rate prices on preventive maintenance programs or major repair options are available from many servicing dealers for all Caterpillar Engines Consult your Caterpillar dealer in order to schedule a before failure overhaul Overhaul Recommendation Caterpillar recommends a scheduled overhaul in order to minimize downtime A scheduled overhaul will provide the lowest cost and the greatest value Schedule an overhaul with your Caterpillar dealer Overhaul programs vary between dealers To obtain specific information about the types of overhaul programs and services consult your Caterpillar dealer 99 Maintenance Section Starting Motor Inspect 101113939 Starting Motor Inspect SMCS Code 1451 040 1453 040 If the starting motor fails the engine may not start in an emergency situation A scheduled inspection of the starting motor is recommended The starting motor pinion and the flywheel ring gear must be in good condition in order for the engine to start properly The engine will not start if the
71. s that are necessary in order to perform the required maintenance on the items that are listed Consult your Caterpillar dealer for assistance To determine the reusability publications that are needed to inspect the engine refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts The Guidelines For Reusable Parts and Salvage Operations is part of an established Caterpillar parts reusability program These guidelines were developed in order to assist Caterpillar dealers and customers reduce costs by avoiding unnecessary expenditures for new parts If the engine parts comply with the established inspection specifications the parts can be reused The use of out of spec parts could result in unscheduled downtime and or costly repairs The use of out of spec parts can also contribute to increased fuel consumption and reduction of engine efficiency New parts are not necessary if the old parts can be reused repaired or salvaged Otherwise the old parts can be replaced or exchanged Your Caterpillar dealer can provide the parts that are needed to rebuild the engine at the least possible cost Overhaul Programs An economical way to obtain most of the parts that are needed for overhauls is to use Caterpillar remanufactured parts Caterpillar remanufactured parts are available at a fraction of the cost of new parts These parts have been rebuilt by Cate
72. stible 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 1 Turn the key start switch to the OFF position Remove the key and all electrical loads 2 Turn OFF the battery charger Disconnect 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 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 connecting the cables 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 68 Maintenance Section Battery Electrolyte Level Check 101206348 Battery Electrolyte Level Check SMCS Code 1401 535 FLV When the engine is not run for long periods of time or
73. sult your Caterpillar dealer or consult Caterpillar Service Technology Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Clean the Cooling System 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the cooling system drain valves if equipped Clean the drain plugs and install the drain plugs 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 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the cooling system filler cap 4 Start the engine Operate the engine for a minimum of 30 minutes with a coolant temperature of at least 82 C 180 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 cooling system drain valves if equipped or remove drain plugs 1 and 2 See Illustration 25 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
74. t SMCS Code 1205 040 The crankshaft vibration damper limits the torsional vibration of the crankshaft The visconic damper has a weight that is located inside a fluid filled case Damage to the crankshaft vibration damper or failure of the 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 A damper that is hot may be the result of excessive friction This could be due to misalignment Use an infrared thermometer to monitor the temperature of the damper during operation If the temperature reaches 100 C 212 F consult your Caterpillar dealer Inspect the damper for evidence of dents cracks and leaks of the fluid If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous smooth and difficult to remove from surfaces If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace all of the seals Inspect the damper and repair or replace the damper for any of the following reasons The damper is dented cracked or leaking The paint on the damper is discolored from heat The engine has had a failure because of a broken crankshaft An analysis of the oil has revealed that the front bearing of the crankshaft is badly worn
75. te 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 6 Flush the cooling system with clean water until the water that drains is clean Close the cooling system drain valves if equipped Clean the drain plugs and install the drain plugs Fill the Cooling System NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 70 Maintenance Section Cooling System Coolant ELC Change Note For information about the proper coolant to use see this Operation and Maintenance Manual Coolant Recommendations Maintenance Section For the capacity of the cooling system see this Operation and Maintenance Manual Refill Capacities Maintenance Section 1 Fill the cooling system with coolant antifreeze Do not install the cooling system filler cap 2 Start the engine Operate the engine in order to purge the air from the cavities of the engine block Allow the coolant to warm and allow the coolant level to stabilize Stop the engine 3 Check the coolant level Maintain the coolant to the proper level on the sight gauge if equipped If a sight gauge is not equipped maintain the coolant within 13 mm 5 inch below the bottom of the filler pipe 4
76. the Operation and Maintenance Manual Cooling System Specifications information for the Caterpillar ELC Extender additions 4 Clean the cooling system filler cap Inspect the cooling system filler cap gaskets Replace the cooling system filler cap if the cooling system filler cap gaskets are damaged Install the cooling system filler cap 100855831 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Climbing equipment may be required to access this service point Refer to the Operation and Maintenance Manual Mounting and Dismount ing topic for safety information Illustration 27 g00313963 1 Sight gauge NOTICE Overfilling the overflow tank if equipped will result in damage to the cooling system If the cooling system has an overflow tank maintain the coolant level in the tank below 1 2 full in order to avoid damage to the cooling system Observe the coolant level in the sight gauge At normal operating temperature the coolant should be in the upper half of the sight gauge If the coolant level is low add the proper coolant mixture Add Coolant Note For the proper coolant mixture to use see this Operation and Maintenance Manual Coolant Recommendations topic Maintenance Section 1 Stop the engine Allow the engine to cool 2 Remove the cooling system filler cap slowly in order to relieve any pressure Pour the proper coolant mixture into the filler pipe
77. the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery e Check the condition of the gauges Replace any gauges which are cracked or can not be calibrated 100524084 Water Pump Inspect SMCS Code 1361 040 A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head a piston seizure or other potential damage to the engine Visually inspect the water pump for leaks If leaking of the water pump seals is observed replace all of the water pump seals Refer to the Service Manual for the disassembly and assembly procedure Inspect the water pump for wear cracks pin holes and proper operation Refer to the Service Manual or consult your Caterpillar dealer if repair is needed or replacement is needed
78. ting Excessive overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface Refer to the Service Manual for the replacement procedure of the water temperature regulator or consult your Caterpillar dealer Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing i00767300 Crankshaft Vibration Damper Inspec
79. tion of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber 4 Use a dial indicator to check the end clearance on the shaft If the measured end play is greater than the Service Manual specifications the turbocharger should be repaired or replaced An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications 5 Inspect the bore of the turbine housing for corrosion 6 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 7 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 100632301 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks a
80. uipped with drain valves remove drain plugs 1 and 2 Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Service Technology Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Clean the Cooling System 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the cooling system drain valves if equipped Clean the drain plugs and install the drain plugs 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 Operate the engine until the temperature reaches 49 C 120 F to 66 C 150 F 71 Maintenance Section Cooling System Coolant Analysis Level Il Obtain 4 Stop the engine and allow the engine to cool Ensure that the engine will not start when the cooling system is drained Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 5 Ope
81. wing reasons e Costly unplanned downtime can be avoided e Many original parts can be reused according to the guidelines for reusable parts e The service life of the engine can be extended without the risk of a major catastrophe due to engine failure Achieve the best cost value relationship per hour of extended service life Overhaul Intervals Some factors that are important for determining the overhaul intervals include the following considerations e Performance of preventive maintenance e Use of recommended lubricants e Use of recommended coolants e Use of recommended fuels Proper installation Operating conditions e Operation within acceptable limits Engine load e Engine speed Generally engines that are operated at a reduced load and or speed achieve more service life before an overhaul However this is for engines that are properly operated and maintained Other factors must also be considered for determining a major overhaul e The total amount of fuel consumption e The service hours of the engine e An increase of oil consumption e An increase of crankcase blowby e The wear metal analysis of the lube oil e An increase in the levels of noise and vibration An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced An increase in the levels of noise and vibration indicates that rotating parts require service Note It is possibl

1 - Safety - Caterpillar

Contents

Download Pdf Manuals

Related Search

Related Contents