3044c industrial engine-maintenance intervals

7/28/2019 3044C Industrial Engine-Maintenance Intervals

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SAFETY.CAT.COM

3044C

INDUSTRIAL ENGINESMaintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU7578-01-01)

2007 CaterpillarAll Rights Reserved


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44 SEBU7578-01Maintenance SectionMaintenance Interval Schedule

i02554724

Maintenance Interval Schedule

SMCS Code: 1000; 7500

When RequiredBattery - Replace .................................................. 46Battery or Battery Cable - Disconnect .................. 46Engine - Clean ...................................................... 55Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 55Engine Air Cleaner Element (Single Element) -

Inspect/Replace .................................................. 58Fuel System - Prime ............................................. 62

Daily

Cooling System Coolant Level - Check ................ 51Driven Equipment - Check .................................... 55Engine Air Cleaner Service Indicator - Inspect ..... 58Engine Oil Level - Check ...................................... 59Fuel System Primary Filter/Water Separator -

Drain ................................................................... 64Walk-Around Inspection ........................................ 69

Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 64

Every 250 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ................................................................. 52

Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 53

Radiator - Clean .................................................... 67

Every 250 Service Hours or 6 Months

Engine Oil Sample - Obtain .................................. 59


Water Pump - Inspect ........................................... 69

Every 500 Service Hours or 6 Months

Alternator and Fan Belts - Inspect/Adjust/Replace ............................................................... 45

Every 500 Service Hours or 1 Year

Engine Air Cleaner Element (Dual Element) -Clean/Replace .................................................... 55

Engine Oil and Filter - Change ............................. 60Fuel System Filter - Replace ................................ 63


Alternator - Inspect ............................................... 45Engine Valve Lash - Inspect/Adjust ...................... 62

Hoses and Clamps - Inspect/Replace .................. 65Starting Motor - Inspect ........................................ 68Turbocharger - Inspect .......................................... 68


Engine Mounts - Inspect ....................................... 59

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ................................................................. 53

Every 3 Years

Cooling System Water Temperature Regulator -Replace ............................................................... 54

Every 3000 Service Hours or 3 Years

Cooling System Coolant (DEAC) - Change .......... 46

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 50

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 48

Overhaul

Overhaul Considerations ...................................... 66


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SEBU7578-01 45Maintenance Section

Alternator - Inspect

i00072207

Alternator - Inspect

SMCS 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. Refer to the Service Manual.

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.

i02554823

Alternator and Fan Belts -Inspect/Adjust/Replace

SMCS Code: 1357-039

Inspection

To 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 check the belt tension, apply 45 N (10 lb ft) of forcemidway between the pulleys. A correctly adjustedbelt will deflect 10 mm (0.39 inch).

Adjustment

g01264847Illustration 19

Typical example

(1) Mounting bolts(2) Bracket(3) Belt(4) Alternator

1. Loosen mounting bolts (1).

2. Move the alternator (4) in order to increase ordecrease the belt tension. To check the belt

tension, apply 45 N (10 lb ft) of force midwaybetween the pulleys. A correctly adjusted belt willdeflect 10 mm (0.39 inch).

3. Tighten mounting bolts (1).

Replacement

Refer to Disassembly and Assembly, V-Belts -Remove and Install.

When new belts are installed, check the belt tensionagain after 20 hours of engine operation.


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46 SEBU7578-01Maintenance SectionBattery - Replace

i01878164

Battery - Replace

SMCS 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. Switch the engine to the OFF position. Removeall electrical loads.

2. Turn off any battery chargers. Disconnect anybattery chargers.

3. The NEGATIVE - cable connects the NEGATIVE- battery terminal to the NEGATIVE - terminalon the starter motor. Disconnect the cable fromthe NEGATIVE - battery terminal.

4. The POSITIVE + cable connects the POSITIVE+ battery terminal to the POSITIVE + terminalon the starting motor. Disconnect the cable fromthe 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 engine start switch is OFF.

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

8. Connect the cable from the NEGATIVE - terminalon the starter motor to the NEGATIVE - batteryterminal.

i01492654

Battery or Battery Cable -Disconnect

SMCS 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.

i01899892

Cooling System Coolant(DEAC) - Change

SMCS 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.


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Cooling System Coolant (DEAC) - Change

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 drain cock or remove the drain plug (1)on the engine. Open the drain cock or remove thedrain plug on the radiator.

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 Caterpillar Service TechnologyGroup:

Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush

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

2. Close the drain cock or install the drain plug in theengine. Close the drain cock or install the drainplug on the radiator. Refer to the SpecificationsManual, SENR3130, Torque Specifications formore information on the proper torques.

NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

3. Fill the cooling system with a mixture of 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 be

at 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 slowly inorder to relieve any pressure. Remove the coolingsystem filler cap. Open the drain cock or removethe drain plug on the engine. Open the drain cockor remove the drain plug on the radiator. Allowthe water to drain. Flush the cooling system withclean water.


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48 SEBU7578-01Maintenance SectionCooling System Coolant (ELC) - Change

Cooling Systems with HeavyDeposits or Plugging

Note: For the following procedure to be effective,there must be some active flow through the coolingsystem components.


2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theSpecifications Manual, SENR3130, TorqueSpecifications for more information on the propertorques.

NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

3. Fill the cooling system with a mixture of 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 system

can 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 slowly inorder to relieve any pressure. Remove the coolingsystem filler cap. Open the drain cock or removethe drain plug on the engine. Open the drain cock

or remove the drain plug on the radiator. Allowthe water to drain. Flush the cooling system withclean water.

Fill

1. Close the drain cock or install the drain plug onthe engine. Close the drain cock or install thedrain plug on the radiator.

2. Fill the cooling system with coolant/antifreeze.Refer to the Operation and MaintenanceManual, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

3. 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.

4. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level in theexpansion bottle (if equipped) at the proper level.

5. 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 cap

is 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.

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

i01897887

Cooling System Coolant (ELC)- Change

SMCS Code: 1350-070; 1395-044

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, CaterpillarTools and Shop Products Guide for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.


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Cooling System Coolant (ELC) - Change

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

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 the

coolant 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

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 drain cock or remove the drain plug (1)on the engine. Open the drain cock or remove thedrain plug on the radiator.

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 Caterpillar Service Technology

Group:

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

Flush


2. Close the drain cock or install the drain plug in theengine. Close the drain cock or install the drainplug on the radiator.

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

Cooling system air locks may result in engine damage.

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).


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50 SEBU7578-01Maintenance SectionCooling System Coolant Extender (ELC) - Add

5. 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. Open the drain cock or removethe drain plug on the engine. Open the drain cockor remove the drain plug on the radiator. Allow

the water to drain. Flush the cooling system withclean water.

Fill

1. Close the drain cock or install the drain plug onthe engine. Close the drain cock or install thedrain plug on the radiator.

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

Cooling system air locks may result in engine damage.

2. Fill the cooling system with Extended Life Coolant(ELC). Refer to the Operation and MaintenanceManual, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

3. 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.

4. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level in theexpansion bottle (if equipped) at the proper level.

5. 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 filler

cap. 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.

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

i02482066

Cooling System CoolantExtender (ELC) - Add

SMCS 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 lines

to 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.


9/28


Cooling 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.


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

system 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 engines cooling systemcapacity. Refer to the Operation and MaintenanceManual, Refill Capacities and Recommendationsarticle for more information.

4. Clean the cooling system filler cap. Inspect thegaskets on the cooling system filler cap. Replace

the cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

i02556136

Cooling System Coolant Level- Check

SMCS Code: 1395-082

Engines With a Coolant RecoveryTank

Check the coolant level when the engine is stoppedand cool.

1. Observe the coolant level in the coolant recoverytank. Maintain the coolant level to COLD FULLmark on the coolant recovery tank.


2. Loosen filler cap slowly in order to relieve anypressure. Remove the filler cap.

3. Pour the proper coolant mixture into the tank.Refer to the Special Publication, SEBU6251,Caterpillar Commercial Diesel Engines FluidsRecommendations for information on the correctmixture and type of coolant. Refer to the Operationand Maintenance Manual, Refill Capacitiesand Recommendations for the cooling system

capacity. Do not fill the coolant recovery tankabove COLD FULL mark.


4. Clean filler cap and the receptacle. Reinstall thefiller cap and inspect the cooling system for leaks.

Note: The coolant will expand as the coolant heatsup during normal engine operation. The additionalvolume will be forced into the coolant recovery tankduring engine operation. When the engine is stoppedand cool, the coolant will return to the engine.

Engines Without a CoolantRecovery Tank

Check the coolant level when the engine is stoppedand cool.


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52 SEBU7578-01Maintenance SectionCooling System Coolant Sample (Level 1) - Obtain


Cooling 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 coolant

level 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.

i02326688

Cooling System CoolantSample (Level 1) - Obtain

SMCS 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.

Table 12

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEACEvery 250

Hours(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.

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

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. This

contaminate 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.


11/28


Cooling System Coolant Sample (Level 2) - Obtain

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of SOS analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.

Supplies forcollecting 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 coolant

sample 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 Recommendationsor consult your Caterpillar dealer.

i01987714

Cooling System CoolantSample (Level 2) - Obtain

SMCS Code: 1350-008; 1395-008; 1395-554; 7542

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.

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

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.

i02556105

Cooling System SupplementalCoolant Additive (SCA) -Test/Add

SMCS 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 SOS 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.


12/28

54 SEBU7578-01Maintenance SectionCooling System Water Temperature Regulator - Replace

SOS Coolant Analysis

SOS coolant samples can be analyzed at yourCaterpillar dealer. SOS 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 SOS Coolant

Analysis.

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 engines 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 supplemental

coolant 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.


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.

i00912898

Cooling System WaterTemperature Regulator -Replace

SMCS 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.


13/28


Driven Equipment - Check

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 result

in 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 engine may 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 the Service Manual for the replacementprocedure of the water temperature regulator, orconsult your Caterpillar dealer.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling system to

a level that is below the water temperature regulatorhousing.

i00174798

Driven Equipment - Check

SMCS 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.

i01646701

Engine - Clean

SMCS Code: 1000-070

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

Moisture can create paths of electrical conductiv-ity.

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

NOTICE

Accumulated 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.

i02537200

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

SMCS 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.


14/28

56 SEBU7578-01Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

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

Servicing the Air Cleaner Elements

Note: The air filter system may not have beenprovided by Caterpillar. The procedure that followsis for a typical air filter system. Refer to the OEMinformation for the correct procedure.

If the air cleaner element becomes plugged, the aircan split the material of the air cleaner element.Unfiltered air will drastically accelerate internalengine wear. Refer to the OEM information for thecorrect air cleaner elements for your application.

Check the precleaner (if equipped) and the dustbowl daily for accumulation of dirt and debris.Remove any dirt and debris, as needed.

Operating in dirty conditions may require morefrequent service of the air cleaner element.

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 air cleaner elements with clean aircleaner elements. Before installation, the air cleanerelements should be thoroughly checked for tearsand/or holes in the filter material. Inspect the gasketor the seal of the air cleaner element for damage.Maintain a supply of suitable air cleaner elementsfor replacement purposes.

Dual Element Air Cleaners

The dual element air cleaner contains a primary aircleaner element and a secondary air cleaner element.

The primary air cleaner element can be used upto six times if the element is correctly cleaned andcorrectly inspected. The primary air cleaner elementshould be replaced at least one time per year. This

replacement should be performed regardless of thenumber of cleanings.

The secondary air cleaner element is not serviceable.Refer to the OEM information for instructions in orderto replace the secondary air cleaner element.

When the engine is operating in environments thatare dusty or dirty, air cleaner elements may requiremore frequent replacement.


(1) Cover(2) Primary air cleaner element(3) Secondary air cleaner element(4) 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 air inlet with tape in order to keep dirtout.

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

5. Remove the tapefrom the air inlet. Install thesecondary air cleaner element. Install a primaryair 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

Refer to the OEM information in order to determinethe number of times that the primary filter element canbe cleaned. 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.


15/28


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

NOTICEDo not tap or strike the air cleaner element.

Do not wash the primary air cleaner element.

Use low pressure (207 kPa; 30 psi maximum) pres-surised air or vacuum cleaning to clean the primaryair cleaner element.

Take extreme care in order to avoid damage to the aircleaner elements.

Do not use air cleaner elements that have damagedpleats, gaskets or seals.

Refer to the OEM information in order to determinethe number of times that the primary air cleanerelement can be cleaned. Do not clean the primary

air filter element more than three times. The primaryair cleaner element must be replaced at least onetime per year.

Cleaning the air filter element will not extend the lifeof the air filter element.

Visually inspect the primary air cleaner elementbefore cleaning. Inspect air cleaner elements fordamage to the pleats, the seals, the gaskets andthe outer cover. Discard any damaged air cleanerelement.

Two methods may be used in order to clean the

primary air cleaner element:

Pressurized air

Vacuum cleaning

Pressurized Air

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 lessthan 205 kPa (30 psi) for cleaning purposes.

Pressurized air can be used to clean primary aircleaner elements that have not been cleaned morethan three times. Use filtered, dry air with a maximumpressure of 207 kPa (30 psi). Pressurized air will notremove deposits of carbon and oil.


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 air hose so that air flows along the length ofthe filter. Follow the direction of the paper pleats inorder to prevent damage to the pleats. Do not aimthe air directly at the face of the paper pleats.

Note: Refer to Inspecting the Primary Air CleanerElements.

Vacuum Cleaning

Vacuum cleaning is a good method for removingaccumulated dirt from the dirty side (outside) of a

primary air cleaner element. Vacuum cleaning isespecially useful for cleaning primary air cleanerelements which require daily cleaning because of adry, dusty environment.

Cleaning from the clean side (inside) with pressurizedair is recommended prior to vacuum cleaning thedirty side (outside) of a primary air cleaner element.

Note: Refer to Inspecting the Primary Air CleanerElements.


16/28

58 SEBU7578-01Maintenance SectionEngine Air Cleaner Element (Single Element) - Inspect/Replace

Inspecting the Primary Air Cleaner

Elements


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 primary

air cleaner elements.

i01897734

Engine Air CleanerElement (Single Element) -Inspect/Replace

SMCS Code: 1054-040; 1054-510

Refer to Operation and Maintenance Manual, EngineAir Cleaner Service Indicator-Inspect.

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.

A wide variety of air cleaners may be installed for usewith this engine. Consult the OEM information for theproper procedure to replace the air cleaner.

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.


Typical 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.


17/28


Engine Mounts - Inspect

Test the Service Indicator

Service 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, if

necessary. 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 Nm (18 lb in).

i02537189

Engine Mounts - Inspect

SMCS Code: 1152-040

Note: The engine mounts may not have beensupplied by Caterpillar. Refer to the OEM informationfor further information on the engine mounts and thecorrect bolt torque.

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

Incorrect mounting of the engine

Deterioration of the engine mounts

Loose engine mounts

Any engine mount that shows deterioration shouldbe replaced. Refer to the OEM information for therecommended torques.

i01897042

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

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


(Y) minimum MIN mark. (X) maximum MAX mark.

NOTICEPerform this maintenance with the engine stopped.

1. Maintain the oil level between minimum MINmark (Y) and the maximum MAX mark (X) on oillevel gauge (1). Do not fill the crankcase aboveMAX mark (X).

NOTICE

Operating your engine when the oil level is above theFULL mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oils 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 - Obtain

SMCS Code: 1000-008; 1348-554-SM;7542-554-OC, SM

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


18/28

60 SEBU7578-01Maintenance SectionEngine 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 tocontact the skin.

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.

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.

NOTICEAlways use a designated pump for oil sampling, and

use a separate designated pump for coolant sampling.Using the same pump for both types of samples 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.

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 SOS program for yourengine.

i01900134

Engine Oil and Filter - Change

SMCS Code: 1318-510; 1348-044

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

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, CaterpillarTools and Shop Products Guide for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations and

mandates.

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 the

oil warm. This draining method allows the wasteparticles that are suspended in the oil to be drainedproperly.

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

Drain the Engine Oil

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


19/28


Engine Oil and Filter - Change

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 oilto drain.

After the oil has drained, the oil drain plugs shouldbe 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 of

the 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.

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.

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 order

to arrange for a further analysis if an excessiveamount of debris is found in the oil filter.


(1) Filter mounting base(2) Oil filter gasket

3. Clean the sealing surface of the filter mountingbase (1). Ensure that all of the old oil filter gasketis removed.

4. Apply clean engine oil to the new oil filter gasket(2).

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 toengine components.

5. Install the oil filter. Tighten the oil filter until theoil filter gasket contacts the base. Tighten the oilfilter by hand according to the instructions that areshown on the oil filter. Do not overtighten the oilfilter.

Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to the Operationand Maintenance Manual for more information onlubricant specifications. Fill the crankcase with theproper amount of oil. Refer to the Operation andMaintenance Manual for more information on refillcapacities.

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


20/28

62 SEBU7578-01Maintenance SectionEngine Valve Lash - Inspect/Adjust

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 MINand MAX marks on the oil level gauge.

i00869628

Engine Valve Lash -Inspect/Adjust

SMCS 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 the

valve 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 valve

adjustments 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.

i01905159

Fuel System - Prime

SMCS 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.

Use the following procedure in order to remove airfrom the fuel system:

1. Turn the key switch to the RUN position. Leavethe key switch in the RUN position for 1 minutes.

2. Turn the key switch to the OFF position.


21/28


Fuel System Filter - Replace


Note: Damage to the fuel injection pump, to thebattery, and to the starter motor can occur if thestarter motor is used excessively to purge the air

from the fuel system.

3. Loosen flare nuts (1) for the high pressure fuellines on all of the fuel injection nozzles.

NOTICEDo not crank the engine for more than 10 seconds.

Allow the starter motor to cool for 30 seconds beforecranking again.

Do not engage the starter when the flywheel is turning.

4. Observe the connection at the flare nut. Operate

the starting motor and crank the engine until thefuel is free of air.

5. Tighten flare nuts (1) to a torque of 26.5 Nm(19.5 lb ft) to 32.4 Nm (23.9 lb ft).

6. The engine is now ready to start. Operate theengine at low idle for a minimum of five minutesimmediately after air has been removed from thefuel system.

Note: Running the engine for this period of time willhelp ensure that the pump is completely free of air.

i01905248

Fuel System Filter - Replace

SMCS Code: 1261-510

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off 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.

Turn the fuel supply valve to the OFF position beforeperforming this maintenance. Place a tray under thefuel filter in order to catch any fuel that might spill.Clean up any spilled fuel immediately.


(1) Electric fuel priming pump(2) Fuel filter base(3) Quick release collar(4) Fuel filter(5) Sediment bowl(6) Drain valve for fuel filter

1. Close the fuel supply valve.

2. Clean the outside of the fuel filter assembly. Opendrain valve (6) and drain the fuel and water fromfuel filter (4) into a suitable container.

3. Remove sediment bowl (5).


22/28

64 SEBU7578-01Maintenance SectionFuel System Primary Filter/Water Separator - Drain

NOTICEDo not use a tool in order to remove the fuel filter.

Attempting to remove the fuel filter with a filter wrenchor a filter strap could damage the locking ring.

4. Hold fuel filter (4) and rotate quick release collar(3) counterclockwise. Remove quick release collar(3). The used element should be removed anddiscarded.

NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

5. Ensure that the fuel filter base is clean. Push anew fuel filter fully into the fuel filter base.

6. Hold the fuel filter in place. Fit locking ring (3) intoposition. Rotate the locking ring clockwise in orderto fasten the fuel filter to the fuel filter base.

7. Thoroughly clean sediment bowl (5). Inspect theO-ring seals. Install new O-ring seals, if necessary.Install the sediment bowl to the new element.Hand tighten the sediment bowl. Hand tighteningis the only method that should be used.

8. Prime the fuel system. Refer to Operation andMaintenance Manual, Fuel System - Prime.

i01905299

Fuel System PrimaryFilter/Water Separator - Drain

SMCS 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) Filter(2) Drain

1. Open drain (2). Catch the draining water in asuitable container. Dispose of the draining waterproperly.

2. Close drain (2).

NOTICEThe 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 fuelsystem.

i02436696

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S

NOTICE

Care 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.



23/28


Hoses and Clamps - Inspect/Replace

Fuel Tank

Fuel 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. The

condensation 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 Sediment

Fuel 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 tank

in 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 Tanks

Drain 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 2 micron filter for the breather vent on thefuel 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/Replace

SMCS 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.

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.


24/28

66 SEBU7578-01Maintenance SectionOverhaul Considerations

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

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 systempressure 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 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 caps 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.

i01878912

Overhaul Considerations

SMCS 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 SOS analysis

Oil Consumption as an OverhaulIndicator

Oil consumption, fuel consumption, and maintenanceinformation can be used to estimate the totaloperating cost for your Caterpillar engine. Oilconsumption can also be used to estimate the

required 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.

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 engines 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 Recommendation

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


25/28


Radiator - Clean

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.

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.

Obtain Coolant Analysis

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 SOS CoolantAnalysis (Level II).

SOS Coolant Analysis (Level II)

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

Complete SOS Coolant Analysis (Level I)

Visual inspection of properties

Identification of metal corrosion

Identification of contaminants

Identification of built up impurities (corrosion andscale)

SOS 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 - Clean

SMCS 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 fans 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 inspect

the 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.


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68 SEBU7578-01Maintenance SectionStarting Motor - Inspect

i00651416

Starting Motor - Inspect

SMCS 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.

i01895531

Turbocharger - Inspect(If Equipped)

SMCS Code: 1052-040

Periodic inspection and cleaning is recommendedfor the turbocharger compressor housing (inlet side).

Any fumes from the crankcase are filtered throughthe air inlet system. Therefore, by-products from oiland from combustion can collect in the turbochargercompressor housing. Over time, this buildup cancontribute to loss of engine power, increased blacksmoke and overall loss of engine efficiency.

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 quan-tities of oil to enter the air inlet and exhaust systems.Loss of engine lubricant can result in serious enginedamage.

Minor leakage of a turbocharger housing under ex-

tended low idle operation should not cause problemsas long as a turbocharger bearing failure has not oc-curred.

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 repaired orreplaced.

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

Note: Turbocharger components require precision

clearances. The turbocharger cartridge mustbe balanced due to high rpm. Severe Service

Applications can accelerate component wear.Severe Service Applications require more frequentinspections of the cartridge.

Removal and Installation

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

Cleaning and Inspecting1. Remove the exhaust outlet piping and remove

the air inlet piping from the turbocharger. Visuallyinspect the piping for the presence of oil. Cleanthe interior of the pipes in order to prevent dirtfrom entering during reassembly.

2. Turn the compressor wheel and the turbine wheelby hand. The assembly should turn freely. Inspectthe compressor wheel and the turbine wheel forcontact with the turbocharger housing. Thereshould not be any visible signs of contact betweenthe turbine wheel or compressor wheel and the

turbocharger housing. If there is any indication ofcontact between the rotating turbine wheel or thecompressor 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, dirtand/or moisture is passing through the air filteringsystem. If oil is found only on the back side of thewheel, there is a possibility of a failed turbochargeroil seal.

The presence of oil may be the result of extendedengine operation at low idle. The presence of oil

may also be the result of a restriction of the linefor the inlet air (plugged air filters), which causesthe turbocharger to slobber.

4. Inspect the bore of the turbine housing forcorrosion.

5. Clean the turbocharger housing with standardshop solvents and a soft bristle brush.

6. Fasten the air inlet piping and the exhaust outletpiping to the turbocharger housing.


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Walk-Around Inspection

i00632301

Walk-Around Inspection

SMCS Code: 1000-040

Inspect the Engine for Leaks andfor Loose Connections

A 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 clampedand tight. Check for leaks. Check the condition ofall pipes.

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.

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 for

loose 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.

i02537160

Water Pump - Inspect

SMCS 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.


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70 SEBU7578-01Maintenance SectionWater Pump - Inspect

Visually inspect the water pump for leaks. Renewthe water pump if there is an excessive leakage ofcoolant. Refer to the Disassembly and AssemblyManual, Water Pump - Remove and Install for theDisassembly and Assembly procedure.

3044c industrial engine-maintenance intervals

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