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C9 Industrial Engine-Maintenance Intervals - Safety

1. g00768439 Illustration 49 1 Breather assembly 2 Bolt 3 Hose clamp 4 Hose 1 Loosen hose clamp 3 and remove hose 4 from breather assembly 1 2 Remove bolt 2 and the washer Remove the breather assembly 1 and the seal 3 Wash the breather element in solvent that is clean and nonflammable Allow the breather element to dry before installation 4 Install a breather element that is clean and dry Install breather assembly 1 and the seal 5 Install bolt 2 and the washer Refer to Specifications SENR3130 Torque Specifications for the correct torque 6 Install hose 4 on breather assembly 1 Tighten hose clamp 3 Refer to Specifications SENR3130 Torque Specifications for the correct torques 102139969 Engine Mounts Inspect SMCS Code 1152 040 Inspect the engine mounts for deterioration and for proper bolt torque Engine vibration can be caused by the following conditions e Improper mounting of the engine e Deterioration of the engine mounts Any engine mount that shows deterioration should be replaced Refer to the Specifications Manual SENR3130 Torque Specifications Refer to your Caterpillar dealer for more information 100623423 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 compo
2. e Ensure that the cooling lines are properly clamped and that the cooling lines are tight Check for leaks Check the condition of all pipes e Inspect the water pumps for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pumps and the installation of water pumps and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve cover Inspect the fuel system for leaks Look for loose fuel line clamps or for loose fuel line tie wraps Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Ensure that hoses and tubes are not contacting other hoses tubes wiring harnesses etc Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break Drain the water and the sediment from fuel tanks on a
3. Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 8 Install the core Refer to the Service Manual for the procedure For more information on cleaning the core consult your Caterpillar dealer i01468985 Aftercooler Core Inspect SMCS Code 1064 040 Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the aftercooler for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the aftercooler if necessary For air to air aftercoolers use the same methods that are used for cleaning radiators Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water i
4. 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 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged perform a pressure test A 9S 8140 Pressurizing Pump is used to perform the pressure test The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 102173402 Cooling System Coolant ELC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is
5. Note There should be enough residual fuel in the cylinder head in order to start the engine If the engine stops after starting do not crank the engine for more than 30 seconds Then allow the starting motor to cool for two minutes Repeat this procedure until the engine starts and the engine operates 102436696 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment
6. to remove any debris Note If equipped be sure to flush the heater and any related supply and return lines 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with clean water Install the cooling system filler cap SEBU7772 02 69 Maintenance Section Cooling System Coolant Extender ELC Add 4 Start and run the engine at low idle until the temperature reaches 49 to 66 C 120 to 150 F 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with Extended Life Coolant ELC See Special Publication SEBU6385 Caterpillar On highway Diesel Truck Engine Fluids Recommendations for more inf
7. Code 1000 535 Caterpillar requires all engines that are stored for more than 3 months to follow storage procedures and start up procedures These procedures provide maximum protection to internal engine components Refer to Special Instruction SEHS9031 Storage Procedure For Caterpillar Products for information on these procedures An extension of the oil change interval to 12 months is permitted if you follow the required procedures for storage and start up This extension is permitted if the following intervals in the Operation and Maintenance Manual Maintenance Interval Schedule have not been reached e Operating hours e Fuel consumption i00869628 Engine Valve Lash Inspect Adjust SMCS Code 1102 025 The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust ment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This
8. Primary Air Cleaner Elements 3 Cover the turbocharger air inlet with tape in order to keep dirt out 4 Clean the inside of the air cleaner cover and body with a clean dry cloth 5 Remove the tape for the turbocharger air inlet Install the secondary air cleaner element Install a primary air cleaner element that is new or cleaned 6 Install the air cleaner cover 7 Reset the air cleaner service indicator 76 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace SEBU7772 02 Cleaning the Primary Air Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent 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 si
9. Wiad ete adver adie 71 Every 6000 Service Hours or 6 Years Cooling System Coolant ELC Change 68 Every 10 000 Service Hours Cylinder Head Grounding Stud Inspect Clean TIQHUGN oerni site ete ieri iri wuts cckenendeds 74 Fuel System Primary Filter Water Separator Element Replace ceccceeeeeeeeeeeeeeeneees 85 PM Level 1 Every 10 400 L 2750 US gal of Fuel or 250 Service Hours or 6 Months Air Compressor Filter Clean Replace 61 Battery Electrolyte Level Check n 64 Cooling System Supplemental Coolant Additive SCA Test Add 0 0 ee ceeeceeeeeeeeceeeeseeeeeeeeeeeentaeenes 72 Engine Oil Sample Obtain ceeeeeeeeeees 80 Engine Oil and Filter Change 80 Fan Drive Bearing Lubricate 2 0 83 Fuel System Primary Filter Water Separator Element Replace ccccccceeeeeeeeeeseneeneees 85 Fuel System Secondary Filter Replace 86 Fuel Tank Water and Sediment Drain 87 Hoses and Clamps Inspect Replace 5 88 Radiator Clean stiest ia ae a a aR 92 PM Level 2 Every 83 250 L 22 000 US gal of Fuel or 2000 Service Hours or 1 Year Aftercooler Core Inspect ceeeeeeteceeeeeeeeees 60 Alternator Inspect cececceeceeeeeeeeeeeteeeeeaeees 62 Engine Crankcase Breather Clean asasin 78 Engine Valve Lash Inspect Adjust eee 83 PM Level 3 Every 166 50
10. air brake and the auxiliary air systems before re moving the air compressor and or the air lines could cause personal injury Illustration 36 g01076630 1 Pressure relief valve If the air compressor pressure relief valve that is mounted in the air compressor cylinder head is bypassing compressed air there is a malfunction in the air system possibly ice blockage Under these conditions your engine may have insuffi cient air for normal brake operation Do not operate the engine until the reason for the air bypass is identified and corrected Failure to heed this warning could lead to property damage personal injury or death to the operator or by standers The function of the pressure relief valve is to bypass air when there is a malfunction in the air compressor system The pressure relief valve releases air at 1723 kPa 250 psi Do not stand near the pressure relief valve Compressed air may be released without warning All personnel should also stay clear of the air compressor when the engine is operating and the air compressor is exposed Refer to the Service Manual or refer to the OEM specifications in order to find information concerning the air compressor Consult your Caterpillar dealer for assistance 101544231 Air Compressor Filter Clean Replace If Equipped SMCS Code 1803 070 FQ 1803 510 FQ One of the single most important aspects of preventive maintena
11. air pressure will be 758 to 965 kPa 110 to 140 psi 100072207 Alternator Inspect SMCS Code 1405 040 Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the ammeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs as required Refer to the Service Manual Check the alternator and the battery charger for proper operation If the batteries are 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 102153996 Battery Replace SMCS Code 1401 510 Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite This can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks nea
12. battery charger for proper operation If the batteries are properly charged the needle of the ammeter will register near 0 zero The battery charger must not produce excessive current during start up Alternatively the charger must be automatically disconnected for start up If the engine has an alternator the charger must be automatically disconnected during start up and during engine operation Charging the Battery Never disconnect any charging unit circuit or bat tery circuit cable from the battery when the charg ing unit is operated A spark can cause an explo sion from the flammable vapor mixture of hydro gen and oxygen that is released from the elec trolyte through the battery outlets Injury to per sonnel can be the result Perform the following procedure to charge the battery 1 Ensure that the charger is turned OFF 2 Adjust the voltage of the charger in order to match the voltage of the battery 3 Connect the POSITIVE lead of the charger to the POSITIVE battery terminal Connect the NEGATIVE lead of the charger to the NEGATIVE battery terminal 4 Turn ON the battery charger Overcharging of Batteries Overcharging reduces the service life of batteries Use a battery charger that will not overcharge the battery DO NOT charge the battery if the meter of the battery charger is in the RED zone Overcharging is indicated by the following symptoms e The battery
13. cooler core Note Caterpillar Inc recommends the use of Hydrosolv Liquid Cleaners Table 16 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer Table 16 HydrosolvLiquid Cleaners eo Description Size 1U 8812 4 L 1 US gallon 1U 5490 Hydrosolv4165 19 L 5 US gallon 8T 7570 208 L 55 US gallon 1U 8804 4 L 1 US gallon 1U 5492 Hydrosolv100 19 L 5 US gallon 8T 5571 208 L 55 US gallon 4 Use steam to clean the oil cooler core This removes any remaining residue from the cleaner Flush the fins of the oil cooler core Remove any other trapped debris 5 Wash the oil cooler core with hot soapy water Rinse the oil cooler core thoroughly with clean water Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 6 Dry the oil cooler core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the components in order to ensure cleanliness The oil cooler core should be pressure tested Repair the oil cooler core if necessary Install the oil cooler core For more information about cleaning the cores consult your Caterpillar dealer Obtain Coolant Analysis The concentr
14. 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 SEBU7772 02 93 Maintenance Section Severe Service Application Check Inspect the fins for damage Bent fins may be opened with a comb Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary For more detailed information on cleaning and inspection refer to Special Publication SEBD0518 Know Your Cooling System 100151038 Severe Service Application Check SMCS Code 1000 535 Severe service is an application of an engine that exceeds current published standards for that engine Caterpillar maintains standards for the following engine parameters e Performance power range speed range and fuel consumption Fuel quality Altitude range e Maintenance intervals Oil selection and maintenance Coolant selection and maintenance e Environmental qualities e Installation Refer to the standards for the engine or consult with your Caterpillar dealer in order to determine if the engine is operating within the defined parameters Severe service operation can accelerate component wear Engines that operate under severe conditions may need more frequent maintenance intervals in order to ensure maximum reliability and retention of full service life Due to individ
15. ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove one of the drain plugs Note If equipped be sure to drain the heater and any related supply and return lines Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Serv
16. is very warm to the touch e A strong odor of acid is present e The battery emits smoke or a dense vapor gas Perform one of the following procedures if the battery shows symptoms of overcharging Reduce the rate of charging by a significant amount Complete the charging at the reduced rate Turn OFF the charger Table 12 describes the effects of overcharging on different types of batteries Table 12 Effects of Overcharging Batteries Type of Battery Effect Caterpillar General Service All of the battery cells have Batteries a low level of electrolyte Caterpillar Premium High Output Batteries When the plates of the battery are inspected through the filler holes the plates may appear to be warped This is caused by an excessive temperature The battery may not pass a load test Caterpillar Maintenance Free Batteries The battery may not accept a charging current The battery may not pass a load test 64 Maintenance Section Battery Electrolyte Level Check SEBU7772 02 Checking After Stopping Ensure that the battery charger is connected properly Observe the meter of the charger Record the amperage 102340858 Battery Electrolyte Level Check SMCS Code 1401 535 When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the bat
17. primary air cleaner element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will not be used the primary air cleaner element can be stored for future use Illustration 46 g00281694 Do not use 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 i01900118 Engine Air Cleaner Service Indicator Inspect If Equipped SMCS Code 7452 040 Some engines may be equipped with a different service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendations in order
18. 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 Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations or consult your Caterpillar dealer 101987714 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 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 Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant 72 Maintenance Section SEBU7772 02 Cooling System Supplemental Coolant Additive SCA Test Add Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6
19. the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal 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 tur
20. use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 3 Back flush the core with cleaner Caterpillar recommends the use of Hydrosolv liquid cleaner Table 11 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 11 Hydrosolv Liquid Cleaners Part Per Number Description Size 1U 5490 Hydrosolv 4165 174 6854 Hydrosolv 100 19 L 5 US gallon 19 L 5 US gallon 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information 4 Steam clean the core in order to remove any residue Flush the fins of the aftercooler core Remove any other trapped debris 5 Wash the core with hot soapy water Rinse the core thoroughly with clean water Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 6 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the core in order to ensure cleanliness
21. 0 L 44 000 US gal of Fuel or 4000 Service Hours or 2 Years Aftercooler Core Clean Test ccccseseeeeeeeee 60 Air Compressor Inspect ccceeeeeeeeeeeeeeetteees 61 SEBU7772 02 59 Maintenance Section Maintenance Interval Schedule Belt Tensioner Inspect ceceeeeeeeeeeeeeeees 64 Cooling System Coolant DEAC Change 66 Cooling System Coolant Extender ELC Add 69 Cooling System Water Temperature Regulator Replace i i deta e aaraa aetala dies 73 Crankshaft Vibration Damper Inspect 73 Engine Clean ccccceeeeceeeeeesecceeeeeeeeneeedeeseneedens 74 Engine Mounts Inspect eeeeeeeeeeeeeeeeeeeenneeees 79 Every 208 000 L 55 000 US gal of Fuel or 5000 Service Hours Starting Motor Inspect s es 93 Turbocharger Inspect 0 eeceeeeeeeeeeeeeeetteeeeeeeaes 94 Water Pump Inspect 0 eeeeeeeeteeeeenneeaeees 95 Every 340 000 L 90 000 US gal of Fuel or 10 000 Service Hours Cylinder Head Grounding Stud Inspect Clean WAGON a ia cap dies E nl teen elk eds 74 Overhaul Considerations ccceeeeeeeeereeeeeenees 89 60 Maintenance Section Aftercooler Core Clean Test SEBU7772 02 101546702 Aftercooler Core Clean Test SMCS Code 1064 070 1064 081 1 Remove the core Refer to the Service Manual for the procedure 2 Turn the aftercooler core upside down in order to remove debris NOTICE Do not
22. 1 drop of NITRITE TEST SOLUTION A to the mixing bottle Move the bottle in a circular motion in order to mix the solution 6 Repeat 5 until the solution changes color from red to light gray green or blue Record the number of drops of NITRITE TEST SOLUTION A that were required to cause the color change 7 Use Table 14 to interpret the results Table 14 Number of Concentration Maintenance Drops of SCA Required Less than 25 Less than the Add SCA recommended Retest the concentration of coolant SCA 25 to 30 The None recommended concentration of SCA More than 30 More than the Remove the recommended coolant concentration of Replace with SCA water only Retest the coolant Add the SCA If Necessary Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly Note Always dispose of fluids according to local regulations 2 If necessary drain some coolant in order to allow space for the addition of the SCA SEBU7772 02 73 Maintenance Section Cooling System Water Temperature Regulator Replace NOTICE Excessive supplemental coolant additive concentra tion can form deposits on the higher temperature sur faces of the cooling s
23. 251 Caterpillar Commercial Diesel Engines Fluids Recommendations or consult your Caterpillar dealer 102017557 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and eyes Do not drink cooling system coolant additive Note Caterpillar recommends an S O S coolant analysis Level 1 Test the Concentration of the SCA Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Follow the instructions that are provided in the kit Water and SCA NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Use the instructions that follow 1 Fill the syringe to the 1 0 ml mark with the coolant 2 Dispense the 1 0 mL coolant sample from the syringe into the empty mixing bottle 3 Add tap water to the mixing bottle in order to bring the level up to the 10 ml mark Place the cap on the bottle and shake the bottle 4 Add 2 to 3 drops of the NITRITE INDICATOR SOLUTION B to the mixing bottle Move the bottle in a circular motion in order to mix the solution 5 Add
24. 51 g00588944 Element with debris 2 Cut the oil filter open with a 175 7546 Oil Filter Cutter Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element Ferrous metals may indicate wear on the steel and cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts brass parts or bronze parts of the engine Parts that may be affected include the following items main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter Illustration 52 g00103713 Typical filter mounting base and filter gasket 3 Clean the sealing surface of the filter mounting base Ensure that all of the old oil filter gasket is removed 4 Apply clean engine oil to the new oil filter gasket NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 5 Install the oil filter Tighten the oil filter unti
25. C9 INDUSTRIAL ENGINES Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU7772 02 01 2007 Caterpillar CATERPILLAR All Rights Reserved 58 Maintenance Section Maintenance Interval Schedule SEBU7772 02 102471504 Maintenance Interval Schedule SMCS Code 1000 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging 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 Use fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed When Required Battery Replace ooo eeeeeceeeeeeeeeeeeeeeeneeeeeeeneaeees 62 Battery or Battery Cable Disconnect 64 Engine Air Cleaner Element Dual Element Clean Replace 00 0 cccccceeeeeeeeeeeeeteeee
26. Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Check the fuel daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank during the following conditions e Weekly e Oil change e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank A 2 micron filter for the breather vent on the fuel tank is also recommended Refer to Special Publication SENR9620 Improving Fuel System Durablity 88 Maintenance Section Hoses
27. Head Assembly 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 e Salvaging e Repairing e Replacing Using out of spec parts can result in the following problems e Unscheduled downtime e Costly repairs e 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 Crankshaft Bearings Valve Rotators and Crankshaft Seals 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 an
28. R analysis of the oil Repeat Program B if you change the application of the engine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above References Reference Form PEDP7035 Optimizing Oil Change Intervals Reference Form PEDP7036 S O S Fluid Analysis Reference Form PEDP7076 Understanding the S O S Oil Analysis Tests Drain the Engine Oil After the engine has been run at the normal operating temperature stop the engine Attach a DO NOT OPERATE or a similar warning tag to the ignition keyswitch before the engine is serviced Catch the oil in a suitable container Recycle the used oil or dispose of the used oil properly 1 Remove the oil drain plug in order to allow the oil to drain 2 After the oil has drained the oil drain plug should be cleaned and installed Replace the Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 1 Remove the oil filter with a 185 3630 Strap Wrench 82 Maintenance Section Engine Oil and Filter Change SEBU7772 02 Illustration
29. a major catastrophe due to engine failure The best 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 90 Maintenance Section Overhaul Considerations SEBU7772 02 Overhaul Recommendation To minimize downtime Caterpillar Inc recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails 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 Rebuild or Exchange Cylinder
30. and Clamps Inspect Replace SEBU7772 02 If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used 102121526 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Inspect all hoses for leaks that are caused by the following conditions e Cracking e Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extre
31. ation 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 For example considerable deposits are found in the water jacket areas on the external cooling system but the concentrations of coolant additives were carefully maintained The coolant water probably contained minerals that were deposited on the engine over time A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system A full water analysis 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 0 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 1 e Visual inspection of properties e Identification of metal corrosion 92 Maintenance Section Power Take Off Clutch Check Adjust Lubricate SEBU7772 02 e Identification of contaminants e Identification of built up impurities corrosion and scale S 0 S Coolant Analysis Level 2 provides a report of the results
32. be followed to help prevent accidents 101604510 Radiator Clean SMCS Code 1353 070 Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the radiator for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the radiator if necessary Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to 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
33. bine 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 SEBU7772 02 95 Maintenance Section Walk Around Inspection 101185304 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted 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
34. cation NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Cat ELC Extender 3 Add Cat ELC Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations article for more information 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 101197583 Cooling System Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and cool Illustration 40 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
35. cause the engine to run rough Water in the fuel may cause a 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 filtration 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 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 Note A 10 to 15 micron absolute high efficiency fuel filter is required for Caterpillar Electronic Unit Injectors Caterpillar High Efficiency Fuel Filters meet these requirements Consult your Caterpillar dealer for the proper part number 1 Close the main fuel supply valve ee Illustration 56 g00104012 1 Element 2 Bowl 3 Drain 2 Remove element 1 from the element mounting base while bowl 2 is attached 86 Maintenance Section Fuel System Secondary Filter Replace SEBU7772 02 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 cov
36. ce Procedures e Extending the maintenance intervals e Failure to use recommended fuel lubricants and coolant antifreeze 100651416 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar Inc recommends a scheduled inspection of the starting motor If the starting motor fails the engine may not start in an emergency situation Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance 94 Maintenance Section Turbocharger Inspect SEBU7772 02 101539769 Turbocharger Inspect SMCS Code 1052 040 1052 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 q
37. daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the ECM to the cylinder head ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check the condition of the gauges Replace any gauges that are cracked Replace any gauge that can not be calibrated 101057943 Water Pump Inspect SMCS Code 1361 040 1361 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 Visually inspect the water pump for leaks If any leaking is observed replace the water pump seal or the water pump assembly Refer to the Service Manual for the disassembly and assembly procedure 96 Maintenance Section Water Pump Inspect SEBU7772 02 Note Refer to the Service Manual or consult your Caterpillar dealer if any repair is needed or any replacement is needed
38. e engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface Refer to the Service Manual for the replacement procedure of the water temperature regulator or consult your Caterpillar dealer Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 100072369 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations This can result in damage to
39. e the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 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
40. econds Allow the starting motor to cool for two minutes before cranking the engine again SEBU7772 02 85 Maintenance Section Fuel System Primary Filter Water Separator Drain 1 Operate the starting motor This will fill the fuel filter and the fuel lines with fuel 2 Once the engine starts operate the engine at low idle Do not raise the engine speed above an idle until the engine operates smoothly 100259781 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 ee o l Illustration 55 g00104007 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 102415789 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ Water in the fuel can
41. eeeeeeeeeeeeeeees 75 Engine Storage Procedure Check sees 83 Fuel System Prime 2 eeeecceeeeeeeeeeeeeeeeees 84 Severe Service Application Check 93 Daily Air Tank Moisture and Sediment Drain 62 Cooling System Coolant Level Check 70 Driven Equipment Check cccceeeeetteeeees 74 Engine Air Cleaner Service Indicator Inspect 77 Engine Oil Level Check eccceeeeeeeeeeeeeeenneeees 79 Fuel System Primary Filter Water Separator Draien enapan aaraa ane a a aae TA 85 Power Take Off Clutch Check Adjust Lubricate 92 Walk Around Inspection 0 cccccceeeeeeeeeeeetereeees 95 Initial 20 to 40 Service Hours Belts Inspect AdjUSt ceeeeeeeeeeeeeeeeeeeenteeees 65 Every Week Battery Charger Check 0 ceeceececeeeeeeeeeeeeenneees 63 Engine Air Precleaner Check Clean 78 Jacket Water Heater Check siseses 89 Every 250 Service Hours Belts Inspect Adjust ee eeeeeeeeeeetteeeeeetnteeeeerees 65 Initial 500 Service Hours Cooling System Coolant Sample Level 1 10 te 11 ME EE errr eer T creer ere arc rert ite 71 Engine Valve Lash Inspect Adjust 0 0 0 83 Every 500 Service Hours Cooling System Coolant Sample Level 1 Obtain 2 oie ee teed 71 Every Year Cooling System Coolant Sample Level 1 OBTAIN cbs reassess E AE es een Bas 71 Cooling System Coolant Sample Level 2 OD1AIN ce avis
42. er over any dis connected fuel system components NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 3 Dispose of the fuel in the fuel filter element 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 e 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 eng
43. ew service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 102498263 Engine Air Precleaner Check Clean SMCS Code 1055 070 1055 535 1 3 2 Ny as aaa g00736588 Illustration 48 Typical precleaner 1 Wing nut 2 Cover 3 Body Check the engine air precleaner weekly for debris and dirt Clean the precleaner when any material which would impair the performance of the engine is found Check and clean the precleaner by performing the following steps 1 Remove wing nut 1 and cover 2 2 Check for an accumulation of dirt and debris in body 3 3 Clean the body if necessary 4 After cleaning the precleaner install cover 2 and wing nut 1 Your precleaner may vary from the precleaner which is pictured above For further information about maintaining your precleaner see your Caterpillar dealer Note When the engine is operated in dusty applications more frequent cleaning is required 101724662 Engine Crankcase Breather Clean SMCS Code 1317 070 NOTICE Perform this maintenance with the engine stopped SEBU7772 02 79 Maintenance Section Engine Mounts Inspect NOTICE If the crankcase breather is not maintained on a regu lar basis it can become plugged A plugged breather will cause excessive crankcase pressure that may cause crankshaft seal leakage
44. he battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Turn the start switch to the OFF position Turn the ignition switch if equipped to the OFF 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 Tape the leads in order to help prevent accidental starting 4 Proceed with necessary system repairs Reverse the steps in order to reconnect all of the cables Belt Tensioner Inspect If Equipped SMCS Code 1358 040 Illustration 37 g00426964 Belt tensioner SEBU7772 02 65 Maintenance Section Belts Inspect Adjust Inspect the belt tensioner for unusual noise excessive looseness and or shaking of the bearings If the belt tensioner should require disassembly refer to the Service Manual for the procedure 102486694 Belts Inspect Adjust SMCS Code 1357 025 1357 040 Inspection Belt tension should be checked initially between the first 20 to 40 hours of engine operation After the initial check the belt tension should be checked at every oil change To maxim
45. ice Tool Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1 Flush the cooling system with clean water in order to remove any debris SEBU7772 02 67 Maintenance Section Cooling System Coolant DEAC Change 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the cooling system filler cap 4 Start and run the engine at low idle for a minimum of 30 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 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 equi
46. ich are associated with the present conventional coolants The Cat ELC Extender only needs to be added once NOTICE Use only Cat Extended Life Coolant ELC Extender with Cat ELC Do NOT use conventional supplemental coolant addi tive SCA with Cat ELC Mixing Cat ELC with conven tional coolants and or conventional SCA reduces the Cat ELC service life Check the cooling system only when the engine is stopped and cool 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 70 Maintenance Section Cooling System Coolant Level Check SEBU7772 02 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 Publi
47. ine and check for leaks Run the engine for one minute Stop the engine and check for leaks again Detection of 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 under tightening 101503750 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 1 Stop the engine Turn the ignition switch to the OFF position or disconnect the battery Refer to the Operation and Maintenance Manual Battery or Battery Cable Disconnect topic Maintenance Section for more information Shut off the fuel supply valve if equipped 2 Remove the used fuel filter and discard the used fuel filter 3 Clean the gasket sealing surface of the fuel filter ba
48. information 84 Maintenance Section Fuel System Prime SEBU7772 02 102113137 Fuel System Prime SMCS Code 1258 548 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components Prime the fuel system in order to fill the fuel filter Prime the fuel system in order to purge trapped air The fuel system should be primed under the following conditions e Running out of fuel e Storage e Replacement of the fuel filter Engines that are Equipped with a Fuel Priming Pump NOTICE Do not loosen the fuel lines at the fuel manifold The fittings may be damaged and or a loss of priming pres sure may occur when the fuel lines are loosened 1 Open the fuel priming pump and operate the fuel priming pump until a strong pressure is felt This procedure will require considerable strokes Lock the fuel priming pump NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 2 Promptly start the engine If the engine runs rough continue t
49. insing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze Refer to the Operation and Maintenance Manual Refill Capacitites and Recommendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 68 Maintenance Section Cooling System Coolant ELC Change SEBU7772 02 2 Start and run the engine at low idle Increase the engine rpm to 1500 rpm Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine
50. ize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged For applications that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched The additional load on the new belt could cause the new belt to break If the belts are too loose vibration causes unnecessary wear on the belts and pulleys Loose belts may slip enough to cause overheating If the belts are too tight unnecessary stresses are placed on the pulley bearings and on the belts This may shorten the service life of the components Remove the belt guard if equipped Inspect the condition and adjustment of the alternator belts and accessory drive belts if equipped To check the belt tension apply 110 N 25 Ib ft of force midway between the pulleys A correctly adjusted belt will deflect 9 mm 0 35 inch to 15 mm 0 59 inch If the belt does not require replacement or adjustment install the belt guard If the belt requires adjustment or replacement perform the following procedure to adjust the belt tension Adjustment Alternator Belt Illustration 38 g00768640 1 Nut 2 Adjusting Nut 3 Bolt 4 1 Slightly loosen mounting bolt 3 and nut 4 2 L
51. l 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 Fill the crankcase with the proper amount of oil Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section for more information NOTICE If equipped with an auxiliary oil filter or system extra oil must be added when filling the crankcase Follow the OEM or filter manufacturer s recommendations If the extra oil is not added the engine may starve for oil NOTICE To help prevent crankshaft or bearing damage crank engine to fill all filters before starting Do not crank engine for more than 30 seconds 2 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 3 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL marks on the ENGINE STOPPED side of the oil level gauge SEBU7772 02 83 Maintenance Section Engine Storage Procedure Check 101430860 Engine Storage Procedure Check SMCS
52. lant samples of commercial coolants that meet the Cat EC 1 specification for engine coolant 2 The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified e Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat DEAC Diesel Engine Antifreeze Coolant e Commercial heavy duty coolant antifreeze 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 Note Level 1 results may indicate a need for Level 2 Analysis 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 you must 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 Caterpillar dealer 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
53. mber of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings The secondary air cleaner element is not serviceable or washable The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element When the engine is operating in environments that are dusty or dirty air cleaner elements may require more frequent replacement Illustration 43 g00736431 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
54. me temperature changes the hose will heat set Heat setting causes hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Replace the Hoses and the Clamps Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine Allow the engine to cool 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suitable clean container The coolant can be reused 3 Drain the coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose 7 Install the hose clamps with a torque wrench Note Refer to the Specifications SENR3130 Torque Specifications in order to locate the proper torques 8 Refill the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler ca
55. n 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 SEBU7772 02 61 Maintenance Section Air Compressor Inspect After cleaning start the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Note If parts of the aftercooler system are repaired or replaced a leak test is highly recommended The FT1984 Aftercooler Testing Group is used to perform leak tests on the aftercooler Refer to the Systems Operation Testing and Adjusting Aftercooler Test and the Special Instruction SEHS8622 for the proper testing procedure Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary For more detailed information on cleaning and inspection see Special Publication SEBD0518 Know Your Cooling System 102113479 Air Compressor Inspect SMCS Code 1803 040 Do not disconnect the air line from the air com pressor governor without purging the air brake and the auxiliary air systems Failure to purge the
56. nce for the air compressor is the induction of clean air The type of maintenance that is required for the air compressor and the maintenance interval depends on the type of air induction system that is used Operating conditions dust dirt and debris may require more frequent service Refer to the Service Manual for the type of air compressor that is installed on the engine Follow the maintenance recommendations that are provided by the OEM of the air compressor Some engines use boost air pressure so the engine air cleaner will require servicing 62 Maintenance Section Air Tank Moisture and Sediment Drain SEBU7772 02 100847451 Air Tank Moisture and Sediment Drain If Equipped SMCS Code 1466 543 M amp S Moisture and sediment in the air starting system can cause the following conditions e Freezing e Corrosion of internal parts e Malfunction of the air starting system When opening the drain valve wear protective gloves a protective face shield protective cloth ing and protective shoes Pressurized air could cause debris to be blown and result in personal injury 1 Open the drain valve that is on the bottom of the air tank Allow the moisture and sediment to drain 2 Close the drain valve 3 Check the air supply pressure The air starting motor requires a minimum of 620 kPa 90 psi of air pressure to operate properly The maximum air pressure must not exceed 1550 kPa 225 psi The normal
57. nd Recommendations for further information about oils that may be used in Caterpillar engines SEBU7772 02 81 Maintenance Section Engine Oil and Filter Change Table 15 Oil Change Interval for C 9 Industrial Engine Operating Conditions Severe Normal High Fuel Altitude Load Sulfur above Multiqrad Factor from 1830 m Oil Type above 0 3 to 6000 ft 43 L 0 5 11 US W gal per hour of fuel 3 CatDEO osohr 250hr 250 hr 250 hre Preferred API CH 4 11 0 minimum 250 hr 250 hr 250 hr 250 hr TBN Preferred API CH 4 TBN 250 hr 250 hr 250 hr 250 hr below 11 0 API CG 4 250 hr 250 hr 250 hr 250 hr 1 The standard oil change interval in this engine is 250 hours if the operating conditions and recommended oil types that are listed in this table are met If the type of oil the quality of the oil and the operating conditions meet certain standards the oil change intervals may be increased to 500 hours Refer to Special Publication PEDP7035 Optimizing Oil Change Intervals in order to determine whether the oil change interval can be extended beyond 250 hours Normal conditions include these factors Fuel sulfur below 0 3 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not include high load factor harsh operating cycles or harsh environments 8S 3 Continuous heavy load cycles a
58. nd very little idle time result in increased fuel consumption and oil contamination These factors deplete the oil additives more rapidly If the average fuel consumption of your engine exceed 43 L 11 US gal per hour follow the High Load Factor recommendations in Table 15 To determine average fuel consumption for your engine measure average fuel consumption for a period of 50 to 100 hours If the application of the engine is changed the average fuel consumption may change For sulfur content above 0 5 refer to Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines in Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations 5 In order to verify an oil change interval of 500 hours refer to Program A below 6 Use Program B below to determine an appropriate interval 4 Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Program A e Proceed to Program B High load factors can shorten the service life of your engine oil e Change to a preferred oil type in Table 15 Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each interval is adjusted an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared I
59. needed when the ELC is drained and replaced Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove the cooling system drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tool Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1 Flush the cooling system with clean water in order
60. nents to contact the skin a ad lt ADD FULL 5 g00110310 Illustration 50 Y ADD mark X FULL mark NOTICE Perform this maintenance with the engine stopped 1 Maintain the oil level between ADD mark Y and FULL mark X on oil level gauge 1 Do not fill the crankcase above FULL mark X NOTICE Operating your engine when the oil level is above the FULL mark could cause your crankshaft to dip into the oil The air bubbles created from the crankshaft dipping into the oil reduces the oil s lubricating char acteristics and could result in the loss of power 2 Remove the oil filler cap and add oil if necessary Clean the oil filler cap Install the oil filler cap 80 Maintenance Section Engine Oil Sample Obtain SEBU7772 02 Engine Oil Sample Obtain SMCS Code 1000 008 1348 554 SM 7542 554 OC SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine 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 complet
61. nt Dual Element Clean Replace 101553486 Engine Air Cleaner Element Dual Element Clean Replace SMCS Code 1054 037 1054 510 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air cleaner element e Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element e The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected e The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the nu
62. o operate the engine at low idle Do not raise the engine rpm above an idle until the engine operates smoothly 3 If the engine does not start open the fuel priming pump and repeat Steps 1 and 2 in order to start the engine Engines that are Not Equipped with a Fuel Priming Pump If the engine is not equipped with a fuel priming pump you can use the following procedures to prime the fuel system These procedures will allow only filtered fuel to enter the fuel system Fuel Filter Bases that are Equipped with a Plug NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components Illustration 54 g01076450 1 Plug 2 Fuel filter 1 Remove plug 1 in order to fill fuel filter 2 Ensure that air is able to vent from the fitting of the plug while the fuel filter is being filled Clean up any spilled fuel immediately Clean plug 1 Install plug 1 NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 2 Start the engine and operate the engine at low idle Do not raise the engine speed above an idle until the engine operates smoothly Fuel Filter Bases that are Not Equipped with a Plug NOTICE Do not crank the engine continuously for more than 30 s
63. of both the analysis and the maintenance recommendations For more information about coolant analysis see your Caterpillar dealer 101506009 Power Take Off Clutch Check Adjust Lubricate SMCS Code 3055 036 3055 086 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 require several adjustments until the new plates are worn in Illustration 57 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
64. oosen nut 1 3 Tighten adjusting bolt 2 and mounting bolts 3 and 4 Tighten bolt 1 Refer to the Specifications Manual SENR3130 Torque Specifications If new belts are installed check the belt tension again after 30 minutes of engine operation at the rated rom 66 Maintenance Section Cooling System Coolant DEAC Change SEBU7772 02 Water Pump Belt Illustration 39 g00426869 Typical example Exploded view of the drive assembly for a water pump belt 1 Mounting bolt 2 Square hole 3 Adjusting bolt 1 Slightly loosen mounting bolt 1 and adjusting bolt 3 2 Adjust the belt tension with a square drive in square hole 2 3 Tighten adjusting bolt 3 and mounting bolt 1 Refer to the Specifications Manual SENR3130 Torque Specifications 4 Install the belt guard if equipped If new belts are installed check the belt tension after 30 minutes of engine operation at the rated rpm 102139869 Cooling System Coolant DEAC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated NOTICE Use of commercially available cooling system clean
65. ormation on cooling system specifications Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling 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 102482066 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1395 081 Cat ELC Extended Life Coolant does not require the frequent additions of any supplemental cooling additives wh
66. p s gaskets Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks SEBU7772 02 89 Maintenance Section Jacket Water Heater Check 102486400 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 For an ambient temperature of 0 C 32 F the heater should maintain the jacket water coolant temperature at approximately 32 C 90 F 102436705 Overhaul Considerations SMCS Code 7595 043 Reduced hours of operation at full load will result in a lower average power demand and reduced fuel consumption 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 increased oil consumption excessive engine blowby and reduced power Arctic temperatures extremely high temperatures corrosive environments or extremely dusty conditions contribute to premature wear and the need for an overhaul The following factors are important when a decision is being made on the proper time for an engine overhaul e The need for preventive maintenance e The qualit
67. pped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water If equipped be sure to flush the heater and any related supply and return lines Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques Cooling Systems with Heavy Deposits or Plugging Note For the following procedure to be effective there must be some active flow through the cooling system components 1 Flush the cooling system with clean water in order to remove any debris Note If equipped be sure to flush the heater and any related supply and return lines 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the cooling system filler cap 4 Start and run the engine at low idle for a minimum of 90 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete r
68. r batteries Do not smoke when batteries are serviced The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury Turn the key start switch to the OFF position Remove the key and all electrical loads N Turn OFF the battery charger Disconnect the charger oo The NEGATIVE cable connects the NEGATIVE battery terminal to the ground plane Disconnect the cable from the NEGATIVE battery terminal A The POSITIVE cable connects the POSITIVE battery terminal to the starting motor Disconnect the cable from the POSITIVE battery terminal SEBU7772 02 63 Maintenance Section Battery Charger Check Note Always recycle a battery Never discard a battery Return used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before the cables are connected ensure that the key start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Connect the cable from the ground plane to the NEGATIVE battery terminal 101039758 Battery Charger Check SMCS Code 1401 535 Checking Before Start Up Check the
69. re duced efficiency could result in excessive fuel usage and or shortened engine component life Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this maintenance is performed Refer to the Service Manual for more information 102239650 Fan Drive Bearing Lubricate SMCS Code 1359 086 BD Some of the fan drives have grease fittings and some of the fan drives do not have grease fittings If there is no grease fitting periodic lubrication is not required The fan drive requires grease only if the fan drive is equipped with a zerk Illustration 53 g00746166 Typical location of the grease fitting if equipped that is for the fan drive bearing The pulley is shown with the belt guards that have been removed Lubricate the grease fitting that is on the fan drive bearing with Bearing Lubricant or the equivalent Inspect the fan drive pulley assembly for wear or for damage If the shaft is loose an inspection of the internal components should be performed Refer to the Service Manual for additional
70. rical grounding stud and the strap clean and coated with MPGM grease or petroleum jelly 100174798 Driven Equipment Check SMCS Code 3279 535 Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment e Inspection e Adjustment e Lubrication e Other maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM i01646701 Engine Clean SMCS Code 1000 070 Personal injury or death can result from high volt age Moisture can create paths of electrical conductiv ity Make sure that the electrical system is OFF 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 SEBU7772 02 75 Maintenance Section Engine Air Cleaner Eleme
71. sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEHP6001 How To Take A Good Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine 102488152 Engine Oil and Filter Change SMCS Code 1318 510 1348 044 Selection of Oil Change Interval Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Caterpillar oil filters are recommended for oil changes Recommended multigrade oil types are listed in Table 15 Do not use single grade oils Cat DEO Multigrade Oils exceed industry standard ECF 1 Any oil that is used in a Caterpillar engine must meet the ECF 1 standard Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in engine oil change intervals from the recommendations in Table 15 Poor maintenance of air filters or of fuel filters requires reduced oil change intervals See your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments Refer to this Operation and Maintenance Manual Refill Capacities a
72. se Ensure that all of the old gasket is removed 4 Apply clean diesel fuel to the new fuel filter gasket NOTICE Do not fill the secondary fuel filter with fuel before in stalling The fuel would not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts SEBU7772 02 87 Maintenance Section Fuel Tank Water and Sediment Drain NOTICE In order to maximize fuel system life and prevent pre mature wear out from abrasive particles in the fuel a two micron absolute high efficiency fuel filter is re quired for all Caterpillar Hydraulic Electronic Unit In jectors Caterpillar High Efficiency Fuel Filters meet these requirements Consult your Caterpillar dealer for the proper part numbers 5 Install the new fuel filter Spin the fuel filter onto the fuel filter base until the gasket contacts the base Use the rotation index marks on the filters as a guide for proper tightening Tighten the filter for an additional one turn 360 degrees by hand Do not overtighten the filter 6 Open the fuel supply valve Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime topic Maintenance Section for more information Start the engine and inspect the fuel system for leaks NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again
73. side the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements SEBU7772 02 77 Maintenance Section Engine Air Cleaner Service Indicator Inspect Inspecting the Primary Air Cleaner Elements Illustration 45 g00281693 Inspect the clean dry primary air cleaner element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element for tears and or holes Inspect the primary air cleaner element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air cleaner element to a new primary air cleaner element that has the same part number Do not use a primary air cleaner element that has any tears and or holes in the filter material Do not use a
74. tery from freezing If batteries are properly charged ammeter reading should be very near zero when the engine is in operation All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water e A mixture of 0 1 L 0 11 qt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM 101492654 Battery or Battery Cable Disconnect SMCS Code 1402 029 The battery cables or the batteries should not be removed with t
75. the crankshaft and to other engine components A deteriorating damper can cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine Removal and Installation Refer to the Service Manual for the damper removal procedure and for the damper installation procedure Visconic Damper The visconic damper has a weight that is located inside a fluid filled case The weight moves in the case in order to limit torsional vibration Inspect the damper for evidence of dents cracks or leaks of the fluid 74 Maintenance Section Cylinder Head Grounding Stud Inspect Clean Tighten SEBU7772 02 Replace the damper if the damper is dented cracked or leaking Refer to the Service Manual or consult your Caterpillar dealer for damper replacement 101473487 Cylinder Head Grounding Stud Inspect Clean Tighten SMCS Code 7423 040 7423 070 7423 079 Illustration 42 g00768411 Typical example Inspect the OEM harness for good connections and condition The electrical grounding stud must have a wire ground to the battery Tighten the electrical 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 e f the connections are corroded clean the connections with a solution of baking soda and water e Keep the elect
76. to service the air cleaner service indicator The service indicator may be mounted on the air cleaner housing or in a remote location Illustration 47 g00103777 Typical service indicator 78 Maintenance Section Engine Air Precleaner Check Clean SEBU7772 02 Observe the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three pushes e Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are 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 n
77. ual applications it is not possible to identify all of the factors which can contribute to severe service operation Consult your Caterpillar dealer for the unique maintenance that is necessary for the engine The operating environment improper operating procedures and improper maintenance procedures can be factors which contribute to severe service conditions Environmental Factors Ambient temperatures The engine may be exposed to extended operation in extremely cold environments or hot environments Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures Extremely hot inlet air reduces engine performance Air Quality The engine may be exposed to extended operation in an environment that is dirty or dusty unless the equipment is cleaned regularly Mud dirt and dust can encase components Maintenance can be very difficult The buildup can contain corrosive chemicals Buildup Compounds elements corrosive chemicals and salt can damage some components Altitude Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application Necessary adjustments should be made Improper Operating Procedures e Extended operation at low idle e Frequent hot shutdowns e Operating at excessive loads e Operating at excessive speeds e Operating outside the intended application Improper Maintenan
78. uan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartridge must be balanced due to high rpm Severe Service Applications can accelerate component wear Severe Service Applications require more frequent inspections of the cartridge Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil Clean the interior of the pipes in order to prevent dirt from entering during reassembly 2 Turn the compressor wheel and
79. 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 41 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 SEBU7772 02 71 Maintenance Section Cooling System Coolant Sample Level 1 Obtain 102326688 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Note Obtaining a Coolant Sample Level 1 is optional if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC This includes the following types of coolants Table 13 Recommended Interval Type of Coolant Level 1 Level 2 Cat DEAC rane Yearly tv2 Cat ELC Optional Yearly 1 This is the recommended interval for coolant samples for all conventional heavy duty coolant antifreeze This is also the recommended interval for coo
80. x times if the element is properly cleaned and inspected When the primary air cleaner element is cleaned check for rips or tears in the filter material The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean primary air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the 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 Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 44 g00281692 Note When the primary air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows in
81. y of the following conditions e Deflection e Damage to the journals e Bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the following components e Rod bearing e Main bearings 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 SEBU7772 02 91 Maintenance Section Overhaul Considerations Oil Cooler Core During an overhaul Caterpillar Inc recommends the removal of the oil cooler core Clean the oil cooler core Then pressure test the oil cooler core NOTICE Do not use caustic cleaners to clean the core Caustic cleaners can attack the internal metals of the core and cause leakage Note Use this cleaning procedure to clean the oil cooler core 1 Remove the oil cooler core 2 Remove any debris from the oil cooler core To remove debris from the oil cooler core turn the oil cooler core onto one end 3 Flush the oil cooler core internally with cleaner in order to loosen foreign substances This will also help to remove oil from the oil
82. y of the fuel that is being used e The operating conditions e The results of the S O S analysis Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases The oil consumption rate brake specific oil consumption is measured in grams per kW h Ib 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 Costly unplanned downtime can be avoided Many original parts can be reused according to the standards for reusable parts The engine s service life can be extended without the risk of
83. ystem 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 3 Add the proper amount of SCA The concentration of the SCA depends on the type of coolant that is used To determine the proper amount see this Operation and Maintenance Manual Refill Capacities and Recommendations topic 4 Clean the cooling system filler cap Install the cooling system filler cap i00912898 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause th

C9 Industrial Engine-Maintenance Intervals - Safety

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