Owner's Manual – Cat Engine

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7605-04April 2007

Operation andMaintenanceManualC0.5, C0.7, C0.7, C1.1/3011C, C1.5/3013C, C1.6 and C2.2/3024C/3024CTIndustrial Engines and Engines forCaterpillar Built Machines3111-Up (Engine)3131-Up (Engine)4241-Up (Engine)C1M1-Up (Engine)C3M1-Up (Engine)C4M1-Up (Engine)C5M1-Up (Engine)C7M1-Up (Engine)G7M1-Up (Engine)G8M1-Up (Engine)C5N1-Up (Engine)G7N1-Up (Engine)G1P1-Up (Engine)G3P1-Up (Engine)G4P1-Up (Engine)

46 SEBU7605-04Maintenance SectionMaintenance Interval Schedule

i02704717

Maintenance Interval ScheduleSMCS Code: 1000; 7500

When Required

Battery - Replace .................................................. 49Battery or Battery Cable - Disconnect .................. 50Engine - Clean ...................................................... 58Engine Air Cleaner Element (Dual Element) -Clean/Replace .................................................... 58Engine Air Cleaner Element (Single Element) -Inspect/Replace .................................................. 61Fuel System - Prime ............................................. 68Severe Service Application - Check ..................... 77

Daily

Cooling System Coolant Level - Check ................ 54Driven Equipment - Check .................................... 57Engine Air Cleaner Service Indicator - Inspect ..... 62Engine Air Precleaner - Check/Clean ................... 63Engine Oil Level - Check ...................................... 64Fuel System Primary Filter/Water Separator -Drain ................................................................... 70Walk-Around Inspection ........................................ 79

Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 73

Every 250 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ................................................................. 55

Every 250 Service Hours or 6 Months

Alternator and Fan Belts - Inspect/Adjust ............. 47Engine Oil Sample - Obtain .................................. 64

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)



Fuel System Secondary Filter - Replace .............. 70

Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 49Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 56Engine Air Cleaner Element (Single Element) -Replace ............................................................... 61Engine Oil and Filter - Change ............................. 65Engine Protective Devices - Check ...................... 67Hoses and Clamps - Inspect/Replace .................. 73

Radiator - Clean .................................................... 77


Alternator and Fan Belts - Replace ....................... 48Engine Valve Lash - Inspect/Adjust ...................... 67Turbocharger - Inspect .......................................... 78


Alternator - Inspect ............................................... 47Engine Crankcase Breather - Replace ................. 63Engine Mounts - Inspect ....................................... 64Starting Motor - Inspect ........................................ 78

Every Year



Fuel Injection Nozzles - Test/Exchange ................ 67Water Pump - Inspect ........................................... 80

Every 3000 Service Hours or 2 Years

Cooling System Coolant (DEAC) - Change .......... 50Cooling System Water Temperature Regulator -Replace ............................................................... 57

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 53

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 52

Overhaul

Overhaul Considerations ...................................... 74

SEBU7605-04 47Maintenance SectionAlternator - Inspect

i02676048

Alternator - InspectSMCS Code: 1405-040

Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and proper battery charging. Inspect theammeter (if equipped) during engine operation inorder to ensure proper battery performance and/orproper performance of the electrical system. Makerepairs, as required.

Check the alternator and the battery charger forproper operation. If the batteries are properlycharged, the ammeter reading should be very nearzero. All batteries should be kept charged. Thebatteries should be kept warm because temperatureaffects the cranking power. If the battery is too cold,the battery will not crank the engine. The battery willnot crank the engine, even if the engine is warm.When the engine is not run for long periods of timeor if the engine is run for short periods, the batteriesmay not fully charge. A battery with a low charge willfreeze more easily than a battery with a full charge.

i02226340

Alternator and Fan Belts -Inspect/AdjustSMCS Code: 1357-025; 1357-040

S/N: 3111-Up

S/N: 4241-Up

S/N: C1M1-Up

S/N: C3M1-Up

S/N: C4M1-Up

S/N: C5M1-Up

S/N: C7M1-Up

S/N: G7M1-Up

S/N: G8M1-Up

S/N: C5N1-Up

S/N: G7N1-Up

S/N: G1P1-Up

S/N: G3P1-Up

S/N: G4P1-Up

InspectionTo maximize the engine performance, inspect thebelts for wear and for cracking. Replace belts that areworn or damaged.

For applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new belt tocarry more load because the older belt is stretched.The additional load on the new belt could cause thenew belt to break.

If the belts are too loose, vibration causesunnecessary wear on the belts and pulleys. Loosebelts may slip enough to cause overheating.

To accurately check the belt tension, Gauge144-0235 Belt Tension Gauge should be used.

48 SEBU7605-04Maintenance SectionAlternator and Fan Belts - Replace

g01003936Illustration 29Typical example(1) 144-0235 Belt Tension Gauge

Install the gauge (1) at the center of the belt betweenthe alternator and the crankshaft pulley and checkthe belt tension. The correct tension for a new belt is400 N (90 lb) to 489 N (110 lb). The correct tensionfor a used belt that has been in operation for 30minutes or more at the rated speed is 267 N (60 lb)to 356 N (80 lb).

If twin belts are installed, check and adjust thetension on both belts.

Adjustment

g01091158Illustration 30

Typical example(1) Adjusting bolt(2) Mounting bolts

1. Loosen the mounting bolts (2) and the adjustingbolt (1).

2. Move the alternator in order to increase ordecrease the belt tension.

3. Tighten the adjusting bolt (1). Tighten the mountingbolts (2). Refer to the Specifications Manual forthe correct torque settings.

i02226343

Alternator and Fan Belts -ReplaceSMCS Code: 1357-510

g01091158Illustration 31Typical example

(1) Adjusting bolt(2) Mounting bolts

For applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new belt tocarry more load because the older belt is stretched.The additional load on the new belt could cause thenew belt to break.

Note: When new belts are installed, check the belttension again after 20 hours of engine operation.

Refer to the Disassembly and Assembly Manual forthe installation procedure and the removal procedurefor the belt.

SEBU7605-04 49Maintenance Section

Battery - Replace

i02153996

Battery - ReplaceSMCS Code: 1401-510

Batteries give off combustible gases which canexplode. 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 inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the key start switch to the OFF position.Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect thecharger.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the ground plane. Disconnectthe 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 abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure thatthe key start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE “+” battery terminal.

8. Connect the cable from the ground plane to theNEGATIVE “-” battery terminal.

i02601752

Battery Electrolyte Level -CheckSMCS Code: 1401-535

When the engine is not run for long periods of time orwhen the engine is run for short periods, the batteriesmay not fully recharge. Ensure a full charge in orderto help prevent the battery from freezing.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

1. Remove the filler caps. Maintain the electrolytelevel to the “FULL” mark on the battery.

If the addition of water is necessary, use distilledwater. If distilled water is not available use cleanwater that is low in minerals. Do not use artificiallysoftened water.

2. Check the condition of the electrolyte with the245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and1 L (1 qt) of clean water

• 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 theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fit properly.Coat the clamps and the terminals with 5N-5561Silicone Lubricant, petroleum jelly or MPGM.

50 SEBU7605-04Maintenance SectionBattery or Battery Cable - Disconnect

i01492654

Battery or Battery Cable -DisconnectSMCS Code: 1402-029

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the start switch to the OFF position. Turn theignition switch (if equipped) to the OFF positionand remove the key and all electrical loads.

2. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal. When four12 volt batteries are involved, the negative side oftwo batteries must be disconnected.

3. Tape the leads in order to help prevent accidentalstarting.

4. Proceed with necessary system repairs. Reversethe steps in order to reconnect all of the cables.

i02242514

Cooling System Coolant(DEAC) - ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

NOTICEUse of commercially available cooling system clean-ers may cause damage to cooling system compo-nents. Use only cooling system cleaners that are ap-proved for Caterpillar engines.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulator andthe hoses, if necessary.

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

2. Open the cooling system drain valve (if equipped).If the cooling system is not equipped with a drainvalve, remove one of the drain plugs.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Dealer Service Tools Group:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush1. Flush the cooling system with clean water in orderto remove any debris.


Cooling System Coolant (DEAC) - Change

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to TorqueSpecifications, SENR3130 for more informationon the correct torques.

NOTICEDo not fill the cooling system faster than 5 L(1.3 US gal) per minute to avoid air locks.

Cooling system air locksmay result in engine damage.

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

4. Start and run the engine at low idle for a minimumof 30 minutes. The coolant temperature should beat least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve (ifequipped). Clean the drain plugs. Install the drainplugs. Refer to Torque Specifications, SENR3130for more information on the correct torques.

Cooling Systems with HeavyDeposits or PluggingNote: For the following procedure to be effective,there must be some active flow through the coolingsystem components.

1. Flush the cooling system with clean water in orderto remove any debris.



Cooling system air locks may result in engine damage.

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity. Install the cooling system filler cap.

4. Start and run the engine at low idle for a minimumof 90 minutes. The coolant temperature should beat least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.


Fill



1. Fill the cooling system with coolant/antifreeze.Refer to this Operation and Maintenance Manual,“Refill Capacities and Recommendations” topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to 1500 rpm. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

52 SEBU7605-04Maintenance SectionCooling System Coolant (ELC) - Change

3. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap.If the gasket that is on the cooling system fillercap is not damaged, perform a pressure test. A9S-8140 Pressurizing Pump is used to performthe pressure test. The correct pressure for thecooling system filler cap is stamped on the face ofthe cooling system filler cap. If the cooling systemfiller cap does not retain the correct pressure,install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for the correct operating temperature.

i02242512

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

Note: When the cooling system is cleaned, onlyclean water is needed when the ELC is drained andreplaced.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulator andthe hoses, if necessary.

Drain


1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

2. Open the cooling system drain valve (if equipped).If the cooling system is not equipped with a drainvalve, remove the cooling system drain plugs.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Dealer Service Tools:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush1. Flush the cooling system with clean water in orderto remove any debris.




3. Fill the cooling system with clean water. Install thecooling system filler cap.

4. Start and run the engine at low idle until thetemperature reaches 49 to 66 °C (120 to 150 °F).


Cooling System Coolant Extender (ELC) - Add


Fill


Cooling system air locksmay result in engine damage.

1. Fill the cooling system with Extended Life Coolant(ELC). Refer to this Operation and MaintenanceManual, “Refill Capacities and Recommendations”topic (Maintenance Section) for more informationon cooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to high idle. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket that is on the cooling system filler cap isnot damaged, use a 9S-8140 Pressurizing Pumpin order to pressure test the cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install a newcooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i02482066

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-045; 1395-081

Cat ELC (Extended Life Coolant) does not requirethe frequent additions of any supplemental coolingadditives which are associated with the presentconventional coolants. The Cat ELC Extender onlyneeds to be added once.

NOTICEUse only Cat Extended Life Coolant (ELC) Extenderwith Cat ELC.

Do NOT use conventional supplemental coolant addi-tive (SCA) with Cat ELC. Mixing Cat ELC with conven-tional coolants and/or conventional SCA reduces theCat ELC service life.

Check the cooling system only when the engine isstopped and cool.

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

54 SEBU7605-04Maintenance SectionCooling System Coolant Level - Check

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. It may be necessary to drain enough coolant fromthe cooling system in order to add the Cat ELCExtender.

3. Add Cat ELC Extender according to therequirements for your engine’s cooling systemcapacity. Refer to the Operation and MaintenanceManual, “Refill Capacities and Recommendations”article for more information.

4. Clean the cooling system filler cap. Inspect thegaskets on the cooling system filler cap. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

i01197583

Cooling System Coolant Level- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

g00285520Illustration 32Cooling system filler cap


1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel to the proper level in the sight glass.


Typical filler cap gaskets

3. Clean the cooling system filler cap and check thecondition of the filler cap gaskets. Replace thecooling system filler cap if the filler cap gaskets aredamaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.


Cooling System Coolant Sample (Level 1) - Obtain

i02603581

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Obtaining a Coolant Sample (Level 1) isoptional if the cooling system is filled with CatELC (Extended Life Coolant). Cooling systems thatare filled with Cat ELC should have a Coolant Sample(Level 2) that is obtained at the recommended intervalthat is stated in the Maintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC. This includes the followingtypes of coolants:

• Commercial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze

Table 26

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEAC Every 250Hours(1) Yearly(1)(2)

Cat ELC Optional(2) Yearly(2)

(1) This is the recommended interval for coolant samples for allconventional heavy-duty coolant/antifreeze. This is also therecommended interval for coolant samples of commercialcoolants that meet the Cat EC-1 specification for enginecoolant.

(2) The Level 2 Coolant Analysis should be performed sooner if aproblem is suspected or identified.

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Level 1 results may indicate a need forLevel 2 Analysis.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis,see Special Publication, SEBU6251, “CaterpillarCommercial Diesel Engine Fluids Recommendations”or consult your Caterpillar dealer.

i01987714

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542


Refer to Operation and Maintenance Manual,“Cooling System Coolant Sample (Level 1) - Obtain”for the guidelines for proper sampling of the coolant.

56 SEBU7605-04Maintenance SectionCooling System Supplemental Coolant Additive (SCA) - Test/Add

Submit the sample for Level 2 analysis.

For additional information about coolantanalysis, see Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engines FluidsRecommendations” or consult your Caterpillar dealer.

i02456600

Cooling System SupplementalCoolant Additive (SCA) -Test/AddSMCS Code: 1352-045; 1395-081

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and the eyes. Do not drink cooling systemcoolant additive.

Note: Test the concentration of the SupplementalCoolant Additive (SCA) or test the SCA concentrationas part of an S·O·S Coolant Analysis.

Test for SCA Concentration

Coolant and SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Use the 8T-5296 Coolant Conditioner Test Kitor use the 4C-9301 Coolant Conditioner Test Kitin order to check the concentration of the SCA.Refer to this Operation and Maintenance Manual,“Refill Capacities and Recommendations” for moreinformation.

Water and SCA

NOTICEDo not exceed the recommended eight percent sup-plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Refer to the SpecialPublication, SEBU6251, “Caterpillar CommercialDiesel Engine Fluids Recommendations” for moreinformation.

S·O·S Coolant AnalysisS·O·S coolant samples can be analyzed at yourCaterpillar dealer. S·O·S Coolant Analysis is aprogram that is based on periodic samples.

Level 1

Level 1 is a basic analysis of the coolant. Thefollowing items are tested:

• Glycol Concentration

• Concentration of SCA

• pH

• Conductivity

The results are reported, and recommendationsare made according to the results. Consult yourCaterpillar dealer for information on the benefits ofmanaging your equipment with an S·O·S CoolantAnalysis.

Level 2

This level coolant analysis is recommended when theengine is overhauled. Refer to this Operations andMaintenance Manual, “Overhaul Considerations” forfurther information.

Add the SCA, If Necessary

NOTICEDo not exceed the recommended amount of sup-plemental coolant additive concentration. Excessivesupplemental coolant additive concentration can formdeposits on the higher temperature surfaces of thecooling system, reducing the engine’s heat transfercharacteristics. Reduced heat transfer could causecracking of the cylinder head and other high temper-ature components. Excessive supplemental coolantadditive concentration could also result in radiatortube blockage, overheating, and/or accelerated waterpump seal wear. Never use both liquid supplementalcoolant additive and the spin-on element (if equipped)at the same time. The use of those additives togethercould result in supplemental coolant additive concen-tration exceeding the recommended maximum.


Cooling System Water Temperature Regulator - Replace


1. Slowly loosen the cooling system filler cap inorder to relieve the pressure. Remove the coolingsystem filler cap.

Note: Always discard drained fluids according tolocal regulations.

2. If necessary, drain some coolant from the coolingsystem into a suitable container in order to allowspace for the extra SCA.

3. Add the proper amount of SCA. Referto the Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engines FluidsRecommendations” for more information on SCArequirements.

4. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets are damaged, replace the old coolingsystem filler cap with a new cooling system fillercap. Install the cooling system filler cap.

i02623972

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime.

A water temperature regulator that fails in apartially opened position can cause overheating orovercooling of the engine.

A water temperature regulator that fails in the closedposition can cause excessive overheating. Excessiveoverheating could result in cracking of the cylinderhead or piston seizure problems.

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup inside thecylinders. This excessive carbon buildup could resultin an accelerated wear of the piston rings and wearof the cylinder liner.

NOTICEFailure to replace your water temperature regulatoron a regularly scheduled basis could cause severeengine damage.

Caterpillar engines incorporate a shunt design coolingsystem and require operating the engine with a watertemperature regulator installed.

If the water temperature regulator is installed incor-rectly, the enginemay overheat, causing cylinder headdamage. Ensure that the new water temperature reg-ulator is installed in the original position. Ensure thatthe water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket orcylinder head surface.

Refer to two articles in the Disassembly andAssembly Manual, “Water Temperature Regulators- Remove and Water Temperature Regulators -Install” for the replacement procedure of the watertemperature regulator, or consult your Caterpillardealer.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling system toa level that is below the water temperature regulatorhousing.

i00174798

Driven Equipment - CheckSMCS Code: 3279-535

Refer to the OEM specifications for more informationon the following maintenance recommendations forthe driven equipment:

• Inspection

• Adjustment

• Lubrication

• Other maintenance recommendations

Perform any maintenance for the driven equipmentwhich is recommended by the OEM.

58 SEBU7605-04Maintenance SectionEngine - Clean

i01646701

Engine - CleanSMCS Code: 1000-070

Personal injury or death can result from high volt-age.

Moisture can create paths of electrical conductiv-ity.

Make sure that the electrical system is OFF. Lockout the starting controls and tag the controls “DONOT OPERATE”.

NOTICEAccumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Periodic cleaning of the engine is recommended.Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides the followingbenefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

Note: Caution must be used in order to preventelectrical components from being damaged byexcessive water when you clean the engine. Avoidelectrical components such as the alternator, thestarter, and the ECM.

i01553486

Engine Air Cleaner Element(Dual Element) - Clean/ReplaceSMCS Code: 1054-037; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

Servicing the Air Cleaner ElementsIf the air cleaner element becomes plugged, the aircan split the material of the air cleaner element.Unfiltered air will drastically accelerate internal enginewear. Your Caterpillar dealer has the proper aircleaner elements for your application. Consult yourCaterpillar dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

• Operating conditions (dust, dirt and debris) mayrequire more frequent service of the air cleanerelement.

• The air cleaner element may be cleaned up tosix times if the element is properly cleaned andinspected.

• The air cleaner element should be replaced at leastone time per year. This replacement should beperformed regardless of the number of cleanings.

Replace the dirty paper air cleaner elements withclean air cleaner elements. Before installation, theair cleaner elements should be thoroughly checkedfor tears and/or holes in the filter material. Inspectthe gasket or the seal of the air cleaner element fordamage. Maintain a supply of suitable air cleanerelements for replacement purposes.

Dual Element Air Cleaners

The dual element air cleaner contains a primaryair cleaner element and a secondary air cleanerelement. The primary air cleaner element can beused up to six times if the element is properly cleanedand inspected. The primary air cleaner elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

The secondary air cleaner element is not serviceableor washable. The secondary air cleaner elementshould be removed and discarded for every threecleanings of the primary air cleaner element. Whenthe engine is operating in environments that aredusty or dirty, air cleaner elements may require morefrequent replacement.


Engine Air Cleaner Element (Dual Element) - Clean/Replace

g00736431Illustration 34(1) Cover(2) Primary air cleaner element(3) Secondary air cleaner element(4) Turbocharger air inlet

1. Remove the cover. Remove the primary aircleaner element.

2. The secondary air cleaner element should beremoved and discarded for every three cleaningsof the primary air cleaner element.

Note: Refer to “Cleaning the Primary Air CleanerElements”.

3. Cover the turbocharger air inlet with tape in orderto keep dirt out.

4. Clean the inside of the air cleaner cover and bodywith a clean, dry cloth.

5. Remove the tape for the turbocharger air inlet.Install the secondary air cleaner element. Install aprimary air cleaner element that is new or cleaned.

6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.

Cleaning the Primary Air CleanerElements

NOTICECaterpillar recommends certified air filter cleaning ser-vices that are available at Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary air cleaner element can be used upto six times if the element is properly cleaned andinspected. When the primary air cleaner element iscleaned, check for rips or tears in the filter material.The primary air cleaner element should be replacedat least one time per year. This replacement shouldbe performed regardless of the number of cleanings.

Use clean primary air cleaner elements while dirtyelements are being cleaned.

NOTICEDo not clean the air cleaner elements by bumping ortapping. 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. Enginedamage could result.

Visually inspect the primary air cleaner elementsbefore cleaning. Inspect the air cleaner elements fordamage to the seal, the gaskets, and the outer cover.Discard any damaged air cleaner elements.

There are two common methods that are used toclean primary air cleaner elements:

• Pressurized air

• Vacuum cleaning

60 SEBU7605-04Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

Pressurized Air

Pressurized air can be used to clean primary aircleaner elements that have not been cleaned morethan two times. Pressurized air will not removedeposits of carbon and oil. Use filtered, dry air with amaximum pressure of 207 kPa (30 psi).


Note: When the primary air cleaner elements arecleaned, 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 elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the streamof air directly at the primary air cleaner element. Dirtcould be forced further into the pleats.

Note: Refer to “Inspecting the Primary Air CleanerElements”.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningprimary air cleaner elements which require dailycleaning because of a dry, dusty environment.Cleaning with pressurized air is recommended priorto vacuum cleaning. Vacuum cleaning will not removedeposits of carbon and oil.

Note: Refer to “Inspecting the Primary Air CleanerElements”.

Inspecting the Primary Air CleanerElements


Inspect the clean, dry primary air cleaner element.Use a 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary air cleanerelement. Rotate the primary air cleaner element.Inspect the primary air cleaner element for tearsand/or holes. Inspect the primary air cleaner elementfor light that may show through the filter material. If itis necessary in order to confirm the result, comparethe primary air cleaner element to a new primary aircleaner element that has the same part number.

Do not use a primary air cleaner element that hasany tears and/or holes in the filter material. Do notuse a primary air cleaner element with damagedpleats, gaskets or seals. Discard damaged primaryair cleaner elements.

Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes inspectionwill not be used, the primary air cleaner element canbe stored for future use.



Engine Air Cleaner Element (Single Element) - Inspect/Replace

Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An airflow restrictionmay result. To protect against dirt and damage, wrapthe primary air cleaner elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary air cleaner element into a boxfor storage. For identification, mark the outside ofthe box and mark the primary air cleaner element.Include the following information:

• Date of cleaning

• Number of cleanings

Store the box in a dry location.

i01432811

Engine Air CleanerElement (Single Element) -Inspect/ReplaceSMCS Code: 1054-040; 1054-510

Perform the Operation and Maintenance Manual,“Engine Air Cleaner Service Indicator-Inspect”procedure and perform the Operation andMaintenance Manual, “Engine Air PrecleanerCheck/Clean” procedure (if equipped) beforeperforming the following procedure.

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.


g00310664Illustration 38(1) Air cleaner cover(2) Air filter element(3) Air inlet

1. Remove air cleaner cover (1) and remove air filterelement (2).

2. Cover air inlet (3) with tape or a clean cloth so thatdebris cannot enter the air inlet.

3. Clean the inside of air cleaner cover (1). Clean thebody that holds the air cleaner element.

4. Inspect the replacement element for the followingitems:damage, dirt, and debris.

5. Remove the seal from the opening of the air inlet.

6. Install a clean, undamaged air filter element (2).

7. Install air cleaner cover (1).

8. Reset the air cleaner service indicator.

i02242500

Engine Air Cleaner Element(Single Element) - ReplaceSMCS Code: 1051; 1054-510


62 SEBU7605-04Maintenance SectionEngine Air Cleaner Service Indicator - Inspect

g00109823Illustration 39(1) Air cleaner element. (2) Clamp.

1. Loosen clamp (2) which fastens air cleanerelement (1) to the air inlet. Remove the dirty aircleaner element and clamp.

2. Install clamp (2) on new air cleaner element (1).

3. Install new air cleaner element (1) to the airinlet and tighten clamp (2). Refer to TorqueSpecifications, SENR3130 for the correct torque.

i01900118

Engine Air Cleaner ServiceIndicator - Inspect(If Equipped)SMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differential gaugefor inlet air pressure. The differential gauge for inletair pressure displays the difference in the pressurethat is measured before the air cleaner element andthe pressure that is measured after the air cleanerelement. As the air cleaner element becomes dirty,the pressure differential rises. If your engine isequipped with a different type of service indicator,follow the OEM recommendations in order to servicethe air cleaner service indicator.

The service indicator may be mounted on the aircleaner housing or in a remote location.

g00103777Illustration 40Typical service indicator

Observe the service indicator. The air cleanerelement should be cleaned or the air cleaner elementshould be replaced when one of the followingconditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service IndicatorService indicators are important instruments.

• Check for ease of resetting. The service indicatorshould reset in less than three pushes.

• Check the movement of the yellow core when theengine is accelerated to the engine rated speed.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If the newservice indicator will not reset, the hole for the serviceindicator may be plugged.

The service indicator may need to be replacedfrequently in environments that are severely dusty, ifnecessary. Replace the service indicator annuallyregardless of the operating conditions. Replace theservice indicator when the engine is overhauled, andwhenever major engine components are replaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 N·m (18 lb in).


Engine Air Precleaner - Check/Clean

i00720883

Engine Air Precleaner -Check/CleanSMCS Code: 1055-070; 1055-535


Typical engine precleaner(1) Wing nut(2) Cover(3) Body

Remove wing nut (1) and cover (2). Check for anaccumulation of dirt and debris in body (3). Clean thebody, if necessary.

After cleaning the precleaner, install cover (2) andwing nut (1).

Note: When the engine is operated in dustyapplications, more frequent cleaning is required.

i02657607

Engine Crankcase Breather -ReplaceSMCS Code: 1317-510

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.


Typical example

(1) Screws for the breather cover(2) Breather cover(3) Spring(4) Diaphragm and plate(5) Spacer for turbocharged engines only(6) Joint for turbocharged engines only(7) Cavity(8) Vent hole

1. Loosen the screws (1) and remove the breathercover (2) from the valve mechanism cover.

2. Remove the spring (3). Remove the diaphragmand plate (4).

3. For turbocharged engines, remove the spacer (5)and the joint (6).

4. Clean the vent hole (8) and the cavity (7) in thevalve mechanism cover.

NOTICEMake sure that the components of the breather as-sembly are installed correctly. Engine damage mayoccur if the breather assembly is not working correctly.

5. For turbocharged engines, install a new joint (6)and the spacer (5).

64 SEBU7605-04Maintenance SectionEngine Mounts - Inspect

6. Install a new diaphragm and plate (4) for thebreather assembly into the cavity (7) of thevalve mechanism cover or the spacer (5) forturbocharged engines.

7. Install a new spring (3).

8. Install the breather cover (2) and the four screws(1). Tighten the screws.

i02456872

Engine Mounts - InspectSMCS Code: 1152-040

Inspect the engine mounts for deterioration and forproper bolt torque. Engine vibration can be causedby the following conditions:

• Improper mounting of the engine

• Deterioration of the engine mounts

Any engine mount that shows deterioration should bereplaced. Refer to Special Publication, SENR3130,“Torque Specifications” for the recommendedtorques. Refer to the OEM recommendations formore information.

i00623423

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

g00110310Illustration 43(Y) “ADD” mark. (X) “FULL” mark.

NOTICEPerform this maintenance with the engine stopped.

1. Maintain the oil level between “ADD” mark (Y) and“FULL” mark (X) on oil level gauge (1). Do not fillthe crankcase above “FULL” mark (X).

NOTICEOperating your engine when the oil level is above the“FULL” mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oil’s lubricating char-acteristics and could result in the loss of power.

2. Remove the oil filler cap and add oil, if necessary.Clean the oil filler cap. Install the oil filler cap.

i01935337

Engine Oil Sample - ObtainSMCS Code: 1000-008; 1348-554-SM;7542-554-OC, SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine. S·O·S oilanalysis provides infrared analysis, which is requiredfor determining nitration and oxidation levels.

Obtain the Sample and the Analysis


Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

• Engine model

• Service hours on the engine

• The number of hours that have accumulated sincethe last oil change

• The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of theoil in the crankcase, obtain a warm, well mixed oilsample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.


Engine Oil and Filter - Change

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.


If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEHP6001,“How To Take A Good Oil Sample”. Consult yourCaterpillar dealer for complete information andassistance in establishing an S·O·S program for yourengine.

i02226466

Engine Oil and Filter - ChangeSMCS Code: 1318-510; 1348-044




NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Do not drain the oil when the engine is cold. As the oilcools, suspended waste particles settle on the bottomof the oil pan. The waste particles are not removedwith the draining cold oil. Drain the crankcase withthe engine stopped. Drain the crankcase with theoil warm. This draining method allows the wasteparticles that are suspended in the oil to be drainedcorrectly.

Failure to follow this recommended procedure willcause the waste particles to be recirculated throughthe engine lubrication system with the new oil.

Drain the Engine OilAfter the engine has been run at the normal operatingtemperature, stop the engine. Use one of thefollowing methods to drain the engine crankcase oil:

• If the engine is equipped with a drain valve, turn thedrain valve knob counterclockwise in order to drainthe oil. After the oil has drained, turn the drain valveknob clockwise in order to close the drain valve.

• If the engine is not equipped with a drain valve,remove the oil drain plug in order to allow the oil todrain. After the oil has drained, the oil drain plugshould be cleaned and installed.

Replace the Oil Filter

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

1. Remove the oil filter with a 1U-8760 ChainWrench.

Note: The following actions can be carried out aspart of the preventive maintenance program.

2. Cut the oil filter open with a 175-7546 Oil FilterCutter Gp. Break apart the pleats and inspect theoil filter for metal debris. An excessive amountof metal debris in the oil filter may indicate earlywear or a pending failure.

66 SEBU7605-04Maintenance SectionEngine Oil and Filter - Change

Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are found inthe oil filter element. Ferrous metals may indicatewear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is notuncommon to find small amounts of debris in theoil filter. Consult your Caterpillar dealer in orderto arrange for a further analysis if an excessiveamount of debris is found in the oil filter.

g01091799Illustration 44(1) Oil cooler(2) Adapter(3) Oil filter

Note: The oil cooler (1) and the adapter (2) areinstalled to the C2.2/3024CT engine only.

3. Clean the sealing surface of the cylinder block orthe oil cooler (1).

4. Apply clean engine oil to the new oil filter seal (3).

NOTICEDo 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 toengine components.

5. Install the oil filter. Tighten the oil filter until theoil filter seal contacts the cylinder block or the oilcooler. Tighten the oil filter by hand according tothe instructions that are shown on the oil filter. Donot overtighten the oil filter.

Fill the Engine Crankcase1. Remove the oil filler cap. Refer to this Operationand Maintenance Manual , “Refill Capacitiesand Recommendations” for more information onlubricant specifications. Fill the crankcase with thecorrect amount of oil. Refer to this Operation andMaintenance Manual , “Refill Capacities” for moreinformation on refill capacities.

NOTICEIf equipped with an auxiliary oil filter system or a re-mote oil filter system, follow the OEM or filter manu-facturer’s recommendations. Under filling or overfillingthe crankcase with oil can cause engine damage.

NOTICETo prevent crankshaft bearing damage, crank the en-gine with the fuel OFF. This will fill the oil filters beforestarting the engine. Do not crank the engine for morethan 30 seconds.

2. Start the engine and run the engine at “LOWIDLE” for two minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain back tothe sump for a minimum of ten minutes.


4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the “ADD”and “FULL” marks on the oil level gauge.


Engine Protective Devices - Check

i00626013

Engine Protective Devices -CheckSMCS Code: 7400-535

Alarms and shutoffs must function properly. Alarmsprovide timely warning to the operator. Shutoffs helpto prevent damage to the engine. It is impossibleto determine if the engine protective devices arein good working order during normal operation.Malfunctions must be simulated in order to test theengine protective devices.

A calibration check of the engine protective deviceswill ensure that the alarms and shutoffs activateat the setpoints. Ensure that the engine protectivedevices are functioning properly.

NOTICEDuring testing, abnormal operating conditions must besimulated.

The tests must be performed correctly in order to pre-vent possible damage to the engine.

To prevent damage to the engine, only authorizedservice personnel or your Caterpillar dealer shouldperform the tests.

Visual InspectionVisually check the condition of all gauges, sensorsand wiring. Look for wiring and components thatare loose, broken, or damaged. Damaged wiringor components should be repaired or replacedimmediately.

i00869628

Engine Valve Lash -Inspect/AdjustSMCS Code: 1102-025

The initial valve lash adjustment on new engines,rebuilt engines, or remanufactured engines isrecommended at the first scheduled oil change. Theadjustment is necessary due to the initial wear ofthe valve train components and to the seating of thevalve train components.

This maintenance is recommended by Caterpillaras part of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuringthe valve lash. To obtain an accurate measurement,allow the valves to cool before this maintenance isperformed.

Refer to the Service Manual for more information.

i00626014

Fuel Injection Nozzles -Test/ExchangeSMCS Code: 1254-013; 1254-081

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

Fuel injection nozzles are subject to tip wear. Tipwear is a result of fuel contamination. Tip wear cancause the following problems:

• Increased fuel consumption

• Black smoke

• Misfire

68 SEBU7605-04Maintenance SectionFuel System - Prime

• Rough running

Fuel Injection nozzles should be cleaned, inspected,tested, and replaced, if necessary. Refer to SpecialInstruction, SEHS7292 for using the 8S-2245Injection Cleaning Tool Group. Consult yourCaterpillar dealer about cleaning the fuel injectionnozzle and testing the fuel injection nozzle.

NOTICENever wire brush or scrape a fuel injection nozzle.Wire brushing or scraping a fuel injection nozzle willdamage the finely machine orifice. Proper tools forcleaning and testing the fuel injection nozzles can beobtained from Caterpillar dealers.

The following items are symptoms of a malfunction ofthe fuel injection nozzle:

• Abnormal engine operation

• Smoke emission

• Engine knock

Each fuel injection nozzle must be isolated one ata time in order to determine the malfunctioning fuelinjection nozzle.

1. Start the engine.

2. Loosen each fuel line nut one at a time at the fuelinjection pump. A cloth or similar material must beused in order to prevent fuel from spraying on thehot exhaust components. Tighten each nut beforeloosening the next nut.

3. A defective fuel injection nozzle may be identifiedwhen a fuel line nut is loosened and the followingconditions are present:

• The exhaust smoke is partially eliminated or theexhaust smoke is completely eliminated.

• Engine performance is not affected.

A fuel injection nozzle that is suspected of beingdefective should be removed. A new fuel injectionnozzle should be installed in the cylinder in orderto determine if the removed fuel injection nozzleis defective.

Removal and Installation of theFuel Injection NozzlesFor the removal and the installation of fuel injectionnozzles, special tooling is required. Refer to theService Manual for more information. Consult yourCaterpillar dealer for assistance.

i02226980

Fuel System - PrimeSMCS Code: 1258-548

If air enters the fuel system, the air must be purgedfrom the fuel system before the engine can bestarted. Air can enter the fuel system when thefollowing events occur:

• The fuel tank is empty or the fuel tank has beenpartially drained.

• The low pressure fuel lines are disconnected.

• A leak exists in the low pressure fuel system.

• The fuel filter is replaced.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.


There are two types of fuel filter that may be installedon these engines. The procedure to prime thefuel system will depend on the type of filter that isinstalled on the engine and the type of connector thatis installed on the fuel injection pump. Both types offilter and connections are shown.

Use the following procedure in order to prime the fuelsystem:

SEBU7605-04 69Maintenance SectionFuel System - Prime

g01122124Illustration 46Fuel filter with element

(1) Fuel valve(2) Vent screw

g01122125Illustration 47Fuel filter with canister

(3) Vent screw

1. Ensure that the fuel valve (1) for the fuel filter thathas an element is in the ON position. The fuelvalve for the fuel filter that has a canister may belocated away from the engine. Refer to the OEMinformation for further details.

2. Loosen the vent screw (2) or (3).

3. Operate the hand primer. When fuel free from airflows from the vent screw tighten the vent screw.

g01122126Illustration 48Connector that is installed on 2 and 3 cylinder engines

(4) Connector bolt(5) Fuel return hose for the injector

g01122127Illustration 49Connector that is installed on 4 cylinder engines

(6) Connector bolt

4. Loosen the connector (4) or (6) at the fuel injectionpump.

Note: For illustration 48, the fuel return hose (5) mayneed to be removed at the fuel injection pump.

5. Operate the hand primer. When fuel free from airflows from the connector tighten the connectorbolt.

70 SEBU7605-04Maintenance SectionFuel System Primary Filter/Water Separator - Drain

6. Try to start the engine.

Note: Do not operate the starting motor for morethan 15 seconds. If the engine does not start after 15seconds, stop and wait for 30 seconds before tryingagain.

i01746816

Fuel System PrimaryFilter/Water Separator - DrainSMCS Code: 1260-543; 1263-543

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

NOTICEThe water separator is not a filter. The water separa-tor separates water from the fuel. The engine shouldnever be allowed to run with the water separator morethan half full. Engine damage may result.


(1) Cap(2) Locking ring(3) Element(4) Water separator bowl(5) Drain

1. Open drain (5). Catch the draining water in asuitable container. Dispose of the draining waterproperly.

2. Close drain (5).

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering the fuelsystem.

i02226986

Fuel System Secondary Filter -ReplaceSMCS 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 whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.


Fuel Filter With Canister1. Close the fuel supply valve.


Fuel System Secondary Filter - Replace


2. Clean the outside of the fuel filter assembly.

3. Open the fuel drain (2) in the bottom of thefilter assembly, if equipped. Drain the fuel into asuitable container.

4. Loosen the setscrew (1).

5. Remove the canister (3).


6. Assemble the following items: seals (8), seal (7),canister (9), and base (10). Place washer (5) andseal (6) on setscrew (4).

7. Fasten the assembly to the fuel filter base withsetscrew (4).

The fuel system will need to be primed after thenew filter is installed. Refer to this Operation andMaintenance Manual, “Fuel System - Prime”.

Fuel Filter With Element1. Close the fuel supply valve (1).

72 SEBU7605-04Maintenance SectionFuel System Secondary Filter - Replace


2. Clean the outside of the fuel filter assembly.

3. Loosen the locking ring (3).

4. Remove the casing for the filter (2) and theelement.


5. Assemble the following items: seal (5), filterelement (6) and casing (7).

6. Install the assembled items to the filter head (4).

7. Install the locking ring (8) to the filter head. Rotatethe locking ring in order to lock the assembly.

The fuel system will need to be primed after thenew filter is installed. Refer to this Operation andMaintenance Manual, “Fuel System - Prime”.


Fuel Tank Water and Sediment - Drain

i02571779

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S


Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.


Fuel TankFuel quality is critical to the performance and to theservice life of the engine. Water in the fuel can causeexcessive wear to the fuel system. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes through thefuel system and the fuel returns to the fuel tank. Thiscauses water to accumulate in fuel tanks. Drainingthe fuel tank regularly and obtaining fuel from reliablesources can help to eliminate water in the fuel.

Drain the Water and the SedimentFuel tanks should contain some provision for drainingwater and draining sediment from the bottom of thefuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

Check the fuel daily. Drain the water and sedimentfrom the fuel tank after operating the engine or drainthe water and sediment from the fuel tank after thefuel tank has been filled. Allow five to ten minutesbefore performing this procedure.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayoverflow.

Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel directly from the bottom of the tank. Ifthe engine is equipped with this system, regularmaintenance of the fuel system filter is important.

Fuel Storage TanksDrain the water and the sediment from the fuelstorage tank during the following conditions:

• Weekly

• Oil change

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank. A 4 micron [c] filter for the breather vent onthe fuel tank is also recommended. Refer to SpecialPublication, SENR9620, “Improving Fuel SystemDurablity”.

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaffles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from thestorage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

i02121526

Hoses and Clamps -Inspect/ReplaceSMCS Code: 7554-040; 7554-510

Inspect all hoses for leaks that are caused by thefollowing conditions:

• Cracking

• Softness

• Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubesand hoses carefully. Tighten all connections to the rec-ommended torque.

74 SEBU7605-04Maintenance SectionOverhaul Considerations

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

A constant torque hose clamp can be used in placeof any standard hose clamp. Ensure that the constanttorque hose clamp is the same size as the standardclamp.

Due to extreme temperature changes, the hose willheat set. Heat setting causes hose clamps to loosen.This can result in leaks. A constant torque hoseclamp will help to prevent loose hose clamps.

Each installation application can be different. Thedifferences depend on the following factors:

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps


1. Stop the engine. Allow the engine to cool.

2. Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

Note: Drain the coolant into a suitable, cleancontainer. The coolant can be reused.

3. Drain the coolant from the cooling system to alevel that is below the hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: Refer to the Specifications, SENR3130,“Torque Specifications” in order to locate the propertorques.

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler cap’s gaskets. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

10.Start the engine. Inspect the cooling system forleaks.

i01437994

Overhaul ConsiderationsSMCS Code: 7595-043

Reduced hours of operation at full load will result in alower average power demand. A decreased averagepower demand should increase both the engineservice life and the overhaul interval.

The need for an overhaul is generally indicated byincreased fuel consumption and by reduced power.

The following factors are important when a decisionis being made on the proper time for an engineoverhaul:

• The need for preventive maintenance

• The quality of the fuel that is being used

• The operating conditions

• The results of the S·O·S analysis

Oil Consumption as an OverhaulIndicatorOil consumption, fuel consumption, and maintenanceinformation can be used to estimate the totaloperating cost for your Caterpillar engine. Oilconsumption can also be used to estimate therequired capacity of a makeup oil tank that is suitablefor the maintenance intervals.

Oil consumption is in proportion to the percentageof the rated engine load. As the percentage of theengine load is increased, the amount of oil that isconsumed per hour also increases.


Overhaul Considerations

The oil consumption rate (brake specific oilconsumption) is measured in grams per kW/h (lb perbhp). The brake specific oil consumption (BSOC)depends on the engine load. Consult your Caterpillardealer for assistance in determining the typical oilconsumption rate for your engine.

When an engine’s oil consumption has risen to threetimes the original oil consumption rate due to normalwear, an engine overhaul should be scheduled.There may be a corresponding increase in blowbyand a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

A planned overhaul before failure may be the bestvalue for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according to thestandards for reusable parts.

• The engine’s service life can be extended withoutthe risk of a major catastrophe due to enginefailure.

• The best cost/value relationship per hour ofextended life can be attained.

After Failure Overhaul

Many options are available if a major engine failureoccurs. An overhaul should be performed if theengine block or the crankshaft can be repaired.

If the engine block is repairable and/or the crankshaftis repairable, the overhaul cost should be less thanthe cost of a new engine with a similar exchangecore.

This lower cost can be attributed to these aspects:

• Caterpillar dealer exchange components

• Caterpillar Inc. remanufactured exchangecomponents

Overhaul RecommendationTo minimize downtime, Caterpillar Inc. recommendsa scheduled engine overhaul by your Caterpillardealer before the engine fails. This will provide youwith the best cost/value relationship.

Note: Overhaul programs vary according to theengine application and according to the dealer thatperforms the overhaul. Consult your Caterpillardealer for specific information about the availableoverhaul programs and about overhaul services forextending the engine life.

If an overhaul is performed without overhaul servicefrom your Caterpillar dealer, be aware of the followingmaintenance recommendations.

Rebuild or Exchange

These components should be inspected according tothe instructions that are found in various Caterpillarreusability publications. The Special Publication,SEBF8029 lists the reusability publications that areneeded for inspecting the engine parts.

If the parts comply with the established inspectionspecifications that are expressed in the reusableparts guideline, the parts should be reused.

Parts that are not within the established inspectionspecifications should be dealt with in one of thefollowing manners:

• Salvaging

• Repairing

• Replacing

Using out-of-spec parts can result in the followingproblems:

• Unscheduled downtime

• Costly repairs

• Damage to other engine parts

• Reduced engine efficiency

• Increased fuel consumption

Reduced engine efficiency and increased fuelconsumption translates into higher operating costs.Therefore, Caterpillar Inc. recommends repairingout-of-spec parts or replacing out-of-spec parts.

Inspection and/or Replacement

The following components may not last until thesecond overhaul.

• Piston rings

• Thrust bearings

• Main bearings

76 SEBU7605-04Maintenance SectionOverhaul Considerations

• Connecting rod bearings

• Crankshaft seals

• Engine mounts

• Hoses

Caterpillar Inc. recommends the installation of newparts at each overhaul period.

Inspect these parts while the engine is disassembledfor an overhaul.

Inspect the crankshaft for any of the followingconditions:

• Deflection

• Damage to the journals

• Bearing material that has seized to the journals

Check the journal taper and the profile of thecrankshaft journals. Check these components byinterpreting the wear patterns on the followingcomponents:

• Rod bearing

• Main bearings

Note: If the crankshaft is removed for any reason,use the magnetic particle inspection process to checkfor cracks in the crankshaft.

Inspect the camshaft for damage to the journals andto the lobes.

Note: If the camshaft is removed for any reason, usethe magnetic particle inspection process to check forcracks in the camshaft.

Inspect the following components for signs of wear orfor signs of scuffing:

• Camshaft bearings

• Valve lifters

Testing

Test the following components during the overhaul.

• Fuel injection nozzles

• Fuel injection pump

Testing the fuel system during the overhaul willensure that your engine operates at peak efficiency.Your Caterpillar dealer can provide these servicesand components in order to ensure that yourfuel system is operating within the appropriatespecifications.

Cleaning

Caterpillar Inc. recommends the use of HydrosolvLiquid Cleaners. Table 27 lists the Hydrosolv LiquidCleaners that are available from your Caterpillardealer.

Table 27

HydrosolvLiquid Cleaners

PartNumber Description Size

1U-8812 4 L (1 US gallon)

1U-5490 19 L (5 US gallon)

8T-7570

Hydrosolv4165

208 L (55 US gallon)

1U-8804 4 L (1 US gallon)

1U-5492 19 L (5 US gallon)

8T-5571

Hydrosolv100

208 L (55 US gallon)

Obtain Coolant Analysis

The concentration of supplemental coolant additive(SCA) should be checked regularly with test kitsor with S·O·S Coolant Analysis (Level I). Furthercoolant analysis is recommended when the engineis overhauled.

For example, considerable deposits are found in thewater jacket areas on the external cooling system, butthe concentrations of coolant additives were carefullymaintained. The coolant water probably containedminerals that were deposited on the engine over time.

A coolant analysis can be conducted in order to verifythe condition of the water that is being used in thecooling system. A full water analysis can be obtainedby consulting your local water utility company oran agricultural agent. Private laboratories are alsoavailable for water analysis.

Caterpillar Inc. recommends an S·O·S CoolantAnalysis (Level II).


Radiator - Clean

S·O·S Coolant Analysis (Level II)

An S·O·S Coolant Analysis (Level II) is acomprehensive coolant analysis which completelyanalyzes the coolant and the effects on the coolingsystem. An S·O·S Coolant Analysis (Level II) providesthe following information:

• Complete S·O·S Coolant Analysis (Level I)

• Visual inspection of properties

• Identification of metal corrosion

• Identification of contaminants

• Identification of built up impurities (corrosion andscale)

S·O·S Coolant Analysis (Level II) provides a report ofthe results of both the analysis and the maintenancerecommendations.

For more information about coolant analysis, seeyour Caterpillar dealer.

i02559063

Radiator - CleanSMCS Code: 1353-070

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

Inspect the radiator for these items: damaged fins,corrosion, dirt, grease, insects, leaves, oil, and otherdebris. Clean the radiator, if necessary.

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure.When using pressure air, wear a pro-tective face shield and protective clothing.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded.

Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the fan’s air flow. Hold the nozzle approximately6 mm (0.25 inch) away from the fins. Slowly move theair nozzle in a direction that is parallel with the tubes.This will remove debris that is between the tubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

Use a degreaser and steam for removal of oil andgrease. Clean both sides of the core. Wash the corewith detergent and hot water. Thoroughly rinse thecore with clean water.

After cleaning, start the engine and accelerate theengine to high idle rpm. This will help in the removalof debris and drying of the core. Stop the engine.Use a light bulb behind the core in order to inspectthe core for cleanliness. Repeat the cleaning, ifnecessary.

Inspect the fins for damage. Bent fins may be openedwith a “comb”. Inspect these items for good condition:welds, mounting brackets, air lines, connections,clamps, and seals. Make repairs, if necessary.

For more detailed information on cleaning andinspection, refer to Special Publication, SEBD0518,“Know Your Cooling System”.

i00151038

Severe Service Application -CheckSMCS Code: 1000-535

Severe service is an application of an engine thatexceeds current published standards for that engine.Caterpillar maintains standards for the followingengine parameters:

• Performance (power range, speed range, and fuelconsumption)

• Fuel quality

• Altitude range

• Maintenance intervals

• Oil selection and maintenance

• Coolant selection and maintenance

• Environmental qualities

• Installation

Refer to the standards for the engine or consult withyour Caterpillar dealer in order to determine if theengine is operating within the defined parameters.

78 SEBU7605-04Maintenance SectionStarting Motor - Inspect

Severe service operation can accelerate componentwear. Engines that operate under severe conditionsmay need more frequent maintenance intervals inorder to ensure maximum reliability and retention offull service life.

Due to individual applications, it is not possible toidentify all of the factors which can contribute tosevere service operation. Consult your Caterpillardealer for the unique maintenance that is necessaryfor the engine.

The operating environment, improper operatingprocedures and improper maintenance procedurescan be factors which contribute to severe serviceconditions.

Environmental FactorsAmbient temperatures – The engine may beexposed to extended operation in extremelycold environments or hot environments. Valvecomponents can be damaged by carbon buildup ifthe engine is frequently started and stopped in verycold temperatures. Extremely hot inlet air reducesengine performance.

Air Quality – The engine may be exposed toextended operation in an environment that is dirtyor dusty, unless the equipment is cleaned regularly.Mud, dirt and dust can encase components.Maintenance can be very difficult. The buildup cancontain corrosive chemicals.

Buildup – Compounds, elements, corrosivechemicals and salt can damage some components.

Altitude – Problems can arise when the engine isoperated at altitudes that are higher than the intendedsettings for that application. Necessary adjustmentsshould be made.

Improper Operating Procedures• Extended operation at low idle

• Frequent hot shutdowns

• Operating at excessive loads

• Operating at excessive speeds

• Operating outside the intended application

Improper Maintenance Procedures• Extending the maintenance intervals

• Failure to use recommended fuel, lubricants andcoolant/antifreeze

i00651416

Starting Motor - InspectSMCS Code: 1451-040; 1453-040

Caterpillar Inc. recommends a scheduled inspectionof the starting motor. If the starting motor fails, theengine may not start in an emergency situation.

Check the starting motor for proper operation. Checkthe electrical connections and clean the electricalconnections. Refer to the Service Manual for moreinformation on the checking procedure and forspecifications or consult your Caterpillar dealer forassistance.

i02226957

Turbocharger - Inspect(If Equipped)SMCS Code: 1052-040; 1052

A regular visual inspection of the turbocharger isrecommended. Any fumes from the crankcase arefiltered through the air inlet system. Therefore,by-products from oil and from combustion can collectin the turbocharger compressor housing. Over time,this buildup can contribute to loss of engine power,increased black smoke and overall loss of engineefficiency.

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage to theturbocharger compressor wheel can cause additionaldamage to the pistons, the valves, and the cylinderhead.

NOTICETurbocharger bearing failures can cause large quanti-ties of oil to enter the air intake and exhaust systems.Loss of engine lubricant can result in serious enginedamage.

Minor leakage of oil into a turbocharger under extend-ed low idle operation should not cause problems aslong as a turbocharger bearing failure has not oc-cured.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is renewed.

A visual inspection of the turbocharger can minimizeunscheduled downtime. A visual inspection of theturbocharger can also reduce the chance for potentialdamage to other engine parts.


Walk-Around Inspection

Removal and InstallationNote: The turbochargers that are supplied arenonserviceable.

For options regarding the removal, installation, repairand replacement, consult your Caterpillar dealer.Refer to the Service Manual for this engine for theprocedure and specifications.

Inspecting

NOTICEThe compressor housing for the turbocharger mustnot be removed from the turbocharger for cleaning.

The actuator linkage is connected to the compressorhousing. If the actuator linkage is moved or disturbedthe engine may not comply with emmissions legisla-tion.

1. Remove the pipe from the turbocharger exhaustoutlet and remove the air intake pipe to theturbocharger. Visually inspect the piping for thepresence of oil. Clean the interior of the pipesin order to prevent dirt from entering duringreassembly.

2. Check for the presence of oil. If oil is leaking fromthe back side of the compressor wheel, there is apossibility of a failed turbocharger oil seal.

The presence of oil may be the result of extendedengine operation at low idle. The presence of oilmay also be the result of a restriction of the linefor the intake air (clogged air filters), which causesthe turbocharger to slobber.

3. Inspect the bore of the housing of the turbineoutlet for corrosion.

4. Fasten the air intake pipe and the exhaust outletpipe to the turbocharger housing.

i00632301

Walk-Around InspectionSMCS Code: 1000-040

Inspect the Engine for Leaks andfor Loose ConnectionsA walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thoroughinspection of the engine compartment before startingthe engine. Look for items such as oil leaks or coolantleaks, loose bolts, worn belts, loose connections andtrash buildup. Make repairs, as needed:

• The guards must be in the proper place. Repairdamaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICEAccumulated grease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaningor high pressure water.

• Ensure that cooling lines are properly clamped andtight. Check for leaks. Check the condition of allpipes.

• Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by coolantin the cooling system. It is normal for a small amountof leakage to occur as the engine cools down andthe parts contract.

Excessive coolant leakage may indicate the needto replace the water pump seal. For the removal ofwater pump and the installation of water pump and/orseals, refer to the Service Manual for the engine orconsult your Caterpillar dealer.

• Inspect the lubrication system for leaks at the frontcrankshaft seal, the rear crankshaft seal, the oilpan, the oil filters and the valve cover.

• Inspect the fuel system for leaks. Look for loosefuel line clamps.

• Inspect the piping for the air inlet system and theelbows for cracks and for loose clamps.

• Inspect the alternator belt and the accessory drivebelts for cracks, breaks or other damage.

80 SEBU7605-04Maintenance SectionWater Pump - Inspect

Belts for multiple groove pulleys must be replaced asmatched sets. If only one belt is replaced, the belt willcarry more load than the belts that are not replaced.The older belts are stretched. The additional load onthe new belt could cause the belt to break.

• Drain the water and the sediment from fuel tankson a daily basis in order to ensure that only cleanfuel enters the fuel system.

• Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

• Inspect the ground strap for a good connection andfor good condition.

• Inspect the engine-to-frame ground strap for agood connection and for good condition.

• Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolyte levelof the batteries, unless the engine is equipped witha maintenance free battery.

• Check the condition of the gauges. Replace anygauges which are cracked or can not be calibrated.

i02226958

Water Pump - InspectSMCS Code: 1361-040; 1361

A failed water pump may cause severe engineoverheating problems that could result in the followingconditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

Note: The water pump seal is lubricated by thecoolant in the cooling system. It is normal for a smallamount of leakage to occur as the engine cools downand parts contract.

Visually inspect the water pump for leaks. Renewthe water pump seal or the water pump if thereis an excessive leakage of coolant. Refer to theDisassembly and Assembly Manual, “Water Pump- Remove and Install” for the disassembly andassembly procedure.

Documents

Owner's Manual – Cat Engine