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C18 Industrial Engine - Maintenance Intervals - Safety

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1. Illustration 54 g00765094 Typical example Electronics grounding stud side view Inspect the OEM harness for good connections Inspect the condition of the OEM harness 92 Maintenance Section Hoses and Clamps Inspect Replace SEBU7899 05 The electronics grounding stud must have a wire ground to the battery Tighten the electronics grounding stud at every oil change Ground wires and straps should be combined at engine grounds All grounds should be tight and free of corrosion Clean the electronics grounding stud and the terminals for the electronics ground strap with a clean cloth If the connections are corroded clean the connections with a solution of baking soda and water Keep the electronics grounding stud and the strap clean and coated with MPGM grease or petroleum jelly 104301694 Clamps Inspect Replace SMCS Code 7554 040 7554 510 Hoses and clamps must be inspected periodically in order to ensure safe operation and continuous operation of the engine Take proper safety precautions before inspecting or replacing hoses and clamps Note Always use a board or cardboard when the engine components are checked for leaks Leaking fluid that is under pressure can cause serious injury or possible death Leaks that are the size of a pin hole are included Refer to Operation and Maintenance Manual General Hazard Inform
2. Illustration 46 g01414582 Typical installation of the oil level gauge 1 Oil filler cap 2 Oil level gauge a lt ADD FULL 5 g00110310 Illustration 47 Partial view of the oil level gauge Y ADD mark X FULL mark NOTICE Perform this maintenance with the engine stopped NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can cause the crankshaft to dip into the oil This will reduce the power that is devel oped and also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling oil blowing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber De posits in the combustion chamber lead to the following problems guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately 82 Maintenance Section Engine Oil Sample Obtain SEBU7899 05 1 Remove the oil filler cap and check the oil level Maintain the oil level between the ADD mark Y and the FULL mark X on the oil level gauge 1 Do
3. 82 Engine Oil and Filter Change 82 Fuel System Primary Filter Water Separator Element Replace 88 Fuel System Secondary Filter Replace 90 Grounding Stud Inspect Clean Tighten 91 Hoses and Clamps Inspect Replace 92 Radiator Clean 97 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Coolant Sample Level 2 Obtain 72 Every 500 Service Hours Belts Inspect Adjust Replace 67 Starting Motor Inspect 98 Turbocharger 98 Water Pump Inspect 100 Every 2000 Service Hours or 1 Year Alternator Inspect 65 Every Year Coolant Sample Level 2 Obtain 72 Every 3000 Service Hours or 3 Years Aftercooler Core Clean Test 65 Coolant Temperature Regulator Replace 72 Crankshaft Vibration Damper Inspect 74 Driven Equipment Check 75 Electronic Unit Injector Check Replace 75 Engine Clean u 76 Engine Moun
4. 94 Every 250 Service Hours Battery Electrolyte Level Check 66 Coolant Sample Level 1 Obtain 71 Cooling System Supplemental Coolant Additive SCA Test Add 73 Engine Crankcase Breather Clean 80 Fuel System Primary Filter Water Separator Element Replace 88 Fuel System Secondary Filter Replace 90 Grounding Stud Inspect Clean Tighten 91 Hoses and Clamps Inspect Replace 92 Radiator Clean 97 Initial 500 Service Hours or at first oil change Engine Valve Lash 85 Engine Valve Rotators Inspect 85 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Coolant Sample Level 2 Obtain 72 Every 500 Service Hours Belts Inspect Adjust Replace 67 Engine Oil Sample Obtain 82 Engine Oil and Filter Change 82 Starting Motor Inspect 98 Turbocharger 98 Water Pump Inspect 100 Every 2000 Service
5. Illustration 41 g00103777 Typical service indicator Observe the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur The yellow diaphragm enters the red zone e The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments Check for ease of resetting The service indicator should reset in less than three pushes Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 18 lb 80 Maintenance Section Engine Air Precleaner Check C
6. 5 Crank the engine for 30 seconds Use a suitable container to catch the fuel while you crank the engine Allow the starter motor to cool for 2 minutes Note You may use the fuel priming pump 1 IF EOUIPPED for the fuel filter instead of cranking the engine 6 Crank the engine for 30 seconds Allow the starter motor to cool for 2 minutes 88 Maintenance Section Fuel System Primary Filter Water Separator Drain SEBU7899 05 7 Repeat Step 6 until the engine starts and the engine runs Note Failure to tighten all fittings could result in serious fuel leaks 8 After the engine has operated smoothly for 30 seconds turn the priming valve 3 to the Open Run position Note Shortened injector life may occur if the priming valve 3 is left in the Closed Prime position 9 Clean any residual fuel from the engine components 102927285 Fuel System Primary Filter 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 when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any comp
7. Cooling System Supplemental Coolant Additive SCA Test Add A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system and reguire operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liguid gasket material on the gasket or cylinder head surface NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the flui
8. Every 28400 L 7500 US gal or 500 service hours or 1 yr Shallow sump Deep sump 1 Choose the interval that occurs first Drain the Engine Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine crankcase oil e If the engine is equipped with a drain valve turn the drain valve knob counterclockwise in order to drain the oil After the oil has drained turn the drain valve knob clockwise in order to close the drain valve If the engine is not equipped with a drain valve remove the oil drain plug in order to allow the oil to drain If the engine is equipped with a shallow sump remove the bottom oil drain plugs from both ends of the oil pan After the oil has drained the oil drain plugs should be cleaned and installed
9. Replace the Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 1 Remove the oil filter with a 1U 8760 Chain Wrench 2 Cut the oil filter open with a 175 7546 Oil Filter Cutter Gp Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element Ferrous metals may indicate wear on the steel and cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts brass parts or bronze parts of the engine Parts that may be affected include the following items main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter Consult your Cat dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter 84 Maintenance Section Engine Protective Devices Check SEBU7899 05 Illustration 48 g001037
10. The following components may not last until the second overhaul e Thrust bearings e Main bearings e Rod bearings e Valve rotators e Crankshaft seals Caterpillar Inc recommends the installation of new parts at each overhaul period Inspect these parts while the engine is disassembled for an overhaul Inspect the crankshaft for any of the following conditions e Deflection Damage to the journals Bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the following components e Rod bearing e Main bearings Note If the crankshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the crankshaft Inspect the camshaft for damage to the journals and to the lobes Note If the camshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the camshaft Inspect the following components for signs of wear or for signs of scuffing e Camshaft bearings e Camshaft followers Caterpillar Inc recommends replacing the crankshaft vibration damper Oil Cooler Core and Aftercooler Core During an overhaul the removal of the oil cooler core and the aftercooler core is recommended The oil cooler core and the aftercooler core should be cleaned and pressure tested NOTICE Do not use caustic cleaners to c
11. tension again after 30 minutes of engine operation at the rated rpm 68 Maintenance Section Coolant Change SEBU7899 05 104538352 Coolant Change SMCS Code 1350 044 1352 1395 044 1395 Refer to this Operation and Maintenance Manual Fluid Recommendations for the correct intervals for changing the coolant Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated Drain the Cooling System Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitabl
12. Hours or 1 Year Alternator Inspect 65 Every Year Coolant Sample Level 2 Obtain 72 Every 3000 Service Hours or 3 Years Aftercooler Core Clean Test 65 Coolant Temperature Regulator Replace 72 Crankshaft Vibration Damper Inspect 74 62 Maintenance Section Maintenance Interval Schedule SEBU7899 05 Driven Equipment Check 75 Electronic Unit Injector Check Replace 75 Engine Clean siroaa a a ATA 76 Engine Mounts Inspect 81 Engine Protective Devices Check 84 Engine Valve Lash Check 85 Engine Valve Rotators Inspect 85 Fan Drive Bearing Lubricate 86 Speed Sensor Clean Inspect 98 Every 760 000 L 200 770 US gal of Fuel Fan Drive Bearing Replace 86 Overhaul Considerations 94 SEBU7899 05 63 Maintenance Section Maintenance Interval Schedule 104760784 Maintenance Interval Schedule Engines Which Have Shallow Oil Pans SMCS Code 1000 4450 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or
13. Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with clean water Install the cooling system filler cap 4 Start and run the engine at low idle until the temperature reaches 49 to 66 C 120 to 150 F SEBU7899 05 69 Maintenance Section Coolant Change 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if eguipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques Systems Filled with Cat DEAC Conventional Coolant which does not Meet the Cat EC 1 Requirements or Supplemental Coolant Additive SCA and Water 3 Flush the cooling system with clean water in order to remove any debris 4 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques NOTICE Fill the cooling system n
14. Special Publication NENG2500 Cat Deal er Service Tool Catalog and to Special Publication GECJ0003 Cat Shop Supplies and Tools for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to applicable regula tions and mandates Note Caterpillar recommends that an S O S Coolant Analysis Level 1 be performed to check the concentration of SCA Maintain the Proper Concentration of SCA in the Coolant Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly 2 Test the concentration of the SCA with a 286 2578 Nitrite Test Strip or review the results of the S O S Coolant Analysis Level 1 3 If necessary drain some coolant in order to allow space for the addition of the SCA 4 Add the amount of SCA required to maintain a concentration of 3 percent to 6 percent SCA in the coolant 5 Clean the cooling system filler cap Install the cooling system filler cap For further information refer to Special Publication SEBU6251 Cat Commercial Diesel Engine Fluids Recommendations 102933380 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 Damage to the crankshaft vibration damper or failure o
15. analysis Note Level 1 results may indicate a need for Level 2 Analysis 104638756 Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 An S O S Coolant Analysis Level 2 is a comprehensive chemical evaluation of the coolant This analysis is also a check of the overall condition of the cooling system The S O S Coolant Analysis Level 2 has the following features Full coolant analysis Level 1 Identification of metal corrosion and contaminants Identification of buildup of the impurities that cause corrosion and scaling Determination of the possibility of electrolysis within the cooling system of the engine The results are reported and appropriate recommendations are made Obtaining the Sample Refer to Operation and Maintenance Manual Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For further information refer to this Operation and Maintenance Manual Fluid Recommendations 104240223 Coolant Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine SEBU7899 05 73 Maintenance Section
16. and installing the proper hose clamps 6 Carefully inspect the engine for any spilled fuel Make sure that no fuel remains on or close to the engine Note Fuel must be added to the fuel system ahead of the fuel filter 7 Refill the fuel system Refer to this Operation and Maintenance Manual Fuel System Prime for information about priming the engine with fuel 8 Start the engine Inspect the fuel system for leaks Lubrication System Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin 1 Drain the oil from the lubrication system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose with a new hose 5 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 6 Refill the lubrication system Refer to this Operation and Maintenance Manual Engine Oil Level Check in order to ensure that the lubrication system is filled with the proper amount of engine oil 7 Start the engine Inspect the lubrication system for leaks Air System 1 Remove the hose clamps 2 Disconnect the old hose 3 Replace the old hose with a new hose 4 Install hose clamps which have been inspected or install new
17. and check for leaks again Detecting leaks is difficult while the engine is running The primary filter water separator is under suction A leak will allow air to enter the fuel The air in the fuel can cause low power due to aeration of the fuel If air enters the fuel check the components for overtightening or undertightening 90 Maintenance Section Fuel System Secondary Filter Replace SEBU7899 05 103478081 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJ0003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable
18. any maintenance procedures are performed The user is responsible for the performance of all maintenance including the following procedures all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Refer to this Operation and Maintenance Manual Refill Capacities in order to determine the type of oil pan with which your Cat C18 Industrial Engine is eguipped Products that operate in severe operating conditions may reguire more freguent maintenance Refer to this Operation and Maintenance Manual Severe Service Application to determine if the engine is operating in a severe service application When Required Battery Replace 65 Battery or Battery Cable Disconnect 66 Coolant Change 68 Coolant Extender ELC Add 7
19. cooling system S O S coolant analysis is a program that is based on periodic samples Note Obtaining a Coolant Sample Level 1 is optional if the cooling system is filled with one of the following coolants Cat ELC Extended Life Coolant Cat ELI Extended Life Inhibitor and Conventional Heavy Duty Coolant Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any of the following coolants Cat DEAC Cat SCA and Conventional Heavy Duty Coolants For additional information about coolant analysis and about other coolants see this Operation and Maintenance Manual Fluid Recommendations or consult your Cat dealer Sampling Conditions If the engine is equipped with a sampling port the engine should be running at operating temperature when the sample is obtained If the engine is not equipped with a sampling port the coolant should be warm Use the following guidelines for proper sampling of the coolant Complete the information on the label for the sampling bottle before you begin to take the samples Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample 72 Maintenance Section Coolant Sample Level 2 Obtain SEBU7899 05 e Place the sample in the mailing tube immediatel
20. engine to cool Before servicing a coolant hose slowly loosen the filler cap for the cooling system in order to relieve any pressure Remove the filler cap for the cooling system a Drain the coolant from the cooling system to a level that is below the hose that is being replaced Drain the coolant into a suitable clean container The coolant can be reused Remove the hose clamps N Disconnect the old hose Replace the old hose with a new hose Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 10 Refill the cooling system 11 Clean the filler cap for the cooling system Inspect the gaskets on the filler cap Replace the filler cap if the gaskets are damaged Install the filler cap 12 Start the engine Inspect the cooling system for leaks Fuel System Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structi
21. not fill the crankcase above FULL mark X 2 In order to choose the correct type of oil for this engine refer to this Operation and Maintenance Manual Fluid Recommendations 3 Clean the oil filler cap Install the oil filler cap 4 Record the amount of oil that is added For the next oil sample and analysis include the total amount of oil that has been added since the previous sample in order to provide the most accurate oil analysis 104237495 Engine Oil Sample Obtain SMCS Code 1348 554 SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm mixed oil sample To avoid contamination of the oil samples the
22. operating environment Inspect the radiator for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the radiator if necessary Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the air nozzle is deadheaded Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This movement will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both sides of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water 98 Maintenance Section Speed Sensor Clean Inspect SEBU7899 05 After cleaning start the engine and accelerate the engine to high idle rpm This procedure will help in the removal of debris and drying of the core Stop the engine Use a li
23. or Battery Cable Disconnect SMCS Code 1401 1402 029 The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury SEBU7899 05 67 Maintenance Section Belts Inspect Adjust Replace 1 Turn the start switch to the OFF position Turn the ignition switch if eguipped to the OFF position and remove the key and all electrical loads 2 Disconnect the negative battery terminal at the battery that goes to the start switch Ensure that the cable cannot contact the terminal When four 12 volt batteries are involved the negative side of two batteries must be disconnected 3 Tapethe leads in order to help prevent accidental starting 4 Proceed with necessary system repairs Reverse the steps in order to reconnect all of the cables 102042962 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspection Inspect the alternator belt and the fan drive belts for wear and for cracking Replace the belts if the belts are not in good condition Check the belt tension according to the information in the Service Manual Specifications Slippage of loose belts can reduce the efficiency of the driven components Vibration of loose belts can cause unnecessary wear on
24. smoke when batteries are serviced 66 Maintenance Section Battery Electrolyte Level Check SEBU7899 05 The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Switch the engine to the OFF position Remove all electrical loads 2 Turn off any battery chargers Disconnect any battery chargers 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the NEGATIVE terminal on the starter motor Disconnect the cable from the NEGATIVE battery terminal 4 The POSITIVE cable connects the POSITIVE battery terminal to the POSITIVE terminal on the starting motor Disconnect the cable from the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Return used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before the cables are connected ensure that the engine start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Connect the cable from the NEGATIVE terminal on the starter motor to the NEGATIVE battery terminal 102601752 Battery Electrolyte Le
25. the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques Fill the Cooling System NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system Refer to this Operation and Maintenance Manual Fluid Recommendations for more information on cooling system specifications Refer to this Operation and Maintenance Manual Refill Capacities for information about the capacity of the cooling system Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for 1 minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass if equipped 70 Maintenance Section Coolant Extender ELC Add SEBU7899 05 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap Only install the used filler cap if the gasket is not damaged Use a 95 8140 Pressurizing Pump to pressure test a reinstalled cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the c
26. the following components Belts e Pulleys Bearings If the belts are too tight unnecessary stress is placed on the components This reduces the service life of the components Replacement For applications that require multiple drive belts replace the drive belts in matched sets Replacing one drive belt of a matched set will cause the new drive belt to carry more load because the older drive belts are stretched The additional load on the new drive belt could cause the new drive belt to fail Alternator Belt Adjustment O 2 1 lt ji oH o g00788814 Illustration 34 1 Remove the belt guard 2 Loosen mounting bolts 1 and adjusting bolt 2 3 Move the assembly in order to increase or decrease the belt tension Tighten adjusting bolt 2 Tighten mounting bolts 1 5 Reinstall the belt guard If new drive belts are installed check the drive belt tension again after 30 minutes of engine operation at the rated rom Adjustment of the Fan Drive Belt 1 Remove the belt guard 2 Loosen the mounting bolt for the pulley 3 Loosen the adjusting nut for the pulley 4 Move the pulley in order to adjust the belt tension 5 Tighten the adjusting nut 6 Tighten the mounting bolt 7 Reinstall the belt guard If new drive belts are installed check the drive belt
27. to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Stop the engine Turn the ignition switch to the OFF position or disconnect the battery Refer to the Operation and Maintenance Manual Battery or Battery Cable Disconnect topic Maintenance Section for more information Shut off the fuel supply valve if equipped 2 It may be necessary to relieve residual fuel pressure from the fuel system before the fuel filter is removed Wait for one to five minutes until the fuel pressure has lowered Use a suitable container in order to catch any fuel that may spill 3 Remove the used fuel filter and discard the used fuel filter 4 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 5 Apply clean diesel fuel to the new fuel filter gasket NOTICE Do not fill the secondary fuel filter with fuel before in stalling The fuel would not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts NOTICE In order to meet expected fuel system component life 4 micron c absolute or less secondary fuel fil tration is required for all Caterpillar Diesel Engines that are equipped with unit injected fuel systems Note that all current Caterpillar Diesel Engines are factory equipped with Caterpillar Advanced Efficiency 4 mi cron c absolute fuel filter
28. tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The fluid sampling bottle includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEGJ0047 How To Take A Good S O S Oil Sample Consult your Cat dealer for complete information and assistance in establishing an S O S program for your engine 104268709 Engine Oil and Filter Change SMCS Code 1318 510 Hot oil and hot components can cause per
29. 0 Engine Air Cleaner Element Dual Element Inspect Clean Replace 76 Engine Oil and Filter Change 82 Engine Storage Procedure Check 85 Fuel System Prime u 86 Daily Coolant Level Check 70 Engine Air Cleaner Service Indicator Inspect 79 Engine Air Precleaner Check Clean 80 Engine Oil Level Check 81 Fuel System Primary Filter Water Separator 88 Fuel Tank Water and Sediment Drain 90 Power Take Off Clutch Check 97 Walk Around Inspection 99 Every Week Jacket Water Heater Check 94 Initial 250 Service Hours or at first oil change Engine Valve Lash Check 85 Engine Valve Rotators Inspect 85 Every 250 Service Hours Battery Electrolyte Level Check 66 Coolant Sample Level 1 Obtain 71 Cooling System Supplemental Coolant Additive SCA Test Add 73 Engine Crankcase Breather Clean 80 Engine Oil Sample Obtain
30. 103901481 Power Take Off Clutch Check SMCS Code 3055 535 NOTICE New power take offs should have the clutch adjust ment checked before being placed into service The clutch adjustment should be checked again after the first ten hours of operation New clutch plates have a wear in period and the clutch may reguire several adjustments until the new plates are worn in Illustration 55 g00781502 1 Instruction plate 2 Serial number plate Check the clutch adjustment regularly after wear in Heavy duty applications which have engagements that are frequent and relatively long periods of clutch slippage require more frequent adjustment than light duty applications The operating torque should be measured in order to determine if a clutch adjustment is required Refer to the OEM information and instruction plate 1 for instructions on lubrication adjustment and other recommendations for service Perform the maintenance that is specified on the instruction plate Do not operate the engine with the Instruction Plate cover removed from the clutch Personal injury may result If the clutch is damaged to the point of burst fail ure expelled pieces can cause personal injury to anyone in the immediate area Proper safeguards must be followed to help prevent accidents 104020194 Radiator Clean SMCS Code 1353 070 Note Adjust the frequency of cleaning according to the effects of the
31. 13 Typical filter mounting base and filter gasket 3 Clean the sealing surface of the filter mounting base Ensure that all of the old oil filter gasket is removed 4 Apply clean engine oil to the new oil filter gasket NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 5 Install the oil filter Tighten the oil filter until the oil filter gasket contacts the base Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Fill the Engine Crankcase 1 Remove the oil filler cap 2 Refer to the Operation and Maintenance Manual Refill Capacities for the amount of oil required to fill the crankcase Fill the crankcase and replace the oil filler cap NOTICE If 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 overfilling the crankcase with oil can cause engine damage NOTICE To prevent crankshaft bearing damage crank the en gine with the fuel OFF This will fill the oil filters before starting the engine Do not crank the engine for more than 30 seconds 3 Start the engine and run the engine at LOW IDLE for 2 minutes Perform this procedure in order to ensure that the lubrication syst
32. 35 1290 510 1290 535 Be sure the engine cannot be started while this maintenance is being performed To prevent pos sible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting the unit injectors The electronic unit injectors use high voltage Dis connect the unit injector enable circuit connector in order to prevent personal injury Do not come in contact with the injector terminals while the en gine is running The operation of a Cat Engine with an electronic unit injector which is improperly adjusted may reduce engine efficiency This reduced efficiency may result in excessive fuel usage and or shortened engine component life Note Only gualified service personnel should perform this maintenance Refer to the Systems Operation Testing and Adjusting Electronic Unit Injector Test for the test procedure Refer to Systems Operation Testing and Adjusting Electronic Unit Injector Adjust for the adjustment procedure Refer to the Disassembly and Assembly Manual for the procedure for the removal and replacement of the injector NOTICE The camshafts must be correctly timed with the crank shaft before an adjustment of the lash for the fuel in jector is made The timing pins must be removed from the camshafts before the crankshaft is turned or dam age to the cylinder block will be the r
33. Caterpillar dealer for information about damper replacement 100934883 Driven Eguipment Check SMCS Code 3279 535 Check the Alignment To minimize bearing problems and vibration of the engine crankshaft and the driven eguipment the alignment between the engine and driven eguipment must be properly maintained Check the alignment according to the instructions that are provided by the following manufacturers e Caterpillar e OEM of the drive coupling e OEM of the driven equipment Torque all of the fasteners to the proper specifications Inspect the Drive Coupling Inspect the drive coupling according to the instructions that are provided by the OEM of the coupling For the following service information see the literature that is provided by the OEM of the coupling e Lubrication requirements e Specifications for the end play e Reusability Guidelines e Replacement instructions Inspect the Rear Gear Train Inspect the crankshaft gear If excessive wear is found replace the crankshaft gear and the large cluster idler If any gear causes damage to other gears through failure replace the entire rear gear train For the correct parts see the Parts Manual for the engine For removal and replacement instructions see the Service Manual Disassembly and Assembly module Consult your Caterpillar dealer for assistance 104230004 Electronic Unit Injector Check Replace SMCS Code 1251 510 1251 5
34. Code 1359 086 BD Some ofthe fan drives have grease fittings and some of the fan drives do not have grease fittings If there is no grease fitting periodic lubrication is not required The fan drive requires grease only if the fan drive is equipped with a zerk Illustration 49 g00746166 Typical location of the grease fitting if equipped that is for the fan drive bearing The pulley is shown with the belt guards that have been removed Lubricate the grease fitting that is on the fan drive bearing with High Speed Ball Bearing Grease or the equivalent Inspect the fan drive pulley assembly for wear or for damage If the shaft is loose an inspection of the internal components should be performed Refer to the Systems Operation Testing and Adjusting Manual for additional information 102053753 Fan Drive Bearing Replace SMCS Code 1359 510 BD 1 Remove Bearings Refer to Disassembly and Assembly Bearing Removal 2 Measure the bearing housings for roundness and for proper size 3 Replace the bearings 102075183 Fuel System Prime SMCS Code 1250 548 1258 548 The Secondary Fuel Filter Has Been Replaced Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Use a suitable contai
35. E Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 If necessary drain enough coolant from the cooling system in order to add the Cat ELC Extender 3 Add Cat ELC Extender according to the requirements for the cooling system capacity Refer to this Operation and Maintenance Manual Refill Capacities for the coolant capacity 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap For further information refer to this Operation and Maintenance Interval Fluid Recommendations 104156593 Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and cool SEBU7899 05 71
36. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A E SEBU7899 05 CATERPILLAR Satay Operation and Maintenance Manual C18 Industrial Engine SEBU7899 05 61 Maintenance Section Maintenance Interval Schedule 104760787 Maintenance Interval Schedule Engines Which Have Deep Oil Pans SMCS Code 1000 4450 7500 S N GJE1 Up S N EJG1 Up S N WJH1 Up S N WRH1 Up Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of all maintenance including the following procedures all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Refer to this Operation and Maintenance Manual Refill Capacities in order to determine the type of oil pan wi
37. Maintenance Section Coolant Sample Level 1 Obtain Illustration 35 g00285520 Cooling system filler cap Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly in order to relieve pressure 2 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe If the engine is equipped with a sight glass maintain the coolant level to the proper level in the sight glass Illustration 36 g00103639 Typical filler cap gaskets 3 Clean the cooling system filler cap and check the condition of the filler cap gaskets Replace the cooling system filler cap if the filler cap gaskets are damaged Reinstall the cooling system filler cap 4 Inspect the cooling system for leaks 104333559 Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and corrosion The analysis also tests the ability of the coolant to protect the engine from boiling and freezing S 0 S Systems Coolant Analysis can be done at your Cat dealer Cat S O S coolant analysis is the best way to monitor the condition of your coolant and your
38. artment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose ofall fluids according to local regulations and mandates NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component OO Illustration 52 g01453091 1 Element 2 Bowl 3 Drain Bowl 2 should be monitored daily for signs of water If water is present drain the water from the bowl 1 Open drain 3 The drain is a self ventilated drain Catch the draining water in a suitable container Dispose of the water properly 2 Close drain 3 NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system 102927282 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ Water in the fuel can cause the engine to run rough Water in the fuel may cause an electronic unit injector to fail If the fuel has been contaminated with water the element should be changed before the regularly scheduled interval The primary filter water separator also provides fi
39. ation for more information Inspect the Hoses and the Clamps Inspect all hoses for leaks that are caused by the following conditions Replace any hose which exhibits any of the following conditions Failure to replace a hose which exhibits any of the following conditions may result in a hazardous situation e Hoses which are cracked e Hoses which are soft e Outer covering that is chafed or cut Exposed wire that is used for reinforcement e Outer covering that is ballooning locally Flexible part of the hose that is kinked or crushed Armoring that is embedded in the outer covering e Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps Inspect all clamps for the following conditions Replace any clamp which exhibits signs of any of the following conditions e Cracking e Looseness Damage Inspect all couplings for leaks Replace any coupling which exhibits signs of leaks Each installation application can be different The differences depend on the following factors e Type of hose Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen which can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Replace hoses that are cracked or soft Replace hoses t
40. condensing process offers full protection to surfaces that cannot be reached with preservatives 0 9 L 1 0 qt of 4C 6792 VCI oil will treat 28 4 L 30 0 qt of engine oil This will give a 3 percent concentration of VCI oil The engine must be completely sealed when the engine is stored in order for the VCI oil to function properly The VCI oil is easily cleaned from the engine when you remove the engine from storage The volatile vapors are removed by simply running the engine to operating temperature A mineral oil base is left behind after the volatile vapors are removed 104242309 Engine Valve Lash Check SMCS Code 1105 535 The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components The maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule to help provide maximum engine life Note Only gualified service personnel should perform this maintenance For procedures on adjusting the valve lash and adjusting the valve bridge see System Systems Operation Testing and Adjusting Engine Valve Lash Inspect Adjust Consult your Cat dealer for assistance Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible in
41. cost value relationship per hour of extended life can be attained After Failure Overhaul If a major engine failure occurs and the engine must be removed many options are available An overhaul should be performed if the engine block or the crankshaft needs to be repaired If the engine block is repairable and or the crankshaft is repairable the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core This lower cost can be attributed to three aspects e Specially designed Caterpillar engine features e Caterpillar dealer exchange components e Caterpillar Inc remanufactured exchange components Overhaul Recommendation To minimize downtime a scheduled engine overhaul by your Caterpillar dealer is recommended This will provide you with the best cost value relationship Note Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life If an overhaul is performed without overhaul service from your Caterpillar dealer be aware of the following maintenance recommendations Unit Fuel Injector Clean the fuel injector body and replace the O rings Replace the O rings and the gasket on the injector sleeve Clean the area around the injector seating in the injecto
42. cover 7 Reset the air cleaner service indicator Cleaning the Primary Air Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Cat dealers The Cat clean ing process uses proven procedures to assure consis tent quality and sufficient filter life Observe the following guidelines if you attempt to clean 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 remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected When the primary air cleaner element is cleaned check for rips or tears in the filter material The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean primary air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals D
43. d the primary air cleaner element can be stored for future use Illustration 40 g00281694 SEBU7899 05 79 Maintenance Section Engine Air Cleaner Service Indicator Inspect Do notuse paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air cleaner elements in Volatile Corrosion Inhibited VCI paper Place the primary air cleaner element into a box for storage For identification mark the outside of the box and mark the primary air cleaner element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location 101900118 Engine Air Cleaner Service Indicator Inspect If Eguipped SMCS Code 7452 040 Some engines may be eguipped with a different service indicator Some engines are eguipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is eguipped with a different type of service indicator follow the OEM recommendations in order to service the air cleaner service indicator The service indicator may be mounted on the air cleaner housing or in a remote location
44. d with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Note If replacing only the water temperature regulator only drain the coolant to a level that is below the water temperature regulator housing Refer to two articles in the Disassembly and Assembly Manual Water Temperature Regulator Remove and Water Temperature Regulator Install for the replacement procedure or consult your Cat dealer 104269112 Cooling System Supplemental Coolant Additive SCA Test Add Systems Which are Filled with Conventional Coolant SMCS Code 1352 045 1395 081 This maintenance procedure is reguired for conventional coolants such as DEAC Do not perform this maintenance for cooling systems that are filled with Cat Extended Life Coolant Cat ELC or Cat Extended Life Inhibitor Cat ELI Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and eyes Do not drink cooling system coolant additive NOTICE Excessive supplemental coolant additive concentra tion can form deposits on the higher temperature sur face
45. e Special Publication SEBD0518 Know Your Cooling System 102676048 Alternator Inspect SMCS Code 1405 040 Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the ammeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs as required Check the alternator and the battery charger for proper operation If the batteries are properly charged the ammeter reading should be very near zero All batteries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine The battery will not crank the engine even if the engine is warm When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge 101878164 Battery Replace SMCS Code 1401 510 Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite This can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not
46. e free battery e Check the condition of the gauges Replace any gauges that are cracked Replace any gauge that can not be calibrated 103543200 Water Pump Inspect SMCS Code 1361 040 A failed water pump might cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure e Other potential damage to the engine A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head a piston seizure or other potential damage to the engine Visually inspect the water pump for leaks If leaking of the water pump seals is observed replace all of the water pump seals Refer to two articles in the Disassembly and Assembly Manual Water Pump Disassemble and Water Pump Assemble for the disassembly and assembly procedure If it is necessary to remove the water pump refer to two articles in the Disassembly and Assembly Manual Water Pump Remove and Water Pump Install Inspect the water pump for wear cracks pin holes and proper operation Refer to the Parts Manual for the correct part numbers for your engine or consult your Caterpillar dealer if repair is needed or replacement is needed
47. e tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank during the following conditions e Weekly e Oil change e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank A four micron c absolute filter for the breather vent on the fuel tank is also recommended If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used 104176149 Grounding Stud Inspect Clean Tighten SMCS Code 7423 040 7423 070 7423 079 The connection of battery cables to a battery and the disconnection of battery cables from a battery may cause an explosion which may result in injury or death The connection and the disconnection of other electrical eguipment may also cause an explosion which may result in injury or death The procedures for the connection and the disconnec tion of battery cables and other electrical eguip ment should only be performed in a nonexplosive atmosphere
48. e to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Stop the engine and allow the engine to cool Ensure that the engine will not start when the cooling system is drained 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 3 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove one of the drain plugs Note If equipped be sure to drain the heater and any related supply and return lines Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Cat dealer or consult Cat Dealer Service Tool Group Inside USA 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL International 1 309 578 7372 Flush Systems Filled with Cat ELC Cat ELI ora Conventional Coolant that Meets the Cat EC 1 Requirements and the Standards of ASTM D6210 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs
49. em has oil and that the oil filters are filled Inspect the oil filter for oil leaks 4 Stop the engine and allow the oil to drain back to the sump for a minimum of 10 minutes 5 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL marks on the oil level gauge 102861779 Engine Protective Devices Check SMCS Code 7400 535 Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately Calibration Check NOTICE During testing abnormal operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine Alarms and shutoffs must function properly Alarms provide timely warning to the operator Shutoffs help to prevent damage to the engine It is impossible to determine if the engine protective devices are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests Consult your Caterpillar dealer or refer to the Service Manual for more information SEBU7899 05 85 Maintenance Section Engine Storage Procedure Check 101458399 Engine S
50. enance Section Overhaul Considerations Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the reguired capacity of a makeup oil tank that is suitable for the maintenance intervals Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases The oil consumption rate brake specific oil consumption is measured in grams per kW h lb per bhp The brake specific oil consumption BSOC depends on the engine load Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine When an engine s oil consumption has risen to three times the original oil consumption rate due to normal wear an engine overhaul should be scheduled There may be a corresponding increase in blowby and a slight increase in fuel consumption Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons e Costly unplanned downtime can be avoided Many original parts can be reused according to the standards for reusable parts The engine service life can be extended without the risk of a major catastrophe due to engine failure e The best
51. ent 2 Bowl 3 Drain 2 Remove element 1 from the element mounting base while bowl 2 is attached 3 Dispose of the contents of the filter Remove bowl 2 from element 1 The bowl is reusable Do not discard the bowl Dispose of the used element 4 Remove the O ring from the gland of the bowl Clean the following components Bowl e O ring e Mounting base Inspect the O ring for damage and for deterioration Replace the O ring if necessary 5 Lubricate the O ring with clean diesel fuel 6 Install bowl 2 on a new element Tighten the bowl by hand Do not use tools in order to tighten the bowl NOTICE The primary filter water separator may be prefilled with fuel to avoid rough running stalling of the engine due to air Do not fill the secondary filter with fuel before installation The fuel would not be filtered and could be contaminated Contaminated fuel will cause accel erated wear to fuel system parts 7 Lubricate the top seal of element 1 with clean diesel fuel The element may be filled with fuel at this time Install the new element on the mounting base Tighten the element by hand NOTICE The water separator is under suction during normal engine operation Ensure that the vent plug is tight ened securely to help prevent air from entering the fu el system 8 Open the main fuel supply valve 9 Start the engine and check for leaks Run the engine for one minute Stop the engine
52. esult 76 Maintenance Section Engine Clean SEBU7899 05 101646701 Engine Clean SMCS Code 1000 070 Personal injury or death can result from high volt age Moisture can create paths of electrical conductiv ity Make sure that the electrical system is OFF Lock out the starting controls and tag the controls DO NOT OPERATE NOTICE Accumulated grease and oil on an engine is a fire haz ard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumulates on the engine Periodic cleaning of the engine is recommended Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits e Easy detection of fluid leaks e Maximum heat transfer characteristics e Ease of maintenance Note Caution must be used in order to prevent electrical components from being damaged by excessive water when you clean the engine Avoid electrical components such as the alternator the starter and the ECM 104322011 Engine Air Cleaner Element Dual Element Inspect Clean Replace SMCS Code 1051 1054 040 1054 070 1054 510 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do notuse air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to
53. f the crankshaft vibration damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A damper that is damaged can cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine Visconic Damper The visconic damper has a weight that is located inside a fluid filled case The weight moves in the case in order to limit torsional vibration Inspect the damper for evidence of fluid leaks If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous smooth and adhering If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace the crankshaft seals Inspect the damper and repair or replace the damper for any of the following reasons The damper is dented cracked or leaking The paint on the damper is discolored from heat The engine has had a failure because of a broken crankshaft Analysis of the oil has revealed that the front main bearing is badly worn There is a large amount of gear train wear that is not caused by a lack of oil SEBU7899 05 75 Maintenance Section Driven Eguipment Check Refer to the Disassembly and Assembly Manual Vibration Damper and Pulley Remove and Install or consult your
54. for specifications or consult your Caterpillar dealer for assistance 101539769 Turbocharger Inspect SMCS Code 1052 040 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Any fumes from the crankcase are filtered through the air inlet system Therefore by products from oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can a
55. ght bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary 103397657 Speed Sensor Clean Inspect SMCS Code 1907 040 1907 070 2 Illustration 56 g01453018 Left side view 1 Secondary speed timing sensor 2 Primary speed timing sensor 1 Remove the speed timing sensors Refer to Disassembly and Assembly Speed Timing Sensor Remove and Install for the removal procedure Check the condition of the plastic end of the speed timing sensors for wear and or contaminants 2 Clean the metal shavings and other debris from the face of the speed timing sensors 3 Install the speed timing sensors Refer to Disassembly and Assembly Speed Timing Sensor Remove and Install for the installation procedure 100651416 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar Inc recommends a scheduled inspection of the starting motor If the starting motor fails the engine may not start in an emergency situation Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and
56. hat show signs of leakage Replace hoses that show signs of damage Replace hose clamps that are cracked or damaged Tighten or replace hose clamps which are loose Replace the Hoses and the Clamps NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates SEBU7899 05 93 Maintenance Section Hoses and Clamps Inspect Replace Cooling System Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved Stop the engine N Allow the
57. hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps Note The bellows and the V clamps that are used on the bellows should never be reused 5 Start the engine Inspect the air lines for leaks 103230758 Jacket Water Heater Check SMCS Code 1383 535 Jacket water heaters help to improve startability in ambient temperatures that are below 21 C 70 F All installations that require automatic starting should have jacket water heaters Check the operation of the jacket water heater Check the operation of the circulation pump if equipped For an ambient temperature of 0 C 32 F the heater should maintain the jacket water coolant temperature at approximately 32 C 90 F 101848653 Overhaul Considerations SMCS Code 7595 043 Reduced hours of operation at full load will result in a lower average power demand A decreased average power demand should increase both the engine service life and the overhaul interval The need for an overhaul is generally indicated by increased fuel consumption and by reduced power The following factors are important when a decision is being made on the proper time for an engine overhaul The need for preventive maintenance The quality of the fuel that is being used e The operating conditions e The results of the S O S analysis SEBU7899 05 95 Maint
58. jury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance 101597115 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to help prevent being burned by hot oil or spray Engine valve rotators rotate the valves when the engine runs This helps to prevent deposits from building up on the valves and the valve seats Perform the following steps after the engine valve lash is set but before the valve covers are installed 1 Start the engine according to Operation and Maintenance Manual Engine Starting Operation Section for the procedure 86 Maintenance Section Fan Drive Bearing Lubricate SEBU7899 05 2 Operate the engine at low idle 3 Observe the top surface of each valve rotator The valve rotators should turn slightly when the valves close NOTICE A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life Ifa damaged rotator is not replaced valve face guttering could result and cause pieces of the valve to fall into the cylinder This can cause piston and cylinder head damage If a valve fails to rotate consult your Caterpillar dealer 102784507 Fan Drive Bearing Lubricate SMCS
59. le change in the sound of the running engine when the air purge screw is tightened The change in the sound of the engine is normal Note Failure to tighten all fittings could result in serious fuel leaks 6 Clean any residual fuel from the engine components 7 After the engine has operated smoothly for 30 seconds turn the priming valve 3 to the Open Run position Note Shortened injector life may occur if the priming valve 3 is left in the Closed Prime position The Engine Has Been Run Out of Fuel NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component 1 Turn the ignition switch to the OFF position 2 Fill the fuel tank s with clean diesel fuel Illustration 51 g00975199 1 Fuel priming pump 2 Air purge screw 3 Priming valve If Equipped 3 Turn the priming valve 3 If Equipped to the Closed Prime position in order to prime the fuel system 4 Open air purge screw 2 for the fuel filter by three full turns Do not remove the air purge screw NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again
60. lean SEBU7899 05 102927289 Engine Air Precleaner Check Clean SMCS Code 1055 070 1055 535 ee g01453058 Illustration 42 Typical engine air precleaner 1 Wing nut 2 Cover 3 Body Remove wing nut 1 and cover 2 Check for an accumulation of dirt and debris in body 3 Clean the body if necessary After cleaning the precleaner install cover 2 and wing nut 1 Note When the engine is operated in dusty applications more frequent cleaning is required 103435665 Engine Crankcase Breather Clean SMCS Code 1317 070 NOTICE Perform this maintenance with the engine stopped If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage Your engine may have one or two crankcase breathers Illustration 43 g01456410 View of the left side of a C18 Industrial Engine that is equipped with two engine crankcase breathers 1 Hose Clamp 2 Hose 3 Valve Cover a View of the left side of a C18 Industrial Engine that is equipped with one engine crankcase breather Illustration 44 901786116 1 Hose Clamp 2 Hose 3 Valve Cover 1 Loosen
61. lean the core Caustic cleaners can attack the internal metals of the core and cause leakage Obtain Coolant Analysis The concentration of supplemental coolant additive SCA should be checked regularly with test kits or with S O S Coolant Analysis Level 1 Further coolant analysis is recommended when the engine is overhauled A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system A full water analysis can be obtained by consulting your local water utility company or an agricultural agent Private laboratories are also available for water analysis Caterpillar Inc recommends an S O S Coolant Analysis Level 2 S O S Coolant Analysis Level 2 An S O S Coolant Analysis Level 2 is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system An S O S Coolant Analysis Level 2 provides the following information e Complete S O S Coolant Analysis Level 2 e Visual inspection of properties SEBU7899 05 97 Maintenance Section Power Take Off Clutch Check Identification of metal corrosion Identification of contaminants e Identification of built up impurities corrosion and scale S O S Coolant Analysis Level 2 provides a report of the results of both the analysis and the maintenance recommendations For more information about coolant analysis consult your Caterpillar dealer
62. life of the engine Water in the fuel can cause excessive wear to the fuel system Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Note Failure to properly close the drain can allow air into the system which could have detrimental results to performance Check the fuel daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of th
63. lso reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartridge must be balanced due to high rpm Severe Service Applications can accelerate component wear Severe Service Applications require more frequent inspections of the cartridge SEBU7899 05 99 Maintenance Section Walk Around Inspection Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil Clean the interior of the pipes in order to prevent dirt from entering during reassembly 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or mois
64. lter Do not aim the stream of air directly at the primary air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements Inspecting the Primary Air Cleaner Elements Illustration 39 g00281693 Inspect the clean dry primary air cleaner element Use a 60W blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element for tears and or holes Inspect the primary air cleaner element for light that may show through the filter material If necessary compare the primary air cleaner element to a new primary air cleaner element that has the same part number Do not use a primary air cleaner element that has any tears and or holes in the filter material Do not use a primary air cleaner element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements Storing Primary Air Cleaner Elements Ifa primary air cleaner element that passes inspection will not be use
65. ltration in order to help extend the life of the secondary fuel filter The element should be changed regularly If a vacuum gauge is installed the primary filter water separator should be changed at 50 to 70 kPa 15 to 20 inches Hg SEBU7899 05 89 Maintenance Section Fuel System Primary Filter Water Separator Element Replace Replace the Element Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair ofthe product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose ofall fluids according to local regulations and mandates NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component 1 Close the main fuel supply valve OO Illustration 53 g01453091 1 Elem
66. ner element The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings The secondary air cleaner element is not serviceable or washable The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element When the engine is operating in environments that are dusty or dirty air cleaner elements may require more frequent replacement SEBU7899 05 77 Maintenance Section Engine Air Cleaner Element Dual Element Inspect Clean Replace Illustration 37 900736431 1 Cover 2 Primary air cleaner element 3 Secondary air cleaner element 4 Turbocharger air inlet 1 Remove the cover Remove the primary air cleaner element 2 The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element Note Refer to Cleaning the Primary Air Cleaner Elements 3 Coverthe turbocharger air inlet with tape in order to keep out dirt 4 Clean the inside of the air cleaner cover and body with a clean dry cloth 5 Remove the tape for the turbocharger air inlet Install the secondary air cleaner element Install a primary air cleaner element that is new or cleaned 6 Install the air cleaner
67. ner to catch any fuel that might spill Clean up any spilled fuel immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component Note Refer to Operation and Maintenance Manual Fuel System Secondary Filter Replace for information on replacing the filter 1 Turn the ignition switch to the OFF position SEBU7899 05 87 Maintenance Section Fuel System Prime Illustration 50 g00975199 1 Fuel priming pump 2 Air purge screw 3 Priming valve If Equipped 2 Turn the priming valve 3 If Equipped to the Closed Prime position in order to prime the fuel system 3 Open air purge screw 2 for the fuel filter by three full turns Do not remove the air purge screw NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 4 Start the engine The engine should start and the engine should run smoothly Note You may use the fuel priming pump for the fuel filter IF EQUIPPED instead of starting the engine and running the engine 5 While the engine is running observe air purge screw 2 When a small drop of fuel appears at the threads of the air purge screw close and tighten air purge screw 2 Note There may be a noticeab
68. o faster than 19 L 5 US gal per minute to avoid air locks 5 Fill the cooling system with a mixture of clean water and Cat Fast Acting Cooling System Cleaner 6 Choose 1 of the following options e Add 0 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity e For cooling systems with heavy deposits or plugging add 0 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity 7 Install the cooling system filler cap 8 Start and run the engine at low idle for a minimum of 30 minutes For cooling systems with heavy deposits or plugging run the engine for 90 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 9 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water If equipped be sure to flush the heater and any related supply and return lines Close the drain valve if equipped Clean
69. o not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean primary air cleaner elements e Pressurized air e Vacuum cleaning 78 Maintenance Section SEBU7899 05 Engine Air Cleaner Element Dual Element Inspect Clean Replace 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 less than 205 kPa 30 psi for cleaning purposes Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 38 g00281692 Note When the primary air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside To help prevent damage to the paper pleats aim the hose so that the air flows inside the element along the length of the fi
70. on system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve cover 100 Maintenance Section Water Pump Inspect SEBU7899 05 Inspect the fuel system for leaks Look for loose fuel line clamps or for loose fuel line tie wraps Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Ensure that hoses and tubes are not contacting other hoses tubes wiring harnesses etc Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break e Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the ECM to the cylinder head ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenanc
71. ons may cause personal injury or death NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components Note High pressure fuel lines may be installed between the high pressure fuel pump and the fuel injectors High pressure fuel lines are constantly charged with high pressure Do not check the high pressure fuel lines with the engine or the starting motor in operation Wait for 10 minutes after the engine stops before you perform any service or repair on high pressure fuel lines Waiting for 10 minutes will to allow the pressure to be purged 1 Drain the fuel from the fuel system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose with a new hose 94 Maintenance Section Jacket Water Heater Check SEBU7899 05 5 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting
72. ooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 104445671 Coolant Extender ELC Add SMCS Code 1352 544 NL Note Refer to this Operation and Maintenance Manual Fluid Recommendations Cooling System for the maintenance interval for the addition of the coolant extender Cat ELC Extended Life Coolant and Cat ELI Extended Life Inhibitor do not require the frequent additions of any supplemental cooling additives The Cat ELC Extender will only be added one time Note Do not use conventional supplemental coolant additive SCA with Cat ELC or with Cat ELI Check the cooling system only when the engine is stopped and cool Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTIC
73. partment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water Ensure that the cooling lines are properly clamped and that the cooling lines are tight Check for leaks Check the condition of all pipes Inspect the water pumps for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pumps and the installation of water pumps and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubricati
74. prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Cat dealer has the proper air cleaner elements for your application Consult your Cat dealer for the correct air cleaner element Check the precleaner if eguipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation thoroughly check the air cleaner elements for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air clea
75. r is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi when the air nozzle is deadheaded Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both sides of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water After cleaning start the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Note If parts of the aftercooler system are repaired or replaced a leak test is highly recommended Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary For more detailed information on cleaning and inspection se
76. r sleeve Refer to the Service Manual for the complete procedure or consult with your Caterpillar dealer for assistance Rebuild or Exchange Cylinder Head Assembly Connecting Rods Pistons Cylinder Liners Turbocharger Cylinder Packs Oil Pump and Fuel Transfer Pump These components should be inspected according to the instructions that are found in various Caterpillar reusability publications The Special Publication SEBF8029 lists the reusability publications that are needed for inspecting the engine parts If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline the parts should be reused Parts that are not within the established inspection specifications should be dealt with in one of the following manners Salvaging e Repairing e Replacing Parts that do not comply with the established inspection specifications can result in the following problems 96 Maintenance Section Overhaul Considerations SEBU7899 05 Unscheduled downtime e Costly repairs Damage to other engine parts e Reduced engine efficiency e Increased fuel consumption Reduced engine efficiency and increased fuel consumption translates into higher operating costs Therefore Caterpillar Inc recommends repairing out of spec parts or replacing out of spec parts Inspection and or Replacement Piston Rings Crankshaft Bearings Valve Rotators and Crankshaft Seals
77. s Caterpillar does not warrant the quality or perfor mance of non Caterpillar fluids and filters 6 Install the new fuel filter Spin the fuel filter onto the fuel filter base until the gasket contacts the base Use the rotation index marks on the filters as a guide for proper tightening Tighten the filter according to the instructions that are on the fuel filter Do not overtighten the filter 7 Open the fuel supply valve The engine will need to be purged of air Refer to the Operation and Maintenance Manual Fuel System Prime topic Maintenance Section for more information 104363480 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates SEBU7899 05 91 Maintenance Section Grounding Stud Inspect Clean Tighten Fuel Tank Fuel guality is critical to the performance and to the service
78. s of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temperature components Excessive supplemental coolant additive concentra tion could also result in blockage of the heat exchang er overheating and or accelerated wear of the water pump seal Do not exceed the recommended amount of supple mental coolant additive concentration NOTICE Do NOT mix brands or types of SCA Do NOT mix SCAs and extenders Failure to follow the recommendations can result in shortened cooling system component life 74 Maintenance Section Crankshaft Vibration Damper Inspect SEBU7899 05 NOTICE Use Only Approved SCAs Conventional coolants require the maintenance addition of SCA throughout their expected life Do NOT use an SCA with a coolant unless specifically approved by the coolant supplier for use with their coolant It is the responsibility of the coolant manufacturer to ensure compatibility and ac ceptable performance Failure to follow the recommendations can result in shortened cooling system component life NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to
79. sonal injury Do not allow hot oil or hot components to contact the skin Do notdrain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase with the engine stopped Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil SEBU7899 05 83 Maintenance Section Engine Oil and Filter Change Interval for Engine Oil and Engine Oil Filter Change Note The intervals stated in table 20 are only valid when preferred lubricants are used Using fluids other than the preferred fluids causes the engine to operate in a severe service application Refer to this Operation and Maintenance Manual Severe Service Application for information about the effect of using fluids which are not preferred on the maintenance intervals Refer to this Operation and Maintenance Manual Refill Capacities before this procedure is started in order to determine the following e The type of oil pan The refill capacity for engine oil Table 20 Intervals for Changing the Engine Oil and Engine Oil Filter Every 14200 L 3750 US gal or 250 service hours or 1 yr
80. th which your Cat C18 Industrial Engine is eguipped Products that operate in severe operating conditions may reguire more freguent maintenance Refer to this Operation and Maintenance Manual Severe Service Application to determine if the engine is operating in a severe service application When Required Battery Replace 65 Battery or Battery Cable Disconnect 66 Coolant 68 Coolant Extender ELC Add 70 Engine Air Cleaner Element Dual Element Inspect Clean Replace 76 Engine Oil and Filter Change 82 Engine Storage Procedure Check 85 Fuel System Prime 86 Daily Coolant Level Check 70 Engine Air Cleaner Service Indicator Inspect 79 Engine Air Precleaner Check Clean 80 Engine Oil Level Check 81 Fuel System Primary Filter Water Separator ta aeta 88 Fuel Tank Water and Sediment Drain 90 Power Take Off Clutch Check 97 Walk Around Inspection 99 Every Week Jacket Water Heater Check
81. the hose clamp and remove the hose from the valve Cover 2 Remove the valve cover Refer to Disassembly and Assembly Valve Mechanism Cover Remove and Install SEBU7899 05 81 Maintenance Section Engine Mounts Inspect gt eee eoo GES Q VE Illustration 45 g01456434 3 Wash the breather in solvent that is clean and nonflammable Allow the breather to dry before installation 4 Install the valve cover Refer to Disassembly and Assembly Valve Mechanism Cover Remove and Install 5 Install the hose on the valve cover Install the hose clamp 102139969 Engine Mounts Inspect SMCS Code 1152 040 1152 Inspect the engine mounts for deterioration and for proper bolt torgue Engine vibration can be caused by the following conditions Improper mounting of the engine e Deterioration of the engine mounts Any engine mount that shows deterioration should be replaced Refer to the Specifications Manual SENR3130 Torque Specifications Refer to your Caterpillar dealer for more information 104339070 Engine Oil Level Check SMCS Code 1348 535 FLV Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin mt u L
82. torage Procedure Check SMCS Code 1000 535 The oil change interval may be extended to 12 months for a vehicle that is operated seasonally and placed in storage for the remainder of the year by using the reguired storage procedures and the reguired start up procedures This extension is permitted if the following categories for oil change intervals in the Operation and Maintenance Manual Maintenance Interval Schedule have not been reached e Mileage e Operating hours e Fuel consumption If an engine is out of operation and if use of the engine is not planned special precautions should be made If the engine will be stored for more than three months a complete protection procedure is recommended For more detailed information on engine storage see Special Instruction SEHS9031 Storage Procedure For Caterpillar Products If the engine will not be started for several weeks the lubricating oil will drain from the cylinder walls and from the piston rings Rust can form on the cylinder liner surface Rust on the cylinder liner surface will cause increased engine wear and a reduction in engine service life Caterpillar recommends the use of volatile corrosion inhibitor VCI oil in order to prevent internal engine damage due to moisture during storage These inhibitors in the VCI oil act by evaporating inside the engine The inhibitors then condense over the inside surfaces of the engine The evaporation process and the
83. ts Inspect 81 Engine Protective Devices Check 84 Engine Valve Lash 85 Engine Valve Rotators Inspect 85 Fan Drive Bearing Lubricate 86 Speed Sensor Clean Inspect 98 64 Maintenance Section Maintenance Interval Schedule SEBU7899 05 Every 760 000 L 200 770 US gal of Fuel Fan Drive Bearing Replace 86 Overhaul Considerations 94 SEBU7899 05 65 Maintenance Section Aftercooler Core Clean Test 102783957 Aftercooler Core Clean Test Air To Air Aftercooler If Eguipped SMCS Code 1064 070 1064 081 Note Adjust the freguency of cleaning according to the effects of the operating environment Inspect the aftercooler for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the aftercooler if necessary For air to air aftercoolers use the same methods that are used for cleaning radiators Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Pressurized ai
84. ture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber 4 Use a dial indicator to check the end clearance on the shaft If the measured end play is greater than the Service Manual specifications the turbocharger should be repaired or replaced An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications 5 Inspect the bore of the turbine housing for corrosion 6 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 7 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 101185304 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine com
85. vel Check SMCS Code 1401 535 FLV When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing All lead acid batteries contain sulfuric acid which can burnthe Skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions A mixture of 0 1 kg 0 2 Ib of baking soda and 1 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 the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM 101492654 Battery
86. y after obtaining the sample in order to avoid contamination e Never collect samples from expansion bottles Never collect samples from the drain for a system Timing of the Sampling Table 19 Recommended Interval Type of Coolant Level 1 Level 2 Cat DEAC Cat SCA Conventional Heavy Duty Coolants Cat ELC Cat ELI Commercial EC 1 Coolants Every 250 hours Yearly Optional Yearly 1 The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified Note Check the SCA Supplemental Coolant Additive of the conventional coolant at every oil change or at every 250 hours Perform this check at the interval that occurs first Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Cat dealer NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Submit the sample for Level 1

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